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This is a Continuation in Part of U.S. patent application Ser. No. 09/260,447, filed Mar. 2, 1999, now U.S. Pat. No. 6,086,750.
FIELD OF THE INVENTION
The present invention relates generally to the field of oil refining and more particularly to a method of pre-treating refinery stock and additives related to that method.
BACKGROUND OF THE DISCLOSURE
Assume that a gathering line from an oil field delivers a flow of crude oil to a refinery. Prior to treatment in the refinery, including distillation into the various fractions of commercial importance, it is necessary to evaluate the feedstock for metal salts and similar contaminants in the feedstock. If left unchecked, the metal salts typically will accelerate corrosion of the process vessels. With the customary increases in temperature, the metal salts will generate acids which react with the metal surfaces in the process equipment, thereby severely corroding the surfaces of the process equipment, leading to early equipment failure. This mechanism is discussed below. The present disclosure is directed to a reduction in the metal salts. The problem is materially aggravated for crude stocks which have an API gravity of 25 or less. Especially, a crude stock which has an API gravity of about 20 to 25 poses a significant problem. The problem derives in part from the difficulties of separating oil and water where the feed has that range of gravity. Effectively, this relates to the lack of density differences between water and oil.
To provide a bit of background, there are three major metal salts which may be recovered from a producing formation. While they may be in trace quantities, even as few as a few parts per million (ppm hereafter) in the feed will pose a problem. This is especially true of sodium, calcium, and magnesium making up the salts in the flowing feedstock. The presence of some quantity of water may give rise to a water/oil segregation which can in some instances take the metal salts out of the oil. By suitable pretreatment steps, the salt in the oil can be reduced. However, this is more difficult when the oil is very close in density to water. In the past, simply inputting the feed into a large storage tank (or tank farm comprised of many tanks) and waiting for a long interval would tend to drop the water to the bottom. As the water and oil densities become close, there is less likelihood of settling out the water and any water soluble salts that are in it. Therefore, there is a serious problem in removing the salts in crude feedstocks having an API gravity of about 20 to 25.
It is sometimes helpful to add a trace of water, the amount to be discussed, to the flowing crude oil so that the salts can go into solution in the water. The water added will form stable water droplets in the oil. By adding a demulsifier and through the use of high voltage contacts forming an electric field, sometimes the water droplets can be collected and segregated taking advantage of the electric field stress across the flow. This ultimately segregates the water which is then the preferential solvent for the salts and this enables removal of some, perhaps most of the salts in the flow. It is cooperative with a typical wash water added to the heated oil momentarily which comprises about 4% to 8% of the flowing oil volume with a view of removing somewhere between 20% to about 80% of the salt in the crude oil. Interestingly, with high gravity oil, more of the salts can be gotten out because more of the water is taken out, working with a greater density difference between oil and water. If, however, the crude oil has an API gravity of about 20 to 25, removal is degraded, even to as little as 20% of the salt. Leaving 80% of the salt in the crude oil is highly undesirable.
The present disclosure is directed to a method and apparatus for handling that kind of crude and effectively removing far more than just 20% of the salt. Targeting a removal rate of 95% or more of the salts, the present disclosure sets forth a method of pretreatment for the refinery feedstock which assists remarkably in salt removal. It does this by changing the surface tension between the water droplets in the oil, thereby enabling agglomeration of the water. Moreover, the water more readily disperses in the crude. Effectively, the water is more easily collected, thereby converting it more readily from the droplets dispersed through the oil stream. On the one hand, the droplets are highly desirable, thereby yielding a larger oil/water interface for surface contact to thereby preferentially dissolve the metal salts, and yet afterwards, the water is more easily removed thereby taking more of the metal salts with the water. Effectively, the process of the present disclosure overcomes the propensity of metal salts to stay in suspension in the crude oil. They are brought preferentially into the salt water, removed, thereby protecting the downstream equipment from corrosion.
One aspect of the present invention is the injection of a pretreatment mix of water and a special ethoxylated polyol demulsifier with water. The water is added in the range of up to an effective amount being about 1% of the total crude flow. The polyol added is typically in the range of about 5 or 10 ppm; the amount can be increased or decreased dependent on the severity of the problem and the relative API gravity of that particular crude feedstock. As the gravity increases, the amount or the degree of need for the present polyol demulsifier addition is reduced. The method of application will be set forth in detail below. It will be given in the context of an operating crude oil processing unit typically incorporating a distillation column for breaking down the crude into the various cuts or subsequent use. Further, the context will provide a method of use and will also provide a method of manufacture of the ethoxylated polyol for the present disclosure.
Since the filing of my U.S. patent application Ser. No. 09/260,447 filed Mar. 2, 1999 now U.S. Pat. No. 6,086,750. I have also discovered that the addition of caustic to process provides three additional benefits: ( 1 ) the caustic help to water-wet the solid crystalline salts or inorganic materials; ( 2 ) the caustic also forms metal hydroxides with other contaminants in the oil, making them more water soluble and thus more easily removed from the oil; and ( 3 ) the caustic greater enhances the breakout of water from the oil. I have found that caustic in the pH range of 7-12, and preferably in the pH range of 9-12, in addition to the water and other additives of my method, provide significant enhancement of the benefits of my method.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawing.
It is to be noted, however, that the appended drawing illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 illustrates a crude oil distillation system equipped with a pretreatment apparatus and capable of adding the pretreatment materials to enable salt and water removal to thereby reduce the amount of metal salts input to the high temperature crude processing unit; and
FIG. 2 shows a graph of metal salt activity as a function of temperature.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A crude processing system is set forth in the attached view. Beginning at the far left, the system 10 includes as set of gathering lines 12 which connect to the well heads of one or many producing wells. The gathering lines 12 then connect with an oil pipeline 14 . It is of sufficient length to deliver the untreated crude oil production. The numeral 16 identifies a water tank which connects with the pump 18 which adds water to the pipeline in an amount to be discussed. The tank 20 is a supply of an ethoxylated polyol demulsifier. The tank 20 delivers that through a pump 22 into the line for reasons and purposes to be described.
The crude delivery line is input to a tank farm. A crude oil storage tank 24 is provided with the flow. The size of the tank 24 is a matter of scaling to a desired size. The tank is sized so that the crude with a trace of water added from the water supply 16 is introduced. This is a pretreatment step which is important to the processing to the crude oil downstream. Considering now, however, the tank farm, the tank 24 is one of several tanks. In a typical situation, the tanks are relatively large so that the crude is held for an interval of hours. Assume that the flow of the pipeline 14 is sufficient to fill the tank in 12 hours. By using three tanks, the first tank can be filled in 12 hours and then is permitted to sit for 24 hours without disturbance. During that 24 hour interval, the second tank is then filled and then the third tank is filled, and then the pipeline 14 is reconnected to the first tank. The tanks are filled and are permitted to sit for an interval of about 24 hours. This works nicely with tanks which are approximately equal in size. In all instances, the feedline is connected to the tanks at some midpoint on the tank. Assume that the height of each tanks is equal and arbitrarily set that height at 20 feet. The feedline will introduce the oil at a height anywhere from about two feet to perhaps ten feet above the bottom of the tank. The tanks are filled by the pipeline 14 . They are drained through individual outlet lines 26 from each of the tanks. These outlet lines are connected above the bottom. They are typically connected above the bottom at a height of about one to three feet above the bottom of the tanks. The tanks are equipped with a bottom and the bottom ideally tapers to a centralized bottom or sump. A water drain line 28 is illustrated for one of the tanks, but it will be understood that it is replicated for all the tanks. The tanks thus funnel the accumulated heavier materials (water primarily) at the bottom and they are drained in a controllable fashion so that the primary discharge is salt water for reasons to be explained.
Continuing with the equipment, the tanks connect through a pump 30 which then is input to a heat exchanger 32 . A heated fluid is provided through the line 34 and delivers heat in the heat exchanger. This raises the temperature in a manner to be described. A water supply line 36 is connected to the flow of heated crude oil and is delivered with the crude into a horizontal desalter tank 40 . The desalter tank encloses an electrified grid connected to a power supply to impress an electric field across the heated emulsion. The tank 40 has a discharge line 42 at the bottom. This delivers out of the tank any salt water that is recovered in the desalter. More will be noted concerning that operation. The desalter is connected to an outlet line 44 where the desalted crude flows out of the tank. The line 42 is connected from the very bottom of the tank 40 to assure that the heavier materials are removed at the bottom. They are removed from the system and are not further processed.
The line 44 then connects with another heat exchanger which is provided with a heated fluid input through the line 46 . The heat exchanger 48 raises the temperature to a greater level. The next stage is heating in a furnace 50 . Representative temperature levels for that will be given below. The last stage of the equipment is input of the heated crude into a distillation column or tower 60 . This is delivered through a feedline 52 serially continuing from the heat exchanger 48 . The feedline 52 is input at a midpoint on a distillation column or tower 60 . Gases or vapors are removed from the top by a top fractional cut line 62 . Very light gasoline is removed on the line 64 while heavier gasoline is delivered on the line 66 . The line 68 is a typical diesel cut obtained from the distillation column. The bottoms from the column are removed by the line 70 . The lines 62 through 70 are tapped from the distillation column at heights which are selected to control the discharge from the column. Generally, the column has a multitude of trays in it with an internal reflux flow moving from tray to tray. Vapors rise while liquids fall. The process is continued in a feedback mode so that the distillation tower provides the appropriately selected molecular cuts of the feed. Generally, each fractional cut is directed to a different market, primarily because it has different values and different heat content.
In general terms, the heat exchanger 32 in conjunction with the heat exchanger 48 raises the temperature of the crude to about 500 to about 550° F. The furnace 50 raises the temperature of the crude to about 600 up to about 650° F. It assures that the temperature is appropriate for operation of the distillation column. With all of the components heated to the representative temperatures given, metal salts are much more chemically active and initiate acid formation which reacts with the steel surfaces to create corrosive damage.
FIG. 2 of the drawings is a curve of metal salt hydrolysis as a fiction of temperature. It includes three curves which relate to the most common metal salts encountered in produced crude oil. They are typically chlorides, and are commonly sodium, calcium, and magnesium. While the relative proportions may differ, it is not significantly important that sodium is present. FIG. 2 explains why this is so. By contrast, even though magnesium is less plentiful in most situations, the magnesium chloride provides the greatest problem. As explained earlier, the temperature is in the range of 600° F. or 650° F. going into the distillation column. At that temperature level, very little of the sodium and calcium salts is converted. By contrast, practically all of the magnesium chloride is converted. Ultimately, this creates a significant conversion of HCI acid in the oil and that will create far greater damage than the damage resulting from the other two salts. FIG. 2 therefore illustrates how the high percent is hydrolyzed at the prevailing temperatures in this process and thereby creates a lot of damage resulting from the magnesium salt. Even upstream of the furnace 50 , this is something of a problem at the other equipment, but the conversion of the other two salts is substantially nil.
The present disclosure is directed to reducing corrosion. It works in conjunction with the desalter 40 previously mentioned. The water supply 36 normally delivers wash water in the amount of about 4% to about 8%. That is added to the flow and is therefor proportional to the flow. It is then removed in the desalter tank 40 . Stratification is normally accomplished at that stage to thereby enable the water that is added to now be removed. In the optimum circumstance, a short dwell time is all that is needed. In ordinary operation, the water is simply added and mixed with the oil, and then is removed by the salt water removal line 42 along with the salts, and this is especially true with metal salts which are more readily water soluble. The present disclosure contemplates the pretreatment addition of water from the water source 16 at a rate which is sufficient for the present system. This tends to be in the range of about one quarter, but perhaps even better at one half percent up to about one percent of the total crude flow. The water flow is preferably metered into the crude flow in the line 14 so that the water flow tracks or follows the rate of crude oil pumped through the line 14 . Accordingly, by adding this much water, and then adding the ethoxylated polyol demulsifier from the supply 20 , the pretreatment significantly reduces the amount of metal salts delivered into the system.
In addition to the water metered into the line 14 , the tank 16 may also include a caustic. As used herein, the term “caustic” specifically refers to hydroxyl ion contributors, such as for example but not limited to magnesium, ammonium, calcium, sodium, and potassium hydroxide. I have found that injecting the caustic at about 7-12 pH, and preferably at about 9-12 pH, significantly enhances the water-wetting of the salts, forms metal hydroxides with metal contaminants so that they are easily removed from the oil, helps to break out the water from the oil once its job is done. The caustic is injected, in addition to the demulsifier.
The demulsifier of the present invention is added at rate of up to twenty ppm, but it appears normally that crude oil having an API gravity of about 22 to about 23 can be treated with about five to ten ppm of the additive. This is effectively added immediately adjacent to the water injection so it can be treated in part as an injectable along with the water if desired. They are shown as separate sources with separate pumps in the system illustrated so that separate control can be asserted over the two additives namely, the trace of water and the ethoxylated polyol demulsifier. These two additives, hence, a single additive in a real sense, are mixed into the flowing oil which is permitted to settle. A large portion of the salts are taken out of the storage tanks 24 . They are removed by collecting the sediment in the tanks. Sometimes, the sediment is known as BSW which refers to the water and any other particulate trash, emulsified water droplets, and so on. All of these are collected and delivered through the bottom drains in the tanks. Thereafter, the temperature of the feed is raised to an intermediate temperature. An intermediate temperature is somewhere between about 150iF and about 300iF. With the temperature raised by the heat exchanger 32 , settlement time in the tank 40 is markedly changed. With ambient temperatures prevailing on the tank 24 , it takes hours to accomplish settlement or stratification. Indeed, many droplets will simply not settle without a long time interval, but the intervals cannot be readily accommodated with lower gravity crude oil feedstocks. The elevated temperature accomplished with the desalting tank 40 speeds up segregation. It speeds up the recovery of water at the bottom along with the water soluble salts in it. This then enables removal from the bottom drain line 42 . It also encourages and assists in water removal with the metal salts. Some representative examples should be considered. The salts that do the most damage are salts of sodium, calcium and magnesium. It is possible that other salts will be mixed with it. For these reasons, there is a greater risk of problem with magnesium compared to other metal salts.
Consider as an example a system using the ethoxylated polyol of the present disclosure. For example, working with Mayan crude having an API gravity reading of about 22 to about 23, the amount of water added from the water supply 16 was adjusted to something in the range of one half to one percent of the crude flow. The ethoxylated polyol was added at the rate of about ten ppm. A settlement interval of 24 hours for each of the tanks 24 was sufficient. The heat exchanger 32 raised the oil temperature from prevailing outdoor ambient temperature to something in excess of 200iF. The water supply line 36 added water at the rate of not more than 8%, typically in the range of about 4% to 5%, and that water was removed from the desalter tank at elevated temperature. At this juncture, two “cuts” had been taken from the salt content in the system. It was deemed relatively successful by the removal of the metal salts in two stages just noted. Considering the example further, the feed ultimately delivered to the distillation column provided at a temperature of about 600iF, and routinely operated at about 625iF.
The ethoxylated polyol of the present disclosure is obtained by using a starting material of polypropylene glycol having a molecular weight in the range of about 3,500 to 4,500. That is initially reacted at about 300iF to about 350iF in an appropriate container for an adequate interval with ethylene oxide heated to a temperature as noted at about 300iF to 350iF. It is appropriate to add about 15 to 20 moles of ethylene oxide for each mole of the polypropylene glycol. The preferred oxide is the C2 molecule because C3 or C4 is too oil-like and will not act readily at the water/oil interface. Therefore C2 is preferred.
While the foregoing is directed to preferred embodiment, the scope thereof is determined by the claims which follow.
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A metal salt removal procedure for use with a crude oil flow is disclosed. A small amount of water, and a caustic in the range of 7-12 pH, and preferably 9-12 pH, are injected to form water bubbles surrounded by oil. An ethylene oxide reacted with polypropylene glycol at 350° F. or so yields a water soluble demulsifier added at the rate of a few ppm to the water in oil mix. The added reaction product, a polyol, enables metal salt isolation in the water.
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BACKGROUND OF THE INVENTION
The instant invention relates generally to dispensing devices and more specifically it relates to a sailboat chlorine dispenser for a swimming pool.
Numerous dispensing devices have been provided in prior art that are adapted to distribute chlorine and other chemicals into swimming pools. For example, U.S. Pats. No. 3,202,322; 3,677,711 and 4,546,503 all are illustrative of such prior art. While these units may be suitable for the particular purpose to which they address, they would not be as suitable for the purposes of the present invention as heretofore described.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a sailboat chlorine dispenser that will overcome the shortcomings of the prior art devices.
Another object is to provide a sailboat chlorine dispenser that will dispense chlorine more evenly due to its shape as a sailboat wherein wind will help move the dispenser around water in a pool.
An additional object is to provide a sailboat chlorine dispenser that will dispense chlorine more quickly due to the sleeve containing the chlorine rotated and activated by water movement in a pool.
A further object is to provide a sailboat chlorine dispenser that is simple and easy to use.
A still further object is to provide a sailboat chlorine dispenser that is economical in cost to manufacture.
Further objects of the invention will appear as the description proceeds.
To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a side elevational view of the invention.
FIG. 2 is an exploded perspective view of the chlorine dispenser portion of the invention.
FIG. 3 is a side elevational view of a modified chlorine dispenser portion.
FIG. 4 is a cross sectional view taken along line 4--4 in FIG. 3 showing a rotating sleeve activated by spring biased pivotal fins.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, FIG. 1 illustrates a sailboat chlorine dispenser 10 consisting of a flotation member 12 being in the shape of a sailboat. A perforated hollow container 14 is affixed to lowest portion of the flotation member 12 to dispense chlorine therefrom into water in a pool.
The sailboat flotation member 12 includes a hollow hull 16 having a flat keel 18 extending downwardly therefrom. A deck 20 that has a small hole 22 therein is affixed to top of the hollow hull 16. A mast 24 is provided that has a foresail 26 and a mainsail 28. Bottom end 30 of the mast 24 fits within the small hole 22 in the deck 20 so that wind will help move the dispenser 10 around the water in the pool.
As best seen in FIG. 2 the perforated hollow container 14 includes a cylindrical hollow housing 32 that has an upper flange 34, a plurality of first vertical rectangular apertures 36 therethrough and an open bottom end 38 with internal threads (not shown). The housing 32 holds the chlorine therein and is affixed at the upper flange 34 to end of the flat keel 18 of the hollow hull 16. A hollow cylindrical sleeve 40 is provided that has a plurality of second vertical rectangular apertures 42 therethrough. The sleeve 40 is of a size to fit onto the housing 32 and be manually turned thereon to control amount of chlorine to exit the first and second vertical rectangular apertures 36 and 42. A cap 44 that has external threads 46 and a lower flange 48 is removably screwed into the bottom end 38 of the housing 32 so that the lower flange 48 will hold the sleeve 40 thereto while sealing the bottom end 38 of the housing 32.
FIGS. 3 and 4 show a modified performated hollow container 50 that includes a hemi-cylindrical hollow housing 52 that has a plurality of first vertical slots 54 therethrough. The housing 52 is affixed at upper end (not shown) to the flat keel 18 of the hollow hull 16. A rotating hollow sleeve 56 has a plurality of second vertical slots 58 therethrough and a plurality of recesses 60 in outer circumference 62 therebetween. The sleeve 56 hold the chlorine therein and is of a size to fit into the housing 52. A plurality of fins 64 are provided. Each of the fins 64 is pivotable at 66 in one of the recesses 60 in the sleeve 56. The fins 64 are spring biased at 68 to fan outwardly therefrom so as to catch water movement as indicated by arrow 70 in FIG. 4 in a pool to rotate the sleeve 56 as indicated by arrow 72 in FIG. 4 until the fins 64 are pushed backward into the recesses 60 by the housing 52 thus to quickly dispense the chlorine from the sleeve 56.
While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it will be understood that various omissions, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing from the spirit of the invention.
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A sailboat chlorine dispenser is provided which will dispense chlorine more evenly due to its shape as a sailboat wherein wind will help move the dispenser around water in a pool. In a modification a sleeve containing the chlorine is rotated and activated by water movement in the pool.
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TECHNICAL FIELD
[0001] The present invention relates to a photoelectric conversion device including a polycrystalline semiconductor.
BACKGROUND ART
[0002] As a photoelectric conversion device to be used for solar photovoltaic power generation, a device provided with a plurality of photoelectric conversion cells on a substrate is exemplified as disclosed in Japanese Unexamined Patent Application Publication No. 2000-299486.
[0003] Such a photoelectric conversion device is formed by two-dimensionally arranging a plurality of photoelectric conversion cells in which a lower electrode layer such as a metal electrode, a light-absorbing layer, a buffer layer, and a transparent conductive film are stacked in this order on a substrate such as glass. The plurality of photoelectric conversion cells are electrically connected in series by connecting the transparent conductive film of one of the adjacent photoelectric conversion cells and the lower electrode layer of the other of the adjacent photoelectric conversion cells through a connection conductor.
[0004] Improvement of photoelectric conversion efficiency is constantly demanded for the photoelectric conversion device. In the photoelectric conversion device, a method of increasing the size of crystal grains of a semiconductor layer serving as a light-absorbing layer may be considered as a method for improving the photoelectric conversion efficiency. However, when the size of the crystal grains of the semiconductor layer is increased, cracks easily appear on the semiconductor layer due to thermal stress or the like and it is difficult to sufficiently improve the photoelectric conversion efficiency.
SUMMARY OF INVENTION
[0005] An object of the present invention is to improve photoelectric conversion efficiency of a photoelectric conversion device.
[0006] A photoelectric conversion device according to an embodiment of the present invention comprises an electrode layer; a first semiconductor layer disposed on the electrode layer and including a polycrystalline semiconductor; and a second semiconductor layer disposed on the first semiconductor layer and forming a pn junction with the first semiconductor layer. An average grain diameter of crystal grains in the first semiconductor layer is larger in a surface portion on the electrode layer side than in a central portion of the first semiconductor layer in a stacking direction.
[0007] According to the present invention, the photoelectric conversion efficiency in the photoelectric conversion device is improved.
BRIEF DESCRIPTION OF DRAWINGS
[0008] FIG. 1 is a perspective view illustrating an example of a photoelectric conversion device according to an embodiment.
[0009] FIG. 2 is a cross-sectional view of the photoelectric conversion device in FIG. 1 .
[0010] FIG. 3 is a graph illustrating distribution of the average grain diameter of crystal grains of a first semiconductor layer.
[0011] FIG. 4 is a graph illustrating distribution of the average grain diameter of crystal grains of a first semiconductor layer in another example of the photoelectric conversion device.
[0012] FIG. 5 is a photograph of a cross section of the first semiconductor layer in another example of the photoelectric conversion device.
DESCRIPTION OF EMBODIMENTS
[0013] Hereinafter, a photoelectric conversion device according to an embodiment of the present invention will be described in detail with reference to the drawings.
<Configuration of Photoelectric Conversion Device>
[0014] FIG. 1 is a perspective view illustrating an example of a photoelectric conversion device according to an embodiment of the present invention and FIG. 2 is a cross-sectional view thereof. In a photoelectric conversion device 11 , a plurality of photoelectric conversion cells 10 are arranged on a substrate 1 and are electrically connected to one another. Although only two photoelectric conversion cells 10 are illustrated in FIG. 1 for convenience of illustration, multiple photoelectric conversion cells 10 may be two-dimensionally arranged in the right-left direction in FIG. 1 or further in a direction perpendicular to the right-left direction in the actual photoelectric conversion device 11 .
[0015] In FIGS. 1 and 2 , a plurality of lower electrode layers 2 are two-dimensionally arranged on the substrate 1 . In FIGS. 1 and 2 , the plurality of lower electrode layers 2 include lower electrode layers 2 a to 2 c arranged in one direction with a gap between them. A first semiconductor layer 3 is disposed over the lower electrode layer 2 a and the lower electrode layer 2 b through a portion on the substrate 1 . In addition, a second semiconductor layer 4 whose conductivity type is different from that of the first semiconductor layer 3 is disposed on the first semiconductor layer 3 . Further, a connection conductor 7 is disposed on the lower electrode layer 2 b along the surface (side surface) of the first semiconductor layer 3 or by penetrating the first semiconductor layer 3 . The connection conductor 7 electrically connects the second semiconductor layer 4 and the lower electrode layer 2 b. One photoelectric conversion cell 10 is formed of the lower electrode layer 2 , the first semiconductor layer 3 , the second semiconductor layer 4 , and an upper electrode layer 5 , and a high-output photoelectric conversion device 11 is configured by connecting adjacent photoelectric conversion cells 10 in series through the connection conductor 7 . In addition, in the photoelectric conversion device 11 in the present embodiment, it is assumed that light is incident from the second semiconductor layer 4 side, but without being limited thereto, light may be incident from the substrate 1 side.
[0016] The substrate 1 supports the photoelectric conversion cells 10 . Examples of a material to be used for the substrate 1 include glass, ceramics, resins, metals, and the like. As the substrate 1 , soda lime glass having a thickness of approximately 1 mm to 3 mm can be used.
[0017] The lower electrode layers 2 (lower electrode layers 2 a, 2 b, and 2 c ) are conductors such as Mo, Al, Ti, or Au disposed on the substrate 1 . The lower electrode layers 2 are formed to have a thickness of approximately 0.2 μm to 1 μm using a known thin film forming method such as a sputtering method or a deposition method.
[0018] The first semiconductor layer 3 includes a semiconductor having a polycrystalline structure. The first semiconductor layer 3 has a thickness of, for example, approximately 1 μm to 3 μm. Examples of the first semiconductor layer 3 include metal chalcogenide such as a group II-VI compound, a group I-III-VI compound, and a group I-II-IV-VI compound.
[0019] The group II-VI compound is a compound semiconductor of group II-B elements (also referred to as group 12 elements) and group VI-B elements (also referred to as group 16 elements). As the group II-VI compound, CdTe and the like are exemplified.
[0020] The group I-III-VI compound is a compound of group I-B elements (also referred to as group 11 elements), group III-B elements (also referred to as group 13 elements), and group VI-B elements. Examples of the group I-III-VI compound include CuInSe 2 (copper indium diselenide, also referred to as CIS), Cu(In,Ga)Se 2 (copper indium gallium diselenide, also referred to as CIGS), and Cu(In,Ga) (Se,S) 2 (copper indium gallium diselenide disulfide, also referred to as CIGSS). Alternatively, the first semiconductor layer 3 may be formed of a multiple compound semiconductor thin film such as copper indium gallium diselenide provided with a thin copper indium gallium diselenide disulfide layer as a surface layer.
[0021] The group I-II-IV-VI compound is a compound of group I-B elements, group II-B elements, group IV-B elements (also referred to as group 14 elements), and group VI-B elements. Examples of the group I-II-IV-VI compound include Cu 2 ZnSnS 4 (also referred to as CZTS), Cu 2 ZnSn(S,Se) 4 (also referred to as CZTSSe), and Cu 2 ZnSnSe 4 (also referred to as CZTSe).
[0022] Further, the average grain diameter of crystal grains of the first semiconductor layer 3 is larger in the surface portion on the lower electrode layer 2 side than in the central portion of the first semiconductor layer 3 in the thickness direction (stacking direction). With such a configuration, occurrence of cracks or the like can be reduced by decreasing stress in the central portion having relatively small crystal grains, and recombination of charges at the grain boundaries is suppressed with relatively large crystal grains in the surface portion on the lower electrode layer 2 side, and thus charge mobility can be improved. Accordingly, the photoelectric conversion efficiency of the photoelectric conversion device 11 is improved.
[0023] Regarding the first semiconductor layer 3 , it is at least desired that the average grain diameter of crystal grains of the surface portion on the lower electrode layer 2 side is larger than that of the crystal grains of the central portion, in a case where the first semiconductor layer 3 is assumed to be divided into the surface portion on the lower electrode layer 2 side, the central portion, and the surface portion on the second semiconductor layer 4 side by being trisected in the thickness direction.
[0024] The average grain diameter of crystal grains is acquired as follows. First, in regard to the cross sections of respective layers trisected as described above, images (also referred to as cross-sectional images) are obtained by photographing 10 arbitrary sites without concentrating at particular regions with a scanning electron microscope (SEM). Next, grain diameters of a plurality of grains are determined using image processing software or the like, from electronic data of the images or data in which the photographed images are captured by a scanner, and the average grain diameters of the crystal grains are calculated by acquiring the average value thereof.
[0025] The average grain diameter of crystal grains in the surface portion on the lower electrode layer 2 side of the first semiconductor layer 3 may be, for example, 100 nm to 500 nm from a viewpoint of improving an adhesion property between the first semiconductor layer 3 and the lower electrode layer 2 . Further, the average grain diameter of crystal grains in the central portion may be 0.2 times to 0.5 times of the average grain diameter of crystal grains in the surface portion on the lower electrode layer 2 side.
[0026] The average grain diameter of crystal grains in the first semiconductor layer 3 may gradually become larger toward the lower electrode layer 2 from the central portion from a viewpoint of reducing strain in the first semiconductor layer 3 . For example, FIG. 3 illustrates an example of distribution of the average grain diameter of crystal grains of the first semiconductor layer 3 in the thickness direction. In FIG. 3 , the horizontal axis represents a distance from the lower electrode layer 2 and the vertical axis represents the average grain diameter of crystal grains. With the average grain diameter of crystal grains being changed to be larger toward the lower electrode layer 2 as just described, it is possible to reduce the occurrence of strain in the first semiconductor layer 3 and the occurrence of cracks or separation of the first semiconductor layer 3 can be further reduced. Further, the distribution of the average grain diameter of crystal grains in the thickness direction can be acquired by dividing the first semiconductor layer 3 into a plurality of layers in the thickness direction and measuring the average grain diameter of the respective layers.
[0027] The second semiconductor layer 4 is a semiconductor layer of a second conductivity type which is different from the conductivity type of the first semiconductor layer 3 . By electrically connecting the first semiconductor layer 3 and the second semiconductor layer 4 , a photoelectric conversion layer with which charges are extracted well is formed. For example, in a case where the first semiconductor layer 3 is a p-type, the second semiconductor layer 4 is an n-type. The first semiconductor layer 3 may be an n-type and the second semiconductor layer 4 may be a p-type. Further, a high-resistance buffer layer may be interposed between the first semiconductor layer 3 and the second semiconductor layer 4 .
[0028] Examples of the second semiconductor layer 4 include CdS, ZnS, ZnO, In 2 S 3 , In 2 Se 3 , In (OH,S), (Zn,In) (Se,OH), (Zn,Mg)O, and the like. The second semiconductor layer 4 is formed to have a thickness of 10 nm to 200 nm using, for example, a chemical bath deposition (CBD) method or the like. In addition, In(OH,S) means a mixed crystal compound containing In as a hydroxide and a sulfide. (Zn,In) (Se,OH) is a mixed crystal compound containing Zn and In as a selenide and a hydroxide. (Zn,Mg)O is a compound containing Zn and Mg as an oxide.
[0029] As illustrated in FIGS. 1 and 2 , the upper electrode layer 5 may be further disposed on the second semiconductor layer 4 . The upper electrode layer 5 is a layer with resistivity lower than that of the second semiconductor layer 4 and with which charges generated in the first semiconductor layer 3 and the second semiconductor layer 4 can be extracted well. From a viewpoint of further improving photoelectric conversion efficiency, the resistivity of the upper electrode layer 5 may be lower than 1 Ω·cm and the sheet resistance thereof may be equal to or lower than 50Ω/□.
[0030] The upper electrode layer 5 is a transparent conductive film of 0.05 μm to 3 μm made of ITO or ZnO, or the like, for example. For improving translucency and conductivity, the upper electrode layer 5 may be formed of a semiconductor having the same conductivity type as that of the second semiconductor layer 4 . The upper electrode layer 5 may be formed by a sputtering method, an evaporation method, a chemical vapor deposition (CVD) method, or the like.
[0031] Further, as illustrated in FIGS. 1 and 2 , a collector electrode 8 may be further formed on the upper electrode layer 5 . The collector electrode 8 is an electrode for further efficiently extracting charges generated in the first semiconductor layer 3 and the second semiconductor layer 4 . The collector electrode 8 is formed, for example, linearly from one end of the photoelectric conversion cell 10 to the connection conductor 7 as illustrated in FIG. 1 . Accordingly, the current generated in the first semiconductor layer 3 and the fourth semiconductor layer 4 is collected in the collector electrode 8 through the upper electrode layer 5 , and is efficiently passed to the adjacent photoelectric conversion cells 10 through the connection conductor 7 .
[0032] The collector electrode 8 may have a width of 50 μm to 400 μm from a viewpoint of improving light transmittance to the first semiconductor layer 3 and having good conductivity. Further, the collector electrode 8 may include a plurality of branched portions.
[0033] The collector electrode 8 is formed by, for example, preparing a metal paste which is obtained by dispersing metal powder such as Ag powder in a resin binder or the like, printing the metal paste into a pattern shape, and curing the metal paste.
[0034] In FIGS. 1 and 2 , the connection conductor 7 is a conductor disposed in a groove penetrating the first semiconductor layer 3 , the second semiconductor layer 4 , and the second electrode layer 5 . A metal, a conductive paste, or the like can be used for the connection conductor 7 . In FIGS. 1 and 2 , the connection conductor 7 is formed by extending the collector electrode 8 , but not limited thereto. For example, the connection conductor 7 may be formed by extending the upper electrode layer 5 .
<Method for Producing Photoelectric Conversion Device>
[0035] Next, a method for producing the photoelectric conversion device 11 having the above-described configuration will be described. Here, a case in which the first semiconductor layer 3 is made of CIGS will be described. First, the lower electrode layer 2 , which is formed of Mo or the like, is formed into a desired pattern using a sputtering method or the like on a main surface of the substrate 1 formed of glass or the like.
[0036] In addition, a precursor layer which becomes the first semiconductor layer 3 is formed on the lower electrode layer 2 with a sputtering method, a coating method, or the like. The precursor layer may be a layer containing a raw material of a compound constituting the first semiconductor layer 3 or a layer containing fine grains of a compound constituting the first semiconductor layer 3 .
[0037] Subsequently, the precursor layer is subjected to a heat treatment at a temperature of 500° C. to 600° C. During the heat treatment, a portion on the lower electrode layer 2 side of the precursor layer is subjected to active heat treatment by being irradiated with infrared light from the substrate 1 side using an IR lamp. Accordingly, the first semiconductor layer 3 whose average grain diameter is larger in the surface portion on the lower electrode layer 2 side than in the central portion in the thickness direction is formed.
[0038] After the first semiconductor layer 3 is formed, the second semiconductor layer 4 and the upper electrode layer 5 are sequentially formed on the first semiconductor layer 3 using a CBD method, a sputtering method, or the like. In addition, the first semiconductor layer 3 , the second semiconductor layer 4 , and the upper electrode layer 5 are processed through a mechanical scribing process or the like and consequently a groove for the connection conductor 7 is formed.
[0039] Thereafter, for example, conductive paste, which is obtained by dispersing metal powder such as Ag powder in a resin binder or the like, is printed in a pattern shape on the upper electrode layer 5 and in the groove, and the collector electrode 8 and the connection conductor 7 are formed by heating and curing the printed conductive paste.
[0040] Finally, the first semiconductor layer 3 to the collector electrode 8 are removed at a position shifted from the connection conductor 7 through a mechanical scribing process so as to provide a plurality of photoelectric conversion cells 10 being divided, thereby obtaining the photoelectric conversion device 11 illustrated in FIGS. 1 and 2 .
<Modification Example of Photoelectric Conversion Device>
[0041] It should be noted that the present invention is not limited to the above-described embodiment, and various changes and modifications are possible without departing from the scope of the present invention.
[0042] For example, the average grain diameter of crystal grains in the first semiconductor layer 3 may be larger in the surface portion on the second semiconductor layer 4 side than in the central portion of the first semiconductor layer 3 in the thickness direction. As a result, recombination of charges at the grain boundaries can be suppressed in the surface portion on the second semiconductor layer 4 side. Consequently, the photoelectric conversion efficiency of the photoelectric conversion device 11 can be further improved. Particularly, as illustrated in FIG. 4 , when the average grain diameter of crystal grains in the first semiconductor layer 3 gradually becomes larger toward the second semiconductor layer 4 from the central portion, occurrence of strain in the first semiconductor layer 3 can be suppressed well. FIG. 4 illustrates distribution of the average grain diameter of crystal grains of the first semiconductor layer 3 in the thickness direction in the same manner as FIG. 3 . Such first semiconductor layer 3 becomes the first semiconductor layer 3 whose average grain diameter is larger in the surface portion on the second semiconductor layer 4 side than in the central portion in the thickness direction by being irradiated with the infrared light from the surface of the precursor layer opposite the lower electrode layer 2 using an IR lamp, when the above-described precursor layer is heated and consequently the first semiconductor layer 3 is formed.
[0043] An example of a photograph of the cross section of the above-described first semiconductor layer 3 is illustrated in FIG. 5 . FIG. 5 is a cross section of the photoelectric conversion device 11 in which Mo is used for the lower electrode layer 2 , CIGS is used for the first semiconductor layer 3 , In(OH,S) is used for the second semiconductor layer (because of the thinness, it is difficult to be confirmed in FIG. 5 ), and AZO is used for the transparent conductive film.
REFERENCE SIGNS LIST
[0000]
1 Substrate
2 , 2 a, 2 b, 2 c Lower Electrode Layer
3 First Semiconductor Layer
4 Second Semiconductor Layer
7 Connection Conductor
10 Photoelectric Conversion Cell
11 Photoelectric Conversion Device
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In order to improve the photoelectric conversion efficiency of a photoelectric conversion device, this photoelectric conversion device is provided with an electrode layer, a first semiconductor layer that is positioned on the electrode layer and contains a polycrystalline semiconductor, and a second semiconductor layer that is positioned on/above the first semiconductor layer and forms a p-n junction with the first semiconductor layer, and an average grain diameter of crystal grains in the first semiconductor layer is larger near the surface on the electrode layer side of the first semiconductor layer than the center of the first semiconductor layer in a thickness direction of the first semiconductor layer. Furthermore, the average grain diameter of the crystal grains in the first semiconductor layer is larger in a surface portion on the second semiconductor layer side of the first semiconductor layer than in the central portion.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Patent Application No. 2004-3884, filed on Jan. 19, 2004 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a clothes drying apparatus, and more particularly, to a clothes drying apparatus having a structured air inlet section provided at a rear end of a rotating drum which radially delivers air into the rotating drum, and improves drying performance.
[0004] 2. Description of Related Art
[0005] Generally, clothes drying machines are adapted to dry clothes contained in a rotating drum horizontally arranged in a housing by a flow of hot air passing through the rotating drum during rotation of the rotating drum at low speed in one direction.
[0006] Such a clothes drying machine includes a rotating drum for receiving clothes to be dried, an intake duct for supplying hot air into the rotating drum, an exhaust duct for exhausting the hot air after the air is circulated in the rotating drum, and a driving unit for rotating the rotating drum in order to rapidly dry the clothes.
[0007] A heater is installed in the intake duct in order to heat air introduced into the intake duct. An exhaust fan is installed in the exhaust duct in order to forcibly externally vent hot air introduced into the rotating drum through the intake duct. An air inlet section is provided at a rear panel mounted to a rear end of the rotating drum and in communication with the intake duct, so as to guide the introduction of hot air into the rotating drum.
[0008] In a general clothes drying apparatus, such an air inlet section has a flat plate structure provided with a plurality of holes, and is arranged at a central portion of a rear panel mounted to a rear end of a rotating drum, as shown in FIG. 5 of Korean Patent Laid-open Publication No. 2001-73539.
[0009] Due to such a structure of the air inlet section, hot air is introduced into the rotating drum in a straight direction at a high flow velocity, so that it is locally supplied to a portion of the interior of the rotating drum. Accordingly, in the interior of the rotating drum, there is a dead region where hot air cannot reach, thereby reducing the contact area of hot air with the clothes. As a result, the drying efficiency of the clothes drying apparatus is degraded.
BRIEF SUMMARY
[0010] Therefore, an aspect of the invention is to provide a clothes drying apparatus having an improved structure of an air inlet section provided at a rear panel mounted to a rear end of a rotating drum, thereby being capable of increasing the flow rate and flow velocity of hot air introduced into the rotating drum while using a small fan size, and thus, allowing the hot air to be uniformly supplied into the entire portion of the interior of the rotating drum without forming a dead region where hot air cannot reach, and increasing the contact area of the hot air with clothes to achieve an enhancement in drying efficiency.
[0011] According to an aspect of the present invention, there is provided a clothes drying apparatus including: a rotating drum; an intake duct which delivers hot air to the rotating drum; and an air inlet section at the rotating drum and in communication with the intake duct. The air inlet section is configured to radially supply the hot air from the intake duct into the rotating drum.
[0012] The air inlet section may have a plurality of through holes extending radially through the convex structure.
[0013] The air inlet section may have a diameter about equal to a diameter of the intake duct.
[0014] The intake duct may have an inlet portion and the apparatus may include a heater installed in the inlet portion to heat air drawn into the intake duct.
[0015] According to another aspect of the present invention, there is provided a clothes drying apparatus including: a rotating drum having a front end and a rear end; an intake duct which delivers hot air to the rotating drum; an exhaust duct which exhausts heat exchanged air heated by heat exchange in the rotating drum; and an air inlet section at the rotating drum and in communication with the intake duct. The air inlet section is at a rear panel mounted to the rear end and has a convex structure which protrudes into the rotating drum. The exhaust duct is connected, at an inlet portion thereof, to a front panel mounted to the front end.
[0016] According to still another aspect of the present invention, there is provided an air inlet of a clothes drying apparatus which uses a rotating drum, including: an air receiving portion in communication with an ambient and which receives air to be delivered into the rotating drum; and an air delivering portion having a convex wall extending into the rotating drum and having a plurality of through holes extending through the convex wall. The air received by the receiving portion is radially delivered to the drum through the plurality of through holes.
[0017] According to another aspect of the present invention, there is provided a method of drying clothes in a clothes drying apparatus using a drum, including: rotating the drum; heating air; delivering the heated air to the drum; and radially supplying the heated air into the drum via an air inlet having a convex wall extending into the rotating drum and having a plurality of through holes extending radially through the convex wall and through which the hot air enters the drum.
[0018] Additional and/or other aspects and advantages of the present invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] These and/or other aspects and advantages of the present invention will become apparent and more readily appreciated from the following detailed description, taken in conjunction with the accompanying drawings of which:
[0020] FIG. 1 is a sectional view schematically illustrating a clothes drying apparatus according to an embodiment of the present invention;
[0021] FIG. 2 is an enlarged sectional view of portion A of FIG. 1 , illustrating an air inlet section according to the embodiment shown in FIG. 1 ; and
[0022] FIG. 3 is a front view of the clothes drying apparatus of FIG. 1 .
DETAILED DESCRIPTION OF EMBODIMENTS
[0023] Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present invention by referring to the figures.
[0024] FIG. 1 is a sectional view schematically illustrating a clothes drying apparatus according to an embodiment of the present invention.
[0025] As shown in FIG. 1 , the clothes drying apparatus according to the illustrated embodiment of the present invention includes a housing 1 , a rotating drum 2 installed in the housing 1 , and adapted to receive clothes to be dried, and a door 13 for opening and closing an opening formed at a front panel 9 mounted to a front end of the rotating drum 2 .
[0026] The housing 1 has an approximately box shape. The door 13 is pivotably mounted to a front wall of the housing 1 to allow the user to put clothes, to be dried, into the rotating drum 2 through the opening formed at the front panel 9 , or to take dried clothes out of the rotating drum 2 through the opening. The housing 1 is provided, at a rear wall 1 a thereof, with intake holes (not shown) for introducing ambient air into an intake duct 7 .
[0027] The rotating drum 2 has a cylindrical structure with openings at front and rear ends thereof. Front and rear panels 9 and 10 , respectively, are mounted to the front and rear ends of the rotating drum 2 , respectively, to close the rotating drum 2 while allowing the rotating drum 2 to be rotatable with respect therewith. The rotating drum 2 is made of a stainless steel, e.g., because it dries clothes by use of hot air.
[0028] The rotating drum 2 is configured to dry clothes while rotating at low speed. To this end, the clothes drying apparatus also includes a driving unit 3 , and a drive motor 4 . The driving unit 3 is coupled to a shaft (not shown) of the drive motor 4 . The driving unit 3 includes a pulley 5 coupled to the shaft of the drive motor 4 , and a belt 6 connected between the pulley 5 and the rotating drum 2 . With this configuration, the driving unit 3 transmits a drive force from the drive motor 4 to the rotating drum 2 . Although a specific belt drive arrangement has been described, it is to be understood that other drive arrangements are possible.
[0029] The front and rear panels 9 and 10 are fixedly mounted to the housing 1 such that they rotatably support the rotating drum 2 . In order to reduce friction generated between each of the front and rear panels 9 and 10 and an associated peripheral end of the rotating drum 2 , a friction reducing member 30 is interposed between each of the front and rear panels 9 and 10 and the associated peripheral end of the rotating drum 2 .
[0030] A plurality of lifters 20 are arranged on an inner peripheral surface of the rotating drum 2 while being uniformly circumferentially spaced apart from one another. The lifters 20 serve to raise the cloths to the top of the rotating drum 2 , and then release the clothes at a desired level to cause the clothes to be dropped to the bottom of the rotating drum 2 , in accordance with rotation of the rotating drum 2 , in order to cause the clothes to be uniformly dried.
[0031] The clothes drying apparatus is configured to dry clothes in accordance with a hot air circulation process for sucking air, heating the sucked air to generate hot air, and venting exhausted hot air. To this end, the clothes drying apparatus also includes the intake duct 7 , a heater 11 , and an exhaust duct 8 .
[0032] The intake duct 7 is opened at its inlet portion while being connected at its outlet portion to the rear panel 10 . The intake duct 7 extends vertically to have the inlet portion at a lower end thereof while having the outlet portion at an upper end thereof. The heater 11 is arranged in the intake duct 7 to heat air introduced into the intake duct 7 . The heater 11 may be an electric heating wire or an electric heating wire sheathed with ceramic. In this embodiment of the present invention, the heater 11 is arranged at an inlet portion of the intake duct 7 .
[0033] The exhaust duct 8 is connected, at an inlet portion thereof, to the front panel 9 while being opened at an outlet portion thereof. The outlet portion of the exhaust duct 8 extends externally beyond the housing 1 . An exhaust fan 12 is arranged in the exhaust duct 8 . With this configuration, ambient air around the housing 1 can be introduced into the rotating drum 2 via the intake duct 7 , and then forcibly vented out of the housing 1 via the exhaust duct 8 . The exhaust fan 12 is rotated by the drive motor 4 , along with the rotating drum 2 .
[0034] The rear panel 10 is provided with an air inlet section 10 a communicating with the intake duct 7 . The air inlet section 10 a has a dome structure protruded into the interior of the rotating drum 2 . The air inlet section 10 a is provided with a plurality of through holes 10 extending radially through the air inlet section 10 a. The air inlet section 10 a has a diameter approximately equal to the diameter of the outlet portion of the intake duct 7 .
[0035] In this embodiment of the present invention, the air inlet section 10 a is integral with the rear panel 10 . However, the air inlet section 10 a may be formed as a separate member. In this case, the air inlet section 10 a may be attached to the rear panel 10 . However, where the air inlet section 10 a is integral with the rear panel 10 , there are advantages in terms of reduction in air resistance, and reduction in machining costs and material costs.
[0036] FIG. 2 is an enlarged sectional of portion A of FIG. 1 . FIG. 2 illustrates an air inlet section according to this embodiment of the present invention.
[0037] As described above, the air inlet section 10 a has a convex structure, that is, a dome structure, protruded into the interior of the rotating drum 2 . The diameter of the air inlet section 10 a may be vary depending on myriad factors including, for example, the heater performance and drying efficiency of the clothes drying apparatus, and respective sizes of the intake and exhaust ducts.
[0038] The through holes 10 b provided at the air inlet section 10 a extend radially through the air inlet section 10 a, as described above. By virtue of such a structure of the through holes 10 b, hot air is introduced into the interior of the rotating drum 2 in radial directions, so that it can be supplied into the rotating drum 2 in an enlarged region. For the same purpose, the through holes 10 b may have different sizes or a non-uniform arrangement. It will be appreciated by those skilled in the art that various designs of the through holes 10 b may be implemented within the scope of the present invention.
[0039] FIG. 3 is a front view of a clothes drying apparatus according to this embodiment of the present invention.
[0040] A controller 14 adapted to control a drying cycle of the clothes drying apparatus is provided at an upper portion of the front wall of the housing 1 . The controller 14 includes a plurality of buttons for allowing the user to set a desired drying mode, and a display panel for displaying an operating state of the clothes drying apparatus. The door 13 is arranged beneath the control unit 14 . Referring to FIG. 3 , the door 13 , the rotating drum 2 installed in the housing 1 , the air inlet section 10 a communicating with the rotating drum 2 to introduce air into the rotating drum 2 , and the inlet portion of the exhaust duct 8 adapted to vent hot air from the rotating drum 2 are shown.
[0041] As shown in FIG. 3 , the air inlet section 10 a is arranged at a right upper portion of the rear panel 10 mounted to the rear end of the rotating drum 2 . Of course, the air inlet section 10 a may be arranged at any position of the real panel 10 . However, since the exhaust duct 8 is arranged at a left lower portion of the front panel 9 mounted to the front end of the rotating drum 2 , the air inlet section 10 a is arranged at a position diagonal to the position of the exhaust duct 8 in the illustrated embodiment of the present invention, in order to allow hot air radially injected into the rotating drum 2 through the air inlet section 10 a to perform heat exchange with clothes, contained in the rotating drum 2 , in an enlarged region.
[0042] The air inlet section 10 a may also be arranged at a left upper portion of the rear panel 10 mounted to the rear end of the rotating drum 2 . In this case, the exhaust duct 8 may be arranged at a right lower portion of the front panel 9 mounted to the front end of the rotating drum 2 . Since the rotating drum 2 rotates, there is little difference between the case in which the air inlet section 10 a is arranged at the left upper portion of the rear panel 10 and the case in which the air inlet section 10 a is arranged at the right upper portion of the rear panel 10 .
[0043] Now, the operation and effect of the clothes drying apparatus provided with the air inlet section 10 a in accordance with this embodiment of the present invention will be described in detail.
[0044] First, the user puts clothes to be dried into the rotating drum 2 , and then closes the door 13 . When the user subsequently operates the clothes drying apparatus, the drive motor 4 , exhaust fan 12 , and heater 11 are energized and the rotating drum 2 is rotated at low speed. Simultaneously, ambient air around the housing 1 is introduced into the intake duct 7 .
[0045] With the rotation of the rotating drum 2 , the clothes are sequentially upwardly raised from the bottom of the rotating drum 2 by the lifters 20 , and then dropped from the top of the rotating drum 2 onto the bottom thereof. The air introduced into the intake duct 7 is heated by the heater 11 , and then fed to the rotating drum 2 through the through holes 10 b of the air inlet section 10 a of the rear panel 10 .
[0046] That is, ambient air is heated by the heater 11 while passing through the intake duct 8 , and is then fed toward the upper end of the intake duct 8 in accordance with a rising effect thereof and a blowing force of the exhaust fan 12 . The hot air is then introduced into the rotating drum 2 while passing through the through holes 10 b of the air inlet section 10 b.
[0047] The hot air is uniformly radially spread in the rotating drum 2 as it is radially introduced into the rotating drum 2 through the through holes 10 b. Since the rotating drum 2 rotates, the hot air supplied in the rotating drum 2 can reach not only clothes raised by the lifters 20 , and then dropped, but also clothes placed on the bottom of the rotating drum 2 .
[0048] Meanwhile, the hot air has increased humidity due to its absorption of humidity from the clothes coming into contact therewith, so that it tends to be mainly distributed in a lower portion of the rotating drum 2 . This hot air is outwardly vented through the exhaust duct 8 in accordance with the blowing force of the exhaust fan 12 , so that it is exhausted to the exterior of the clothes drying apparatus. As described above, the hot air is introduced into the rotating drum 2 not only in parallel directions, but also in radial directions, so that it is uniformly spread in the interior of the rotating drum 2 without being locally concentrated at a portion of the interior of the rotating drum 2 .
[0049] As is apparent from the above description, in accordance with the present invention, the air inlet section provided at the rear panel mounted to the rear end of the rotating drum has an improved structure. Accordingly, it is possible to increase the flow rate and flow velocity of hot air introduced into the rotating drum while using a small fan size. The hot air can also be uniformly supplied into the entire portion of the interior of the rotating drum, so that there is no dead region where hot air cannot reach. Accordingly, the contact area of hot air with clothes increases, thereby enhancing the drying efficiency of the clothes drying apparatus.
[0050] Although a few embodiments of the present invention have been shown and described, the present invention is not limited to the described embodiments. Instead, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.
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A clothes drying apparatus including: a rotating drum; an intake duct which delivers hot air to the rotating drum; and an air inlet section at the rotating drum and in communication with the intake duct. The air inlet section is configured to radially supply the hot air from the intake duct into the rotating drum.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from Japanese Application Serial No. 2005-73339, filed on Mar. 15, 2005, Japanese Application Serial No. 2005-73340, filed on Mar. 15, 2005, and Japanese Application Serial No. 2005-73338, filed on Mar. 15, 2005, the entire contents of each of which are herein incorporated by reference.
BACKGROUND
[0002] Image capturing systems such as video camera systems and still camera systems often include circuitry to enable auto-focusing of an image. Auto-focusing systems often include a combination of photo-sensors and signal processing circuits. Based on signals received from the photo-sensors, the signal processing circuits can determine various settings for the image capturing system.
SUMMARY
[0003] According to an aspect of the present invention, a method for auto-focusing in an image-capturing system includes sampling output signals from an auto-focusing circuit in a first interval of lens distances and determining a first lens distance and a second lens distance corresponding to the two highest values of the sampled output signals in the first interval of lens distances. The method also includes sampling output signals from the auto-focusing circuit in a second interval between the first lens distance and the second lens distance.
[0004] Embodiments can include one or more of the following.
[0005] The method can include determining a lens distance corresponding to the maximum value of the sampled output signals in the second interval and setting the focus position to the determined lens distance. The second interval can be smaller than the first interval. The first interval can include a first set of lens positions having a first distance between each of the lens positions and the second interval includes a second set of lens positions having a second distance between each of the lens positions. The second distance can be smaller than the first distance.
[0006] The method can also include performing signal processing can include performing pre-gamma correction according to predetermined function type, spatially filtering the image signals, weighting and integrating the filtered signals, and outputting the weighted and integrated signals as auto-focusing signals. The method can also include determining a third lens distance and a fourth lens distance corresponding to the two highest values of the sampled output signals in the second interval of lens distances, sampling output signals from the auto-focusing circuit in a third interval between the third lens distance and the fourth lens distance, determining a lens distance corresponding to the maximum value of the sampled output signals in the third interval, and setting the focus position to the determined lens distance.
[0007] According to an aspect of the present invention, an image-capturing system can include a focus lens and an auto-focusing circuit. The auto-focusing circuit can be configured to sample output signals from in a first interval of lens distances and determine a first lens distance and a second lens distance corresponding to the two highest values of the sampled output signals in the first interval of lens distances. The auto-focusing circuit can also be configured to sample output signals in a second interval between the first lens distance and the second lens distance, the second interval being smaller than the first interval.
[0008] Embodiments can include one or more of the following.
[0009] The auto-focusing circuit can be further configured to determine a lens distance corresponding to the maximum value of the sampled output signals in the second interval and set the focus position to the determined lens distance. The image-capturing can also include a signal processing circuit. The signal processing circuit can be configured to perform pre-gamma correction according to predetermined function type, spatially filter the image signals, weight and integrate the filtered signals, and output the weighted and integrated signals as auto-focusing signals to the auto-focusing circuit.
[0010] According to an aspect of the present invention, a method for determining an exposure parameter based on an illumination condition includes calculating a red divided by green (R/G) value, calculating a blue divided by green (B/G) value, and comparing the R/G and B/G values to a predetermined auto-white balancing map to determine an exposure parameter.
[0011] Embodiments can include one or more of the following.
[0012] The method can also include selecting a red signal, a blue signal, a first green signal, and a second green signal in a predetermined area of an imaging device. The predetermined area can include four adjacent pixels. Calculating the R/G value can include determining a first 1/G value based on the first green signal and multiplying the red signal by the first 1/G value. Calculating the B/G value can include determining a second 1/G value based on the second green signal and multiplying the blue signal by the second 1/G value.
[0013] The auto-white balancing map can include a plurality of regions corresponding the different illumination conditions. The auto-white balancing map can include a region corresponding to fluorescent lamp illumination. The method can also include generating a flicker correction signal based on the determined exposure parameter if the R/G and B/G values correspond to the region corresponding to fluorescent lamp illumination. The exposure parameter can be a shutter speed.
[0014] Calculating the R/G value and calculating the B/G value can include selecting a red signal, a blue signal, a first green signal, and a second green signal in a plurality of predetermined areas of an imaging device, calculating a plurality of intermediate R/G values and intermediate B/G values based on the selected red signal, the selected blue signal, the selected first green signal, and the selected second green signal in the plurality of predetermined areas, averaging the calculated intermediate R/G values to generate the R/G value, and averaging the calculated intermediate B/G values to generate the B/G value.
[0015] According to an aspect of the present invention, an image-capturing system can include a circuit configured to calculate a red divided by green (R/G) value, calculate a blue divided by green (B/G) value, and compare the R/G and B/G values to a predetermined auto-white balancing map to determine an exposure parameter.
[0016] Embodiments can include one or more of the following.
[0017] The auto-white balancing map can include a plurality of regions corresponding the different illumination conditions. The auto-white balancing map can include a region corresponding to fluorescent lamp illumination and the circuit if further configured to generate a flicker correction signal based on the determined exposure parameter if the R/G and B/G values correspond to the region corresponding to fluorescent lamp illumination.
[0018] According to an aspect of the present invention, a method includes providing a pre-gamma function having a first region, a second region, and a third region, the derivative of the function in the second region being greater than the derivative of the function in the first and third regions. The method also includes receiving image signals from a predetermined number of locations on an imaging device and performing pre-gamma correction on the received image signals using the pre-gamma function to generate a pre-gamma corrected image signal.
[0019] Embodiments can include one or more of the following.
[0020] Performing pre-gamma correction on the received image signals can include multiplying the received image signals by the derivative of the pre-gamma function in a region of the pre-gamma function corresponding to an illumination level of the received signal. The he image signals can correspond to the image signals for a plurality of green pixels. The pre-gamma function can be an approximately s-shaped function. The method can also include performing signal processing on the pre-gamma corrected signal. Performing signal processing on the pre-gamma corrected signal can include spatially filtering the image signals, weighting and integrating the filtered signals, and outputting the weighted and integrated signals as auto-focusing signals. Spatially filtering the image signals can include spatially filtering the image signals using Lapracian filtering or differential filtering.
[0021] According to an aspect of the present invention, an image-capturing system includes a circuit configured to provide a pre-gamma function having a first region, a second region, and a third region, the derivative of the function in the second region being greater than the derivative of the function in the first and third regions, receive image signals from a predetermined number of locations on an imaging device, and perform pre-gamma correction on the received image signals by multiplying the received image signals by the derivative of the pre-gamma function in a region of the pre-gamma function corresponding to an illumination level of the received signal using the pre-gamma function to generate a pre-gamma corrected image signal.
[0022] Embodiments can include one or more of the following.
[0023] The pre-gamma function can be an approximately s-shaped function.
[0024] In some embodiments, performing multi-sampling can provide higher auto-focusing accuracy and/or can reduce the probability of selecting an undesired signal peak during the auto focus process.
[0025] In some embodiments, performing multi-sampling can reduce the total time for the auto-focus process.
[0026] In some embodiments, the auto-focusing system can realize both higher focusing accuracy and shorter focusing time due to the use of a multi-sampling process.
[0027] In some embodiments, a flicker correction can be implemented using existing hardware and software resources for auto-white balancing, thus providing a low cost flicker correction system and method. In addition, in some embodiments, the flicker correction time can be reduced, because the flicker correction requires no additional process time except existing AWB process time.
[0028] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below.
DESCRIPTION OF DRAWINGS
[0029] FIG. 1 is a block diagram of an auto-focusing system.
[0030] FIG. 2 is a graph of an auto-focusing signal output from auto-focusing circuit.
[0031] FIG. 3 is a flow chart of an auto-focusing process.
[0032] FIG. 4 is a flow chart of a flicker correction process.
[0033] FIG. 5 is a diagram of pixel color pattern on an imaging device.
[0034] FIG. 6 is a diagram of pixel color pattern on an imaging device.
[0035] FIG. 7 is a diagram of pixel color pattern on an imaging device.
[0036] FIG. 8 is a graph representative of an auto-white balancing chart.
[0037] FIG. 9 is a diagram of G pixel pattern on an imaging device.
[0038] FIG. 10 is a graph representative of a pre-gamma correction function.
[0039] FIG. 11 is a graphical representation of a filter.
[0040] FIG. 12 is a graphical representation of a filter.
[0041] FIG. 13 is a graphical representation of a filter.
[0042] FIG. 14 is a block diagram of an auto focus system.
DETAILED DESCRIPTION
[0043] Referring first to FIG. 1 , a block diagram of an auto-focusing system 12 that includes a focus lens 10 and zoom lens 20 is shown. Through the focus lens 10 and the zoom lens 20 , an optical image is projected on a plurality of pixels on an imaging device 30 . The pixels convert the optical image into electrical analog image signals. The electrical analog image signals are converted into digital image signals by an analog digital (A/D) converter (not shown). The digital image signals are fed to an optical black (OB) clamping circuit 40 and clamped to predetermined levels. The clamped digital image signals are fed to a defect correction circuit 50 which electrically corrects the signals. The corrected image signals are fed to a lens shading correction circuit 60 and electrically corrected to image signals without lens shading.
[0044] An output signal line of the lens shading correction circuit 60 is divided into multiple lines (e.g., four lines). The first signal line is connected to offset gain circuit 70 which is connected to a video signal processing circuit (not shown). The second signal line is connected to an auto-exposing (AE) circuit 80 . The third signal line is connected to an auto-white-balancing (AWB) circuit 90 . The fourth signal line is connected to an auto-focusing (AF) circuit 100 .
[0045] The auto-focusing (AF) circuit 100 includes a pre-gamma correction circuit 110 , a spatial filtering circuit 120 , and a weighting and integrating circuit 130 . The weighting and integrating circuit 130 outputs an auto-focusing signal. The auto-focusing (AF) output signal from the auto-focusing (AF) circuit 100 is fed to CPU 140 . The CPU 140 supplies driving signals to drive a focus motor 150 and a zoom motor 160 which move the focus lens 10 and the zoom lens 20 to a focus position.
[0046] During an auto-focusing operation, the auto-focusing circuit 100 analyzes signals from the imaging device 30 . The auto-focusing circuit changes the distance of focus lens 10 by using motor 150 and observes characteristics of the images at the various focus distances to determine if the image is in focus.
[0047] Referring to FIG. 2 , a graph 200 of image samples measured by the auto-focusing circuit 100 as the distance of the focus lens 10 is changed is shown. The horizontal axis 204 is lens moving distance of focus lens 10 and vertical axis 202 is the amplitude of the auto-focus signal output. The amplitude of the auto-focus signal output changes as the distance of the lens changes as the distance of the lens 10 is changed. A larger amplitude signal indicates that the image is more focused than a lower amplitude signal. The auto-focus signal output is maximized at focus position (X AF ) 232 to focus amplitude (A AF ) 231 .
[0048] Referring to FIG. 3 , a flow chart of an auto-focusing operation that uses a multi-sampling process 170 is shown. Process 170 includes measuring a first set of auto-focus signal outputs from the auto-focus circuit 100 within a first interval of lens moving distances (step 172 ). The first sampling uses a relatively large step size to generate a rough sampling of the AF signal outputs over a wide range of lens positions. For example, as shown in FIG. 2 , the first sampling is performed using a step size indicated by arrow 226 and generates AF amplitudes for the auto-focus signal at lens distances 206 , 208 , 210 , 212 , 214 , 216 , 218 , and 219 .
[0049] Based on the determined amplitudes of the AF signal at the samples lens distances, process 170 determines the two samples have the greatest amplitude of the AF signal (step 174 ). These two samples provide a narrowed range of lens distances in which the focus amplitude (A AF ) 231 and focus position (X AF ) 232 is expected to lie. For example, in FIG. 2 , the sampled values 230 and 234 have the greatest amplitudes, therefore, the focus amplitude (A AF ) 231 is expected to lie between lens distances 210 and 212 .
[0050] After the first sampling, a second sampling is performed using a smaller step size for the lens using the lens position associated with the selected first maximum value as the starting lens position and using the lens position associated with the selected second maximum value as the end location of the sampled range (step 176 ). For example, in FIG. 2 , the step size for the second sampling is a quarter of the step size for the first sampling (indicated by arrow 228 ) and begins at location 210 and ends at location 212 .
[0051] Based on the second sampling, process 170 determines the position where maximum value of the auto-focus signal is present (step 178 ). Process 170 sets this lens distance as the focus position (step 180 ). For example, in FIG. 2 , point 232 has the highest measured AF value. Therefore, the lens distance 222 corresponding to the AF value 232 will be set as the lens auto focus distance based on the auto-focus process 170 .
[0052] It is believed that performing multi-sampling can provide higher auto-focusing accuracy and/or can reduce the probability of selecting an undesired signal peak during the auto focus process.
[0053] It is also believed that performing multi-sampling can reduce the total time for the auto-focus process. In order to determine the correct distance for the lens during the auto focus process, the lens must be moved to various positions and samples must be taken at the various positions. For example, if an auto focus procedure uses 16 lens positions (as shown in FIG. 2 ) and 100 ms is needed to move the lens and measure the AF signal at each lens location, then a total of 1.6 seconds would be required to measure the 16 locations. However, using the multi-sampling process described, the first sampling has 8 steps amounting to a time of 800 ms and the second sampling uses four steps amounting to a time of 400 ms. Therefore, the total time for the multi-sampling process is 1.2 seconds as compared to 1.6 seconds for the process that samples all 16 locations. The multi-sampling process maintains the accuracy (e.g., results in the same step size) of the auto-focus while reducing total amount of time needed for the auto focusing.
[0054] As described above, the auto-focusing circuit 100 can realize both higher focusing accuracy and shorter focusing time, due to detailed investigation near the focus position by the double sampling.
[0055] Although the multi-sampling process described above has been shown using a double-sampling process, the auto-focusing process is not limited to a double-sampling process. Rather, any multi-sampling, such as triple-sampling, quadruple-sampling, or more, that is capable of auto-focusing can be used.
[0056] In some embodiments, the auto-focusing system can use one sample having highest amplitude of auto-focus signal instead of two samples, and a second sampling can be performed around this sample.
[0057] Referring back to FIG. 1 , imaging system 12 can be used in a variety of different lighting conditions. These differing lighting conditions can cause various changes in the imaging. For example, when the imaging system 12 is used outside the sun or natural lighting provides the illumination. In contrast, when the imaging system 12 is used indoors a fluorescent lamp may provide the indoor illumination. The light intensity resulting from illumination provided by a fluorescent lamp periodically changes (e.g., 50 Hz or 60 Hz). This phenomenon is referred to as flicker noise. In some cases, flicker noise can generate undesirable effects in the resulting image such as spatially varying luminance change. Conventional auto-exposure circuits often determine exposure parameters by measuring an average value of light intensity and do not correct the exposure parameters in the flicker noise environment. In system 12 , auto-white-balancing (AWB) circuit 90 corrects for flicker noise based on a comparison of the color intensity and a predetermined mapping of the color intensity for various lighting conditions.
[0058] Referring to FIG. 4 , a process 250 for AWB mapping to remove flicker noise based on the color intensity of pixels in image is shown. FIG. 5 shows exemplary mappings of color pixels on an imaging device. FIGS. 6 and 7 show sub-sampled pixels for AWB processing. The auto-white-balancing circuit can use all or part of these color pixels on an imaging device. The color mappings include four color signals that are derived from four color pixels adjacent to each other. For example, a set of red, green, blue, and green (RGBG) pixels in a predetermined area on the imaging device can be used.
[0059] Process 250 calculates a value for R/G and B/G (step 254 ). In some embodiments, the green (G) signal is converted to l/G signal using predetermined conversion table. The R signal and the B signal are multiplied with the 1/G signal to obtain the R/G signal and B/G signal. In other embodiments, the system divides the red signal by the green signal and the blue signal by the green signal without first calculating 1/G.
[0060] The calculated R/G can B/G values are compared to a predetermined auto-white balancing (AWB) map to determine the lighting type (step 256 ). FIG. 8 shows an exemplary AWB map 260 in which the B/G value is graphed on the x-axis 262 and the R/G value is graphed on the y-axis 264 . AWB map 260 is divided into multiple regions (e.g., regions 266 , 268 , 272 , 274 , 276 , 278 , and 280 ) corresponding to various lighting conditions. The regions are determined based on scene information for images taken in various different lighting conditions. For example, region 280 is common scene, region 284 is indoor scene, regions 266 , 268 , 272 , 274 , and 278 are fluorescent lamp scenes and region 276 is an outdoor scene. The number of scenes and/or the shape of the corresponding AWB regions can vary as desired. The AWB map can be determined experimentally or can be calculated based on previously obtained image information. By comparing the R/G signal (x-axis 262 ) and B/G signal (y-axis 264 ) with the AWB map, the system determines whether fluorescent lamp illumination is used. If so, system 90 generates a flicker correction signal and modifies the exposure parameters according to the flicker correction signal (step 258 ). For example, if the analyzed image corresponds to a fluorescent lamp illumination the shutter speed can be increased to be greater than 10 ms to reduce or eliminate the flicker from the resulting image.
[0061] While in the above embodiment, a single calculation of R/G and B/G was used to determine the lighting conditions based on the AWB map, multiple calculations can be used. In some embodiments, the system calculates multiple R/G and B/G values from various portions of the image. These values are averaged to determine an average R/G and an average B/G value to be used to determine the lighting condition from the AWB mapping.
[0062] In some embodiments, the flicker correction described above can be implemented using existing hardware and software resources, thus providing a low cost flicker correction system and method. Furthermore, the flicker correction time can be significantly reduced, because it requires no additional process time except existing AWB process time.
[0063] Referring back to FIG. 1 , the image signals derived from the pixels on the imaging device 30 may include noise which influences the accuracy of the auto focus operation for the imaging device 30 . For example, if there is a low luminosity in the image there may be low auto focus accuracy in comparison to a high luminosity image. Therefore, noise included in the low luminosity image may have a greater effect on the focusing of the system. In order to reduce the effect of the luminosity level on the auto-focusing operation, the input signal can be modified by a pre-gamma correction function. Auto focus circuit 100 provides pre-gamma correction to the image signal to reduce the influence of the noise in low level lighting on the auto focus operation.
[0064] Auto-focusing circuit 100 in image-capturing system 12 performs pre-gamma correction to image signals derived from predetermined pixels on the imaging device 30 and performs signal processing on the pre-gamma-corrected image signals. The signal processing of the pre-gamma-corrected image signals can include spatial filtering of the image signals, weighting and integrating the filtered signals, and outputting the weighted and integrated signals as auto-focusing signals. The pre-gamma correction is performed to multiple signals sampled at predetermined intervals.
[0065] Referring to FIG. 9 which shows an example of image signals derived from predetermined pixels on the imaging device 30 , the pixels on imaging device 30 represent a plurality of green (G) pixels at predetermined positions on the imaging device 30 .
[0066] Referring to FIG. 10 , an exemplary pre-gamma correction function 310 for the auto-focusing system is shown. The pre-gamma correction is performed on multiple signals sampled at predetermined intervals using function 310 . In the graph of the pre-gamma function 310 , the x-axis represents the input signal luminosity and the y-axis represents the output signal that is based on a mathematical transformation of the input signal. The pre-gamma function includes multiple regions 316 , 318 , 320 , 322 , 324 , 326 , 328 , and 330 having differing slopes resulting in an “S-shaped” function. The slope of each region is determined based on the slope of a line formed between two endpoints for the region. The slope can also be determines based on a derivative of the “s-shaped” function at a particular location. The slope of the regions having a relatively low luminosity (e.g., regions 316 and 318 ) and the regions having a relatively high luminosity (e.g., regions 328 and 330 ) is less than the slope of the regions having a moderate luminosity (e.g., regions 322 , 324 , and 326 ).
[0067] In operation, a value of an input signal (e.g., the input shown in FIG. 9 ) is multiplied by the slope of the pre-gamma function for the associated luminosity level. Since the slope of the pre-gamma signal is lower for signal inputs having relatively low or relatively high luminosities, high frequency component of the low and high luminosity signals in the image are reduced. For example, if the signal is at a low luminosity level at input, differential of the signal will be lower relative to the other signals after calculating the pre-gamma correction using function 310 .
[0068] After performing the pre-gamma correction, additional filtering may be performed in the auto focusing circuit 100 . FIGS. 11, 12 , and 13 show graphical representations of Lapracian filtering, vertical differential filtering, and lateral differential filtering respectively. The filtering can be used to emphasize edge components of the image.
[0069] FIG. 14 shows a weighting and integrating circuit 130 in the auto-focusing circuit 100 . The image signals (e.g., represented by arrow 109 ) derived from predetermined pixels on imaging device are input into the pre-gamma correction circuit 110 . The pre-gamma correction on the image signals 109 . The pre-gamma correction is based on the S-shaped function 310 . The pre-gamma correction circuit 110 multiplies the input signals by the slope of the pre-gamma function 310 in the appropriate luminosity range. The pre-gamma-corrected image signals (e.g., represented by arrow 134 ) are fed to the spatial filtering circuit 120 which emphasizes the edge components of the image using a filter such as those shown in FIGS. 11, 12 , and 13 . The filtered image signals are input into the weighting and integrating circuit 130 which averages the filtered image signals to generate an average weighted signal. The weighted and integrated image signals are fed to the CPU 140 .
[0070] The CPU 140 receives the weighted and integrated image signals (also referred to as the auto-focusing signal) and produces the driving signal to drive the focus motor 150 based on the received signal. The focus motor 150 moves the focus lens 10 to the focus position. For example, if the auto focus value is high, the value indicates a high frequency component. In general, the high frequency component will be greater if the image is in focus; and if the image is not in focus then the high frequency component will be small. The magnitude of the high-frequency component indicates to the drive motor the type of correction that should be made to the lens distance to correct the focusing of the image.
[0071] As described above, the auto-focusing circuit 100 can realize both higher focusing accuracy and shorter focusing time.
[0072] Finally, although the present invention has been particularly shown and described above, the present invention is not so limited. For instance, the present invention is not only limited to the signal processing to the pre-gamma-corrected image signals shown and described. Rather, any signal processing that is capable of auto-focusing can be used. Therefore, these and other changes in form and details may be made to the preferred embodiments without departing from the true spirit and scope of the invention as defined by the appended claims.
[0073] Accordingly, other embodiments are within the scope of the following claims:
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Methods and related computer program products, systems, and devices for auto-focusing in an image-capturing system includes sampling output signals from an auto-focusing circuit in a first interval of lens distances and determining a first lens distance and a second lens distance corresponding to the two highest values of the sampled output signals in the first interval of lens distances.
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RELATED APPLICATIONS
The present invention was first described in and claims the benefit of U.S. Provisional Application No. 61/886,939, filed Oct. 4, 2013, the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to an adjustable cane with a folding platform pivotally attached to a bottom thereof.
BACKGROUND OF THE INVENTION
For those that suffer from afflictions such as arthritis or other degenerative diseases, even the most trivial daily activity can become difficult, and sometimes impossible. The use of a conventional walking cane by people that suffer from the aforementioned afflictions, as well as by those of advancing age, provides a stabilizing force, and a means by which they can move about safely and with lessened discomfort. While the use of a walking cane does allow the user to move about, there are numerous disadvantages associated with their use. Perhaps the most troublesome is that when the person is walking or standing and needs to use both hands to perform a function, there is not often a location where the cane can be stored in order to free up the hands. The user is forced to hook it over their arm, walk a distance to where they can store it, or perhaps lay it on the ground. None of these are satisfactory solutions as they are clumsy, and require extra effort, or require bending or stooping over to pick up the cane. Additionally, the single support point base of the cane makes it unstable, especially with off-center use such as when trying to rise from a sitting position to a standing one. Accordingly, there exists a need for a means by which a standard walking cane can be modified to address the deficiencies as described above. The development of the cane fulfills this need.
The apparatus is a cane system that enables the unattended self-standing support of the cane when not in use, and also provides for added assistance when using the cane to rise from a sitting position. The cane shaft telescopes for length adjustment. A platform, positioned at the bottom of the cane, folds out to form an approximate ninety degree (90° ) angle with the cane shaft. This platform can be folded in when it is desired to use the apparatus as a cane in a conventional manner. When folded out, the cane becomes self standing, which is beneficial when both hands are needed to perform functions, and no location is handy to temporarily place the cane. Additionally, the platform, when in a folded out position, imparts a stabilizing force to the upper part of the cane, making it stable when used in an off-center manner. Such usage is common when pushing on the cane when trying to stand up from a sitting position in a chair. A platen formed into the platform enables a user to place his foot on the platform for providing a supplementary stabilizing force when attempting to rise from a sitting position.
Prior art in this field consists of telescoping canes with kickstand style supports. While these supports may present a means to support the cane in a free-standing position, they fail to provide suitable stabilizing balance to assist a user in rising from a seated position. Furthermore, such supports fall short in enabling a user to employ his foot to further stabilize the cane. Other prior art canes are equipped with modified handles that support the cane in a free-standing position, but this requires placing the cane on the ground in an inverted position such that the cane's handle is rested upon the unsanitary ground. Other prior art canes are collapsible, or otherwise foldable, which provides a means to free up a user's hands, but these canes lack the added utility of supplemental stabilization provided by the platform of the current invention. Other prior art canes are equipped with tiltable handles, which may be exploited to provide added leverage for user's, but these again fail to provide suitable stabilizing balance to assist a user in rising from a seated position. Tilt-handle canes further lack the means to support the cane in a free-standing position.
It is an objective of this invention to provide a cane having a platform affixed to a bottom portion thereof to enable free-standing of the cane in an up-right position, thereby freeing up a user's hands.
It is a further objective of this invention to enable the platform to provide stability for a user employing the cane, especially when attempting to rise from a seated position.
It is a further objective of this invention to provide a platen formed into the platform to enable a user to employ his foot by placing it on the platform and supply supplementary stabilizing balance, especially when attempting to rise from a seated position.
It is a further objective of this invention to enable pivoting motion of the platform to deploy and retract the platform at a user's discretion.
It is a further objective of this invention to enable locking the platform in a deployed or retracted position.
It is a further objective of this invention to provide a length adjustment means to the cane so as to enable a user to exploit proper and adequate leverage from the cane based upon a user's stature.
An added benefit of this invention is to provide fingered reliefs in the handle portion for added dexterity and comfort.
An additional benefit of this invention is to provide a slip resistant feature to a bottom of the cane to assist with steadiness while the cane is in use.
SUMMARY OF THE INVENTION
The apparatus comprises a telescoping shaft assembly, a hand grip having a plurality of formed finger reliefs, and a platform assembly. The telescoping shaft assembly comprises a first shaft that slidably inserts into another shaft, where the adjustment of the length of the shaft assembly occurs by the first shaft traversing the length of the second shaft. One (1) shaft is provided with a spring-loaded lock button that engages correspondingly aligned apertures of the other shaft to lock the shafts in relative positions to each other. A top portion of the shaft assembly is provided with the hand grip.
The platform assembly is pivotally attached to a bottom portion of the shaft assembly, and comprises a platform that pivots from an up position to a down position. The up position corresponds to the platform being substantially parallel to the shaft assembly, and the down position corresponds to the platform being substantially perpendicular to the shaft assembly. The platform can be locked in the up or down position. While in the down position, the shaft assembly and platform assembly form a general “L”-shape, where the platform provides a base for added stability. The platform also enables the apparatus to stand freely. In addition, the platform may be used to place a user's foot upon to assist with steadying the apparatus while attempting to rise from a seated position. A platen is formed into the platform to better aid with placement of a user's foot upon the platform. While in an up position, the apparatus can be utilized as a cane in a conventional manner. A bottom portion of the cane is further provided with a high-friction tip such that when it is in the up position, the tip makes contact with the floor.
Furthermore, the described features and advantages of the disclosure may be combined in various manners and embodiments as one skilled in the relevant art will recognize. The disclosure can be practiced without one (1) or more of the features and advantages described in a particular embodiment.
Further advantages of the present disclosure will become apparent from a consideration of the drawings and ensuing description.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present disclosure will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is a perspective view of a walking cane with integral platform 10 , according to a preferred embodiment of the present invention;
FIG. 2 is an environmental view of the walking cane with integral platform 10 depicting an in-use state, according to a preferred embodiment of the present invention;
FIG. 3 is an exploded view of a platform assembly portion 50 of the walking cane with integral platform 10 , according to a preferred embodiment of the present invention;
FIG. 4 a is a close-up view of the platform assembly 50 depicting a deployed state, according to a preferred embodiment of the present invention;
FIG. 4 b is another close-up view of the platform assembly 50 depicting a stowed state, according to a preferred embodiment of the present invention; and,
FIG. 5 is a sectional view of a shaft assembly portion 20 of the walking cane with integral platform 10 taken along section line A-A (see FIG. 1 ), according to a preferred embodiment of the present invention.
DESCRIPTIVE KEY
10 walking cane with integral platform
20 shaft assembly
22 upper shaft section
24 lower shaft section
26 grip
28 finger relief
30 first aperture
32 a locking button
32 b spring
32 c fastener
34 first slot
36 first pin
38 tip
50 platform assembly
52 collar
53 center opening
54 platen
56 second pin
58 second slot
60 third slot
62 second aperture
100 user
105 hand
110 foot
115 floor surface
120 chair
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 5 . However, the invention is not limited to the described embodiment, and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
The present invention describes a walking cane with integral platform (herein described as the “apparatus”) 10 , having a deployable platform assembly 50 affixed to a bottom portion to aid a user 100 while rising from a sitting position upon a furniture item such as a chair 120 , as well as provide a self standing function.
Referring now to FIGS. 1 and 2 , a perspective and environmental views of the apparatus 10 , according to a preferred embodiment of the present invention, are disclosed. The apparatus 10 comprises a length-adjustable shaft assembly 20 , a hand grip 26 having a plurality of formed finger reliefs 28 , and a platform assembly 50 . The shaft assembly 20 is preferably made an aluminum tube material or other light-weight material. The shaft assembly 20 further comprises an upper shaft section 22 and a lower shaft section 24 being adjustably joined together in a telescoping manner via a plurality of first apertures 30 and a spring-loaded locking button 32 a . In use, a user 100 selectively obtains a desired length of the shaft assembly 20 by aligning and engaging the locking button 32 a within a particular first aperture 30 .
The shaft assembly 20 is affixed along a top end portion to an “L”-shaped hand grip 26 . The hand grip 26 preferably comprises a rubber-coated plastic or metal core preferably affixed to the upper shaft 22 being integrally-molded onto said shaft assembly 20 or otherwise equivalently affixed using adhesives, fasteners, or the like.
The shaft assembly 20 also provides pivoting attachment to a platform assembly 50 at a bottom end portion. The platform assembly 50 is to be capable of pivoting downwardly and being locked in a horizontal position allowing a user 100 to step upon the platform assembly 50 with one (1) foot 110 to provide stability to the shaft assembly portion 20 while using the apparatus 10 to stand up from a sitting position in a chair 120 . The platform assembly 50 may also be secured in an upward vertical stowed position (see FIG. 4 b ), allowing the apparatus 10 to be utilized for walking in an aided manner (see FIGS. 3 and 4 a ). The lower shaft section 24 further comprises a cylindrical rubber or soft plastic tip 38 partially inserted, and slightly protruding from a bottom open end portion, to provide high-friction contact with a floor surface 115 while utilizing the apparatus 10 during aided walking.
Referring now to FIG. 3 , an exploded view of a platform assembly portion 50 of the apparatus 10 , according to a preferred embodiment of the present invention, is disclosed. The shaft assembly 20 provides pivoting attachment to the platform assembly 50 at a bottom end portion via integral first slot 34 and first pin 36 portions. The platform assembly 50 comprises a collar 52 comprises a “U”-shaped center opening 53 being shaped so as to rotatingly receive the lower shaft section 24 within. The collar 52 also includes features which enable engagement and rotational attachment to the first slot 34 and first pin 36 portions of the shaft assembly 20 including a second pin 56 , a second slot 58 , a third slot 60 , and a pair of second apertures 62 .
The platform assembly 50 further comprises an integral and forwardly extending flat platen portion 54 being approximately four inches (4 in.) in width and six inches (6 in.) in length. The platen 54 is envisioned being made using a metal or plastic material and provides a suitable surface onto which a user 100 may place their foot 110 , thereby stabilizing the apparatus 10 for use while standing up from a sitting position. The lower shaft section 24 is attached to the collar portion 53 via press-fit of the second pin 56 through opposing second apertures 62 of the collar 52 , and coincidental insertion through the first slot portion 34 of the lower shaft section 24 . The first slot 34 allows the second pin 56 to move freely in a vertical direction, allowing the platform assembly 50 to pivot and to be secured at either vertical or horizontal positions via engagement of the first pin 36 within respective first slot 60 and second slot 58 portions (see FIGS. 4 a and 4 b ).
Referring now to FIGS. 4 a and 4 b , close-up views of the platform assembly 50 depicting deployed and stowed states, according to a preferred embodiment of the present invention, are disclosed. The selectable positioning of the platform assembly 50 allows rotation to a ninety (90° ) degree angle from the bottom of the lower shaft section 24 via rotation of the second pin 56 within the first slot 34 , and subsequent lowering of the platform assembly 50 downwardly such that the first pin 36 engages the second slot 58 . The platform assembly 50 may also be positioned and secured in a vertical stowed position by lifting the platform assembly 50 upwardly, and rotating said platform assembly 50 upward about the second pin 56 until generally vertical. The platform assembly 50 is then lowered such that the first pin 36 engages the third slot 60 .
Referring now to FIG. 5 , a sectional view of the shaft assembly 20 taken along section line A-A (see FIG. 1 ), according to a preferred embodiment of the present invention, is disclosed. The upper shaft section 22 and lower shaft section 24 portions are adjustably joined together in a telescoping manner and secured at a particular combined length via a plurality of first apertures 30 and a locking button 32 a . The equally-spaced first apertures 30 are arranged in a vertical row along a side surface of the upper shaft section 22 , and the corresponding spring-loaded locking button 32 a is located within the lower shaft section 24 . The spring-loaded locking button 32 a is biased outwardly by an integral elongated leaf spring portion 32 b within the lower shaft section 24 , being anchored to said lower shaft section 24 by a fastener 32 c such as a rivet.
It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The preferred embodiment of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the apparatus 10 , it would be utilized as indicated in FIG. 2 .
The method of configuring and utilizing the apparatus 10 for aided walking may be achieved by performing the following steps: procuring the apparatus 10 ; adjusting a length of the shaft assembly 20 by pressing inwardly upon the locking button 32 a ; sliding the shaft sections 22 , 24 relative to each other until obtaining a desired overall length of said shaft assembly 20 ; securing the shaft assembly 20 at the desired length by allowing the locking button 32 a to protrude through an aligned first aperture 30 ; utilizing the apparatus 10 as a normal walking cane by folding the platform assembly 50 upwardly into the stowed position against the shaft assembly 20 by lifting said platform assembly 50 above the first pin 36 ; rotating the platform assembly 50 upwardly to a generally vertical position; securing the platform assembly 50 by lowering the platform assembly 50 downward so as to engage the third slot 60 and first pin 36 portions; using the user's hand 105 to grasp the grip portion 26 using the finger reliefs 28 ; and, utilizing the features of the apparatus 10 to aid a user 100 to walk to a destination.
The method of configuring and utilizing the platform assembly portion 50 of the apparatus 10 may be achieved by performing the following additional steps: lifting the platform assembly 50 above the first pin 36 ; rotating the platform assembly 50 downwardly until at a horizontal orientation; lower the platform assembly 50 so as to engage the second slot 58 and first pin 36 portions; stepping upon the platen portion 54 of the platform assembly 50 with one (1) foot 110 to provide stability to the shaft assembly portion 20 ; using a hand 105 to grasp the hand grip 20 to aid a user 100 while standing up from a sitting position in a chair 120 ; and, benefiting for more secure and safer means to ascend from a sitting position afforded a user 100 of the present invention 10 .
The deployed platform assembly 50 may also act as a stabilizing base allowing the apparatus 10 to be left unattended in a “stand-alone” manner for a period of time to free up both hands of a user 100 when needed.
The foregoing descriptions of specific embodiments have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit to the precise forms disclosed and many modifications and variations are possible in light of the above teachings. The embodiments were chosen and described in order to best explain principles and practical application to enable others skilled in the art to best utilize the various embodiments with various modifications as are suited to the particular use contemplated.
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A telescoping cane with folding platform has a telescoping mechanism to adjust the height. A bottom portion of the cane is pivotally attached to a platform. The platform pivots upward into a parallel position with a shaft of the cane for a stowed position. In a deployed position, the platform is pivoted to a perpendicular position. The wider base of the platform assists a user in balancing his stance when using the cane. The pivoting assembly is further provided with a locking mechanism to maintain the platform in a deployed or stowed position. The cane is also equipped with a platen to assist with placement of user's foot upon the platform, which aids in stabilizing the cane when attempting to rise from a seated position.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a continuation of U.S. patent application Ser. No. 12/964,472, filed Dec. 9, 2010, entitled “Method for Provisioning a Wireless Network,” naming Rong Duan, Sin-Tong Au, Heeyong Kim, and Guang-Qin Ma as inventors, which application is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This relates to development of information from traffic data of a wireless network, where the data includes events that are outside everyday network load. This information assists in anticipating future events and their geographical impact, and thereby assists in provisioning network capacity.
[0003] With the fast development of mobility network technology, the network traffic has increased significantly. To improve the mobility network performance, service providers have invested significant resources to improve the coverage, enhance the quality, and increase the capacity. To illustrate, AT&T has invested more than $1.5 billion from 2007 to 2009 in California alone, and a Verizon-led investment group is committing to invest $1.3 billion in wireless long term evolution development.
[0004] Differentiated from wireline network, wireless network quality is relatively dynamic. It is impacted by the nature of the network's use (e.g., time spent by users to download data from the Internet), retransmit rates that are affected by signal to noise ratios, and by the nature of cell phone use. The easy-to-carry mobile phones are much more engaged with human activities than the wired phones, and hence the network traffic is heavily influenced by what people do. A very significant component in the variability of the wireless network's load and the perceived quality of service is social events. At large social events many cell phone users gather in a small area, such as a sports or concert venue, and—unless some provision is made that causes network capability to overflow. To illustrate how significant an effect an event can have, it is noted that Super Bowl XLIV, for example, which was held at Sun Life Stadium (Miami Garden, Fla.), attracted about 75,000 people, where the normal population for Miami Garden is a bit over 100,000. The call traffic increase is probably much higher than the 175% population increase, and such an increase is not something that the wireless network is typically designed (or should be expected) to handle.
[0005] Clearly, it is important to anticipate events. Events such as the Super Bowl are easy to anticipate because they are scheduled months in advance, but there are many lesser events that cannot be easily anticipated because they are not scheduled well in advance. One way to anticipate events is to be aware of past events, and to predict future events based on the past events. Although many events can he accounted for from data other than actual network traffic data, a much more complete picture can be had by detecting events from the network data itself.
[0006] From a statistical point of view, in general, there are three types of event detection methods: outlier/change point based method, pattern based method, and model based method. For the model based event detection approach (which underlies the approach of this invention) different models have been constructed based on the characteristics of the measured data. For example, the Dynamic Bayesian Networks (DBNs) approach has been applied to detect abnormal events in underground coal mines, Markov random fields (MRFs) have been used to model spatial relationships at neighboring sensor nodes, and the Hidden Markov Model has been used on fMRI (functional Magnetic Resonance Imaging) to detect activation areas. Ihler et al in “Adaptive Event Detection With Time-Varying Poisson Processes,” in KDD ' 06, Proceedings of the 12 th ACM SIGKDD international conference on Knowledge discovery and data mining, New York, N.Y. ACM, 2006, pp. 207-216, utilize a Markov Model Modulated Nonhomogeneous Poisson Process to detect events from highway traffic data collected by one sensor at a specific location.
[0007] In recent years, scan statistics have been a hot topic in spatial analysis and nowadays it appears to be the most effective “hotspots” detection method, The scan statistics are used to test a point process to see if it is purely random, or if any clusters of events are present. There are numerous variations of spatial scan statistics, but they share the three basic properties: the geometry of the scanned area, the probability distributions generating events under null hypothesis, and the shapes and sizes of the scanning window. The spatial scan statistics measure the log-likelihood ratio for a particular region to test spatial randomness. The region with the largest spatial scan statistic is the most likely to be generated by a different distribution. By extending the scan window from circular to cylindrical, the scan statistic extends from spatial domain to spatiotemporal domain. Scan statistics assumes that the null hypothesis is known or can be estimated through Monte Carlo simulation; but the null hypothesis assumption is often invalid and, moreover, the Monte Carlo simulation is computationally expensive.
SUMMARY
[0008] An advance in the art is realized with a method that collects data and subjects it to statistical analysis to detect localized events, which assists in network provisioning. Illustratively, the data employed is hourly network traffic count that is collected at cell sites. By taking the advantage of additive property of Poisson process, the disclosed method integrates spatial neighbor information by aggregating temporal data in various areas, and iteratively estimating the event location and the radius of event impact by examining the posterior probability base on the aggregated data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 presents pseudo code that represents one embodiment in accord with the principles disclosed herein, and
[0010] FIG. 2 presents a flowchart that represents another embodiment in accord with the principles disclosed herein; and
[0011] FIG. 3 illustrates a functional block diagram of a system consistent with at least one embodiment of the invention.
DETAILED DESCRIPTION
[0012] It is well established that network traffic varies with time of day, and also varies with days of the week. Identifying events in such network traffic data is ideally accomplished by learning the normal traffic pattern and special event pattern. However, this problem is challenging due to unknown baseline for normal traffic as well as unknown event information, such as event location, and event duration. Another challenge is the fact that not only the temporal information, but also the spatial information ought to be taken into account.
[0013] To accurately assess event influence to network, it is necessary to consider an event's impact on multiple neighboring cells, where the cells are likely to have different traffic patterns either naturally (e.g., proximity to a train station) or driven by different events. The large amount of data is another difficulty in the network traffic event detection the necessary computing might be unfeasible even though the computing increases only linearly with data.
[0014] Markov Modulated Poisson Process(MMPP) is a popular traffic model for capturing the characteristic of actual network load by describing varying rate parameters at irregular intervals according to Markov process which, basically asserts that the probability of a data point in a series depends on data points that immediately precede it. In “Bayesian Methods and Extensions for the Two State Markov Modulated Poisson Process,” S. L. Scott, in Ph. D. dissertation, Harvard University, Dept. of Statistics, 1998, extends the MMPP from homogeneous Poisson process to non-homogeneous Poisson process by embedding multiple periodic rates in Poisson process, and applies it to network intrusion detection and web traffic data. Ihler et al in the aforementioned article utilize the similar framework on freeway traffic and building entrance event detection. All the proposed methods focus on univariate time series.
[0015] To better appreciate the advance of this invention, it may be helpful to review the Markov Modulated Non-Homogeneous Poisson Process (MMNHPP) for modeling temporal data.
[0016] Let N i (t) denote the observed traffic count at cell site i (i∈ ) and time t, where denotes the considered region, and cell site i is at location L i , which is specified by its latitude, l1 i , and longitude, l2 i ; i.e., the vector L i =[l1 i ,l2 i ]. The actual traffic load (e.g., call count) at cell site i, as a function of reporting times, N i (t), can be represented as N i (t)=N i 0 (t)+N i E (t), where N i 0 (t) is the normal traffic load, and N i E (t) is the increased traffic load due to the presence of one or more events. It is sufficient to model N i 0 (t) and N i E (t) instead of modeling N i (t) directly. To model N i 0 (t) we adopt a non-homogeneous Poisson process with the rate λ i (t) which, to incorporate the multiple periodic temporal patterns in network traffic, is assumed to be
[0000] λ i ( t )=λ i 0 σ i d(t) η i d(t),h(t) , (1)
[0000] where λ i 0 the average rate of the Poisson process over a week at cell site i, σ i d(t) is the day effect (d(t) indicates the day-of-week, d∈{1,2, . . . 7}), and η i d(t),h(t) is the hour effect (h(t) indicates the hour-of-day, h∈{0,1, . . . 23}). Given a sequence of data, we assume that λ 0 i follows Gamma distribution, and σ i d(t) η i d(t),h(t) follow Dirichlet distribution.
[0017] Now we consider the modeling of N i E (t) for the case where events increase the network traffic during a short consistent period (in some applications, it may be more reasonable to consider the case where events decrease the traffic). To indicate the presence of an event at time t, we use a binary process z(t):
[0000]
z
(
t
)
=
{
0
if
there
is
no
event
at
time
t
1
if
there
is
an
event
at
time
t
(
2
)
[0000] The probability distribution of z(t) is defined to be a two-state Markov process with transition matrix:
[0000]
M
z
=
(
1
-
z
o
z
1
z
0
1
-
z
1
)
(
3
)
[0000] where the expected value for the time between events is 1/z 0 and the expected value for event duration is 1/z 1 . Using z(t), the event count N i E (t) can be modeled as Poisson with the rate γ i (t)
[0000]
N
F
i
(
t
)
=
{
0
z
(
t
)
=
0
P
(
N
i
,
γ
i
(
t
)
)
z
(
t
)
=
1
.
(
4
)
[0000] The unknown parameters in the models for N i 0 (t) and N i E /t) can be estimated in the Bayesian framework. Essentially, Markov Chain Monte Carlo (MCMC) sampling is used to estimate the posterior probability p(z(t)=1|N(t)), as described in the aforementioned Ihler et al article.
[0018] Put in layman's terms, in the MMNHPP a given a set of data points is assumed to consist of data points that at times correspond to traffic with no special events present, and at times correspond to traffic that may be including a special event. There is, therefore, a distribution of traffic load measurements without an event, and a distribution of traffic load measurements with an event. The challenge is to find the parameters of the two distributions that best fit the data, under the assumption that those distributions are extended Poisson distributions, where the probability of k events in a given period of time is
[0000]
f
(
k
,
λ
)
=
λ
k
e
λ
k
!
,
[0000] where λ is the expected number of event is that given period of time, it is a function of time t, and is different for the two conditions: with event, and without event.
[0019] Once the best-fitting parameters are chosen, the probability that a given data point belongs to a non-event data can be computed, and the probability that the same given data point belongs to event data can also be computed. If the probability that the given point belongs to event data is greater than the probability that the given point belongs to non-event data, then the conclusion is reached that the point belongs to an event.
[0020] How to find the beast parameter estimates for the aforementioned distributions based on a given corpus of data is well known to artisans in the art of data analysis.
[0021] It may be noted that the model discussed above is for a time series at a single cell site i, and the spatial relations among multiple time series are not considered. In accord with the principles disclosed herein spatial information is taken into account.
[0022] Recognizing that “everything is related to everything else, but near things are more related than distant things,” our strategy is to aggregate a set of closely located time series of similar pattern. Specifically, we define a neighborhood region around the cell site i with the radius r as A r i ={j;∥L j −L i ∥<r} where ∥L j −L i ∥ represents the geographic distance between cell sites i and j. That is, the neighborhood of cell site i, A 4 i , encompasses at least one additional site.
[0023] The observations in A r i can be represented as
[0000] N A i r =N 0 A i r +N E A i r (5)
[0000] where N 0 A i r and N E A i r are the total normal and event observations for all time series in area A r i , respectively. Thus, N 0 A i r and N E A i r can be represented as
[0000]
N
0
A
i
r
=
∑
j
∈
A
i
r
N
0
j
(
t
)
[0000] and
[0000]
N
E
A
i
r
=
∑
j
∈
A
i
r
N
E
j
(
t
)
,
[0000] respectively.
[0024] According to the additive property of the non-homogeneous Poisson process, N 0 A i r is also a non-homogeneous Poisson process given that all time series in A r i are independent Poisson random variables. Hence, the count rate for the neighborhood region A r i can be expressed as
[0000]
λ
0
A
i
r
(
t
)
=
∑
j
∈
A
i
r
λ
0
j
(
t
)
=
∑
j
∈
A
i
r
λ
0
j
(
t
)
σ
d
(
t
)
j
h
(
t
)
.
(
6
)
[0000] We assume that if an event happens at a particular time, it affects the neighboring cells roughly simultaneously, i.e., the starting and ending points of the increased traffic for the affected cells are assumed to be similar enough. Then the temporal Markov process transition matrices for the neighboring cells are also assumed to be the same. We also utilize the fact that driven by the propagation of cellular radio signal, the farther the distance from the signal source, the weaker the signal strength. It is known that if the signal originates from a location L e , then the strength of the signal at location L i can be expressed as
[0000]
a
L
e
-
L
i
n
,
[0000] where n is a value between 2 and 4 depending on geography conditions, and a is a constant.
[0025] In addition to the cellular radio propagation property, from engineering design view, the closer the cell site to the signal, the higher the priority it has, The signal will be picked by farther cell only if the closer one is in overflow, Driven by the above, the spatial impact of an event can be modeled as binary function that relates the current location and the distance from where the event happens.
[0026] When an event takes place at location e, the event's impact at location i, can be expressed as a binary process, as follows:
[0000]
s
i
e
=
{
0
,
L
e
-
L
i
>
R
e
1
,
L
e
-
L
i
≤
R
e
(
7
)
[0000] where R e is the radius of event impact. Combining (1 and (6), in spatiotemporal domain the presence of an event can be indicated by the product of z(t) and s e i . That is, if we let
[0000]
ST
it
e
=
{
0
,
L
e
-
L
i
>
R
e
or
z
(
t
)
=
0
1
,
L
e
-
L
i
≤
R
e
and
z
(
t
)
=
1
(
8
)
[0000] equation (8) implies that the event originates from e only impacts the cells in the area A e R e while z(t)=1. Using equation (8), the increased observations due to the event can be modeled as a Poisson process:
[0000]
N
E
A
e
R
e
(
t
)
~
{
0
,
while
ST
it
e
=
0
P
(
N
;
∑
j
∈
A
e
R
e
γ
j
(
t
)
)
while
ST
it
e
=
1
(
9
)
[0000] From equations (8) and (9) obvious that an event impact is explained by its temporal duration, event location, and the impact radius. As discussed above, the temporal durations are assumed to be the same for all cells in the impacted area A e R e and, hence, the duration can be estimated by Markov process using any of time series in the area A e R e .
[0027] The method disclosed herein comprises collecting data, processing to obtain results, and utilizing the results. The processing, in turn, comprises initialization, aggregation, estimation, re-centralization, and adaptation, where the initialization, aggregation, estimation, re-centralization, and adaptation are iteratively repeated until a preselected criterion is met. The key tasks in each stage are presented in the following.
[0028] Initialization: Overall network traffic data is very voluminous so examining all these cell sites is prohibitively expensive in terms of computation cost. Therefore, in accord with one aspect of our disclosure we begin by identifying a subset of cell sites where a very simple test reveals that at least one event impacts the traffic. This is accomplished by choosing those cells whose peak traffic during the observed time period (the time series of data for the cell) exceeds the traffic value during a chosen portion of the observed time period (e.g., during 75% of the time period), by a preselected amount, and ranking the identified cells by the computed traffic level. We call the identified set the “seed” cell sites, or time series. We note that each event reveals itself as a “seed” in one or more cell sites. We also noted that the above-described approach for limiting the number of cells that are considered is merely illustrative, and that other approaches can be used without departing from the spirit and scope of this invention.
[0029] Aggregation: Choosing each cell in the seed time series we aggregate the data from all cells in a defined neighborhood of the chosen cell, and in an iterative process we increase the size of the neighborhood until a predetermined condition occurs (e.g., acquiring, albeit the smallest number of cell sites).
[0030] Estimation: By fitting the aggregated time series with MMNHPP, we compute the posterior probability of event p(z(t)=1). If p(z(t)=1)>0.5 for time [t s ,t e ] (i.e., time t spanning t s −t e , and t e −t s >h hours (where h, for example, is 3 hours)), then we consider that all of aggregated the time series are affected by some event during the time period of [t s ,t e ]; i.e., t s and t e the starting and ending time points of the event, respectively. Otherwise, we regard it as an outlier. For example, if there is a one hour spike in traffic, we do not consider that to be an event. For a specific detected event, the corresponding time series that were aggregated are the members of the cluster for the event.
[0031] Centralization: For each detected event cluster, we compute the center point by taking an average of the coordinates for all cells that are included in the cluster. The computed center point may be a simple geographical center of all cell sites in the cluster. The geographical center calculation is constrained to not exceed certain bounds, such as to not move farther away from the location of the seed cell than a certain distance. Alternatively, the geographical center can be a weighted calculation that takes account of both geographical locations and traffic levels.
[0032] Adaptation: We set the computed center as the new point about which a neighborhood is computed, and return to the step of aggregating the data, from neighboring cells (starting with the existing size of the neighborhood). Repeat the aggregation, estimation, and centralization steps until a cell site (and a corresponding dine series) is encompassed by the neighborhood but is not impacted by the event under consideration. The underlying assumption here is that if a set of time series with no event is aggregated to the time series with an event X, the effect of event X will be masked somewhat, and we will have reduced probability of concluding that an event occurs. In other words, the decision as to whether to further expand the neighborhood is based on statistical analysis of the aggregated time series (as disclosed above).
[0033] The result of the above process is that the center where the event is perceived to originate (in a center of gravity sense), the spatial impact of the event, and the temporal impact of the event become known.
[0034] It should be understood that there are various approaches for addressing all of the events that are contained in the data. That includes searching for event-impacts in time order, in order of seed strengths, or in any other order (including random).
[0035] FIG. 1 presents the pseudocode of one embodiment in accord with the principles disclosed herein, where the seed sites are sorted by strength, but once a seed site is under investigation, all events that impact that site are considered. Although the pseudocode is straight forward and self-explanatory, the following presents a relatively detailed explanation of the code.
[0036] In line 1 , the variable in corresponds to the number of cell sites whose traffic data has been collected, max(N i ) is the maximum traffic load (e.g., number of calls) at cell site i, at some reporting time interval (e.g., hour), t. Q x (N i ) is the traffic level that is not exceeded for x percent of the time, and TH is a chosen threshold, For example, the maximum number of calls in a certain hour of a certain date cell site i might be 1021 (i.e., max(N i )=1021), whereas during 75% of all other hours the number of calls in cell does not exceed 750 (i.e., Q 75 (N i )=750). Line 4 results in a sorted set of traffic load values D i , each thus identifying cell i where at least one event has an impact. These are seed cell sites.
[0037] Line 5 begins the process for considering each of the seed cell sites are considered, starting with a first cell site (i=1), and line 6 identifies spans of reporting times, or groups of consecutive reporting times, that correspond to times in the considered cell site during which there are event impacts. The number of consecutive reporting times that must be found to constitute a group is a preselected constant, h, such as the aforementioned three hours. The number of such groups is E i (line 7 ).
[0038] Line 8 begins the process of considering each of the events in the considered cell site, starting with the earliest event, (j=1).
[0039] Line 9 computes the duration of event. That is, since a particular grouping of reporting times is considered, the duration of an event is defined by the starting time, and the stopping time; i.e., by [t s ,t e ].
[0040] Line 10 evaluates whether the computed duration of event j is close (as far geographical location as well as starting and stopping times) to an already considered event that control passes to line 11 , which adds the site of the seed to the corresponding cluster, increments index j and line 12 returns control to line 9 (to assess the event next in time on site i. Otherwise, control passes to line.
[0041] Line 14 initializes the iterative process, by setting the center location of the event at the geographical location of the cell site i (that is, the geographical coordinates of the cell site's antenna). It also chooses a circular area of a small initial radius r 0 , sets the number of sites within that area, C A r C , at 1, sets the duration of the event relative to the center to the duration at cell site i, and sets the change of overall probability of an event impacting within the area centered on center c to some number a>0.
[0042] The iterative process proceeds by testing whether the duration of the event relative to the center is approximately the same as the duration of the event relative to the geographical location of the cell site i, and whether the change of overall probability of an event impacting within the area centered on center c is positive. If so—and it is so in the first iterative loop by the initialization process—then the steps of lines 16 - 19 increase the radius (and thereby increase the area) until at least one other cell sites is found within the area.
[0043] At this point, line 21 computes a new geographical center (from the geographical coordinates of the encompassed cell sites) and line 22 sums the traffic loads of the encompassed cell sites. Line 23 employs the aforementioned statistical means for computing the duration of the event relative to the new center, Lastly, line 27 outputs the duration and expanse of the events.
[0044] FIG. 2 presents a block diagram of a second embodiment. Block 100 identifies the seeds pursuant to a process that, for example, follows steps 1 - 4 of FIG. 1 . It is noted that any particular cell may have more than one seed (at different reporting times). The result is a set of seeds that, optionally, are not even sorted. Control then passes to block 102 where a first seed in the set is chosen (by setting variable i to 1), and control passes to block 104 . Block 104 notes the geographical location of the cell site to which the chosen seed belongs and sets the current perception of the center of the event that is reflected by the seed to that geographical location. Control then passes to block 106 Which identifies the duration of the event (i.e. the set of consecutive reporting times that correspond to the event) using the statistical approach disclosed above.
[0045] It is possible that the considered seed (other than the very first seed, of course) was already accounted for while considering a previous seed. Therefore, control passes from block 106 to block 108 , which considers whether the seed i that is to be currently considered has been previously handled when considering a previous seed, j. If it has been previously considered, control passes to block 124 . Otherwise, control passes to block 110 , which defines the smallest area (for example, a circular area about the event's perceived center with the smallest radius) that results in the addition of a cell site (from among all geographically neighboring cell sites; that is, Δ k>0, where k is the number of cell sites that are encompassed by the chosen area, It should be understood that the initial area or territory that is chosen is one that includes the site where the seed event resides plus some minimum number of additional sites. That area can be circular, thus being defined by a radius, and the radius can begin with some minimum value that is iteratively increased until another site is encompassed, or it can start with an incremental increase over the distance from the site where the seed event resides to the geographically next closest site. It is understood, of course, that an increase of the neighborhood that results in the addition of one cell site may result in the addition of a number of cell sites.
[0046] From block 110 control passes to block 112 where the traffic loads of the cell sites encompassed by the chosen area are aggregated (e.g., summed), and control passes to block 114 , which determines, based on the statistical approach disclosed above (see line 23 in FIG. 1 ) whether the traffic count that is attributable to the event has increased, If so, control passes to block 114 where the event's duration is re-determined, and control passes to block 116 , which computes the event's duration and passes control to block 118 , which enlarges the geographical area of investigation only so much as to increase the number of encompassed cell sites, Control then passes to block 120 which re-computes the perceived event center and re-establishes the set of cell sites encompassed by the existing neighborhood size before returning control to block 112 .
[0047] When block 114 concludes in the negative (that the traffic count attributable to the event has not increased), control passes to block 122 , which stores the information about the addressed event, its perceived center and reach (i.e,, the last-employed radius), and passes control to block 124 . Block 124 determines whether the addressed seed is the last seed to be addressed. If not, control passes to block 128 Which increments index I and returns control to block 104 . Otherwise, control passes to block 126 , which sends the information stored by block 124 to whatever network provisioning system the user of the method desires. This may comprise, for example, a schedule that is created from the stored information for delivering portable cells (“cells on wheels”) to the appropriate geographical areas so that they can be employed when future events are expected.
[0048] A method, executed on a processing platform 302 , for enabling a wireless network 308 to be provisioned, includes collecting from access points (APs) 306 of said network, traffic volume data in successive time intervals. The method includes identifying event seeds, which are those of said APs where during one or more time spans of a preselected number contiguous ones of said time intervals the traffic volume in said time intervals exceeds a chosen threshold. The method includes processing each of the event seeds, through iterative processing cycles, to identify for each of said event seeds an estimated event center and associated event impact territory. The method includes providing information about the events identified by said processing to a provisioning system 304 of wireless network 308 . The territory may be expressed by a radius of a circle 310 centered about said associated event center. The processing in each of the processing cycles may include statistical analysis. The statistical analysis may be a Markov Modulated Nonhomogenous Poisson Process that is employed to estimate probability with which said traffic data is indicative of an event. Each of the iterative processing cycles may include statistical analysis, and each such cycle may begin with one of said event seeds, which occurs at a particular AP, an estimated event center that is associated with geographical coordinates of said particular AP, and a territory that encompasses said particular AP and a minimum number, greater than zero, of neighboring APs, and at each of said cycles enlarging said territory and augmenting said estimated event center based on the APs encompassed by said enlarged territory, until a preselected condition is met that terminates said iterative processing. The territory may be defined by a radius of a circle about said event center, and at each cycle of the iterative processing said radius is enlarged only so much as to encompass a minimum number of APs that were not already encompassed in the immediately previous cycle. The condition may be met with traffic attributed to said event is not increased with the enlarged territory.
[0049] The above embodiments descriptions are, of course, illustrative, and other embodiments can be realized by a person skilled in the art. For example, Additionally, while the above disclosure is couched in terms of a cellular network and cell sites, it should be realized that this, too, is merely illustrative and that any access point (AP) via which traffic can enter the telecommunication network, can serve as data sources.
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A method that collects data and subjects it to statistical analysis to detect localized events, which assists in network provisioning. illustratively, the data employed is hourly network traffic count that is collected at cell sites. By taking the advantage of additive property of Poisson process, the method integrates spatial neighbor information by aggregating temporal data in various areas, and iteratively estimating the event location and the radius of event impact by examining the posterior probability base on the aggregated data.
| 7
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a deodorizing means for compactors of the home appliance type.
2. Description of the Prior Art
Compactors for compressing household waste or trash have come into use in recent years. Such appliances include a ram or platen which descends into a bin or receptacle containing the trash to effect the compaction. The receptacle may be mounted in a drawer which is slidable out of the compactor to deposit trash to be compacted and to remove the compacted trash. The receptacle is usually designed so that at least several days, and more often, a week's compacted trash may accumulate in the bin before the bin becomes filled and it is necessary to carry the compacted trash out to the garbage.
Given the high food waste content of household trash, it will be readily appreciated that offensive and undesirable odors will emanate from the trash prior to its disposal. As a result, it is a common practice to provide a means for masking the odors of the compacted trash.
Typically, an aerosol spray container is provided which sprays a deodorant on the trash. However, the use of an aerosol spray container suffers several shortcomings. In some schemes, the aerosol container is mounted in the compactor cabinet and activated by opening the door through which the trash is inserted or removed from the trash compactor. This often causes the aerosol to squirt on the user's hand as the trash is inserted or removed.
In other arrangements, the aerosol spray is activated by the descent of the ram. Since deodorant is not usually needed at this time, because the compaction process serves to suppress odors, this approach is inefficient.
Still other schemes provide a means which may be actuated by the home owner to provide the aerosol spray. However, this requires the odor rise to obnoxious levels before the user takes corrective action.
In all of the foregoing arrangements, intermittent deodorization of the compacted trash is provided by the aerosol spray.
SUMMARY OF THE PRESENT INVENTION
In contrast to existing deodorizers which operate on the intermittent principle, the present invention contemplates a deodorizer means for trash compactors which continuously deodorizes the trash in the interior of the compactor.
The present invention provides a deodorizing arrangement which establishes a stratum of deodorant laden air in the upper part of the trash compacting chamber which is particularly effective in separating the user of the compactor from the odors of the trash lying in the receptacle.
Briefly, the present invention contemplates a means containing a deodorant material positioned within the cabinet of a trash compactor. The deodorant material continuously releases a scent into the air within the compactor for masking the trash odors. The deodorizing means is preferably positioned above the receptacle where the restricted air circulation forms a heavily scented air layer which separates the user from the odors in the receptacle. This heavily scented air may be expelled from the compactor cabinet upon the opening and closing of the drawer containing the receptacle thereby producing a pleasing effect on the user.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a trash compactor showing the improved deodorizing means of the present invention.
FIG. 2 is an enlarged cross sectional view taken along line 2--2 of FIG. 1 showing in greater detail the deodorizing means of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to the Figures, there is shown in FIG. 1 a trash compactor identified by the numeral 10. Trash compactor 10 includes cabinet 12 containing a compacting mechanism, not shown, in the upper portions thereof by which platen or ram 14 may be made to descend for the compaction of trash and return to the upper storage position shown in FIG. 1.
Receptacle 30 for receiving the trash to be compacted is positioned in the lower portion of cabinet 12. Access to the interior of cabinet 12 is provided by a drawer 32 having a drawer front panel 34 formed of one of the vertical walls of cabinet 12. A support deck 36 on which receptacle 30 rests is attached to the lower portions of drawer front panel 34. Drawer front panel 34 is preferably higher than receptacle 30. Drawer 32 is movable into and out of cabinet 12 on horizontal rails 38 and is held in the closed position by catch 40.
In operation, drawer 32 is opened, the trash to be compacted deposited in receptacle 30, and the drawer closed. Switch 42 is closed to actuate the compacting mechanism through an operating cycle in which ram 14 is driven into and out of receptacle 30. Drawer 32 is then opened to deposit more trash and the operating cycle repeated until receptacle 30 is full. As noted supra, most trash compactors are designed so that the trash ordinarily produced by a typical family in a week may be accommodated in receptacle 30 before the receptacle must be removed from the compactor and emptied.
During the week period in which trash accumulates in receptacle 30, offensive and undesirable odors will develop both from the food scraps in the trash and from the microbiological activity occurring over such a period at room temperature.
The improved deodorizing means of the present invention for masking such odors is identified by the numeral 50. As shown in FIG. 1, deodorizing means 50 is located across the opening in cabinet 12 formed by drawer front panel 34. Deodorizing means 50 includes a pair of spacers 52 which abut the inner surface of drawer front panel 34 when drawer 32 is closed. Between spacers 52 a holder in the form of a tray 54 is formed in which a deodorant material may rest. As shown in FIG. 2, tray 54 includes forward lip 56 which retains deodorant material 58 in the tray, a rear wall 60 containing slots 62 and slot 64 in bottom wall 66. The slots permit the air to circulate over deodorant material 58 and the scent of the deodorant to diffuse.
Many types of deodorant material may be used. For exemplary purposes, the deodorant material is shown in the Figures as a deodorant incorporated in a binder and formed into a block. It will be appreciated that numerous other types of deodorants may be used including an impregnated plastic, such as permeable polyethylene, a liquid deodorant applied by a wick, and the like.
With drawer 32 closed, deodorant material 58 continuously deodorizes the air within cabinet 12, thereby masking odors arising from the compacted trash. Because of the limited air circulating within cabinet 12 and because of the location of deodorant material 58 above receptacle 30, a stratum of air, heavily scented with the deodorant, tends to form above receptacle 30. When drawer 32 is opened and particularly when drawer 32 is closed, this stratum of air is expelled into the room exposing the user bending over the compactor to a pleasing odor and separating him from the odors produced by the trash laying in receptacle 30. It also assures the user that adequate deodorization is occurring.
While a compactor 10 having a cabinet 12 is shown, it will be appreciated that the deodorizer means of the present invention is equally suitable for use with a compactor of the built-in type which is enclosed, for example, by kitchen cabinetry. In such a compactor, a frame work having a front wall is provided for mounting compaction mechanism 14 and for receiving drawer 32.
Various modes of carrying out the invention are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention.
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A deodorizer containing a deodorant material is mounted within the cabinet of a trash compactor for continuously releasing a scent to the air in the cabinet to mask odors emanating from the compacted trash.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a replacement window, and more particularly, to a double-hung replacement window resistant to hurricane-force winds.
[0003] 2. Description of the Prior Art
[0004] Most replacement windows sold in the United States are subjected to air infiltration, water infiltration, and structural integrity tests before being made commercially available. These three tests remain widely accepted throughout North America and performed on just about every window or door currently sold in the United States.
[0005] After Hurricane Andrew devastated Florida in August 1992, Dade and Broward counties enacted new window durability standards. As a result of the enacted standards, windows certified in Dade County are now subjected to a structural integrity test, a battery of missile impact tests, and a cyclical test.
[0006] To test structural integrity, a double-hung replacement window specimen is mounted on a wall and exterior surfaces of the window specimen is exposed to elevated air pressure. As described herein, a double-hung replacement window generally includes a window frame, a first sash, a second sash, a first insulated glass unit positioned in the first sash, and a second insulated glass unit positioned in the second sash. Exterior surfaces are generally those surfaces which are exposed to nature, while interior surfaces are generally those surfaces exposed to an interior room of a structure.
[0007] Water is then sprayed in and around the exterior window frame and sash surfaces of the double-hung replacement window specimen during the elevated air pressure exposure to simulate wind driven precipitation climate. The amount of air and water that penetrates through the double-hung replacement window specimen is then measured and recorded.
[0008] Next, three specimens of a double-hung replacement window are placed on another wall in preparation for a missile impact test. The missile impact test simulates the ability of the double-hung replacement window to prevent large objects from penetrating through the window frame, sashes, and insulated glass units. The missile impact test is facilitated by a pneumatic cannon placed a few feet away from the double-hung replacement window, wherein the pneumatic cannon is loaded with a 2″×4″×7′ (approximate) piece of wood, or other object weighing nine pounds.
[0009] In specimen one, a piece of wood fired at the double-hung replacement window at approximately fifty feet per second, and impacts the meeting rail of the sashes, wherein the meeting rails are defined as an overlap region of the first sash and the second sash. Another piece of wood is then shot directly into a center portion of one of the insulated glass units.
[0010] In specimen two, a piece of wood impacts a center portion of one of the insulated glass units and another piece of wood impacts one of the insulated glass units approximately six inches away from one of the frame jamb. In specimen three, a piece of wood is fired at the meeting rail of the sashes and another piece of wood impacts one of the insulated glass units approximately six inches away from one of the frame jamb.
[0011] During the missile impact test, the insulated glass units can develop holes no larger than approximately five inches by one-sixteenth of an inch, but the pieces of wood cannot penetrate through the insulated glass units and into a simulated living area. If holes are formed in the insulated glass units, the holes can be covered with plastic prior to cyclical testing.
[0012] Finally, one or more of the battered and damaged double-hung replacement window specimens are then positioned in openings defined by one side of a hollow, box-shaped container. Each double-hung replacement window specimen is sealed in the opening to create an airtight seal. Air is then pumped into the hollow, box-shaped container, causing each specimen to bow or flex away from the container. The air is then evacuated, causing each specimen to bow inwardly toward the hollow portion of the box-shaped container. This cyclical test is repeated 9,000 times. If there is no failure, the double-hung replacement window passes certification.
[0013] Because the durability tests are quite rigorous, a need exists for a replacement window which will pass the strict testing discussed above.
SUMMARY OF THE PRESENT INVENTION
[0014] The present invention seeks to help provide a replacement window that will accommodate strict building codes. A replacement window according to the present invention generally includes a window frame having a window header, a window sill, a first frame jamb, and a second frame jamb, wherein the first frame jamb and the second frame jamb each connect the window header to the window frame, and the window header, the window sill, and the first frame jamb and the second frame jamb define a window frame opening.
[0015] At least one sash may be positioned in the window frame opening. One type of sash, such as a first sash, generally includes a first sash header, a first sash sill spaced away from the first sash header and oriented substantially parallel to the first sash header, a first sash jamb connected to one end of the first sash header and one end of the first sash sill, and a second sash jamb spaced away from the first sash jamb and is oriented substantially parallel to the first sash jamb and is connected to another end of the first sash header and another end of the first sash sill, wherein the first sash header, the first sash sill, the first sash jamb, and the second sash jamb define a first opening.
[0016] Another type of sash, such as a second sash preferably used in combination with the first sash in double-hung replacement window applications, is also movably positioned in the window frame opening. The second sash generally includes a reinforced, second sash header, a second sash sill spaced away from the second sash header and oriented substantially parallel to the second sash header, a third sash jamb connected to one end of the second sash header and one end of the second sash sill, and a fourth sash jamb spaced away from the third sash jamb and is oriented substantially parallel to the third sash jamb and is connected to another end of the second sash header and another end of the second sash sill. The second sash header, the second sash sill, the third sash jamb, and the fourth sash jamb define a second opening. Unlike the first sash, the second sash header of the second sash is reinforced with a reinforcement member preferably connected to or encased in the second sash header. The reinforcement member preferably has a hollow, double I-beam shape and is made from vinyl, metal, wood, or other suitable material. The reinforcement member may extend along an entire length of the second sash header or may be sectioned into two pieces. A reinforcement pin may be positioned adjacent to the second sash header of the second sash.
[0017] At least one jamb retainer clip may be positioned adjacent to the first frame jamb and another jamb retainer clip is preferably positioned adjacent to the second frame jamb. Each of the jamb retainer clips define a reinforcement pin orifice which receives a corresponding reinforcement pin, discussed above. The first frame jamb and the second frame jamb each also define a first balance track and a second balance track, and one jamb retainer clip may be positioned in the second balance track of the first frame jamb and another jamb retainer clip may be positioned in the second balance track of the second frame jamb.
[0018] A plurality of shoe balances are also provided, wherein one of the plurality of shoe balances may be positioned in the first balance track defined by the first frame jamb, another one of the plurality of shoe balances may be positioned in the first balance track defined by the second frame jamb, another one of the plurality of shoe balances may be positioned in the second balance track defined by the first frame jamb, and another of the plurality of shoe balances may be positioned in the second balance track defined by the second frame jamb. The shoe balances slide in the balance tracks and are used to connect the sashes to the window frame.
[0019] These and other advantages of the present invention will be clarified in the description of the preferred embodiment taken together with the attached drawings in which like reference numerals represent like elements throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is a plan view of an interior surface of a replacement window according to the present invention, with reinforcement elements shown in phantom;
[0021] [0021]FIG. 2 is a perspective view of an exterior surface of the replacement window shown in FIG. 1;
[0022] [0022]FIG. 3 is a perspective plan view of the interior surface of the replacement window shown in FIG. 2;
[0023] [0023]FIG. 4A is a bottom view of a first sash;
[0024] [0024]FIG. 4B is a bottom view of a second sash;
[0025] [0025]FIG. 5 is a perspective view of the replacement window shown in FIGS. 1 and 3, with the first sash shown in FIG. 4A installed in the replacement window and pivoted away from a window frame of the replacement window and the second sash shown in FIG. 4B installed in the replacement window and pivoted away from the window frame of the replacement window;
[0026] [0026]FIG. 6 is a perspective view of the second sash shown in FIG. 4B pivoted away from a window frame of the replacement window;
[0027] [0027]FIG. 7 is a magnified perspective view of the window frame shown in FIG. 6;
[0028] [0028]FIG. 8 is a cross-sectional end view of a second sash header according to the present invention;
[0029] [0029]FIG. 9 is a top perspective view of the second sash header shown in FIG. 8; and
[0030] [0030]FIG. 10 is a front elevation view of three windows showing impact locations.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] The preferred embodiment of a replacement window 10 according to the present invention is generally shown in FIG. 1. The replacement window 10 includes a window frame 12 , a first sash 14 , a second sash 16 , a first insulated glass unit 18 , a second insulated glass unit 20 , a reinforcement member 22 , a reinforcement pin 24 preferably biased by a spring 26 , a pin lever 28 connected to the reinforcement pin 24 , and a jamb retainer clip 30 defining a reinforcement pin orifice 32 . The reinforcement pin 24 is received in the reinforcement pin orifice 32 defined by the jamb retainer clip 30 .
[0032] As shown generally in FIGS. 1 - 3 , the window frame 12 generally includes a frame header 34 , a frame sill 36 spaced away from the frame header 34 and oriented substantially parallel to the frame header 34 , a first frame jamb 38 connected to another end of the frame header 34 and one end of the frame sill 36 , and a second frame jamb 40 spaced away from the first frame jamb 38 and is oriented substantially parallel to the first frame jamb 38 and is connected to another end of the frame header 34 and the other end of the frame sill 36 . As shown in FIG. 2, the frame header 34 , frame sill 36 , first frame jamb 38 , and second frame jamb 40 may each further define a screen track 42 on an exterior portion of the window frame 12 for receiving a framed screen 44 . The window frame 12 may be made from vinyl, wood, metal, plastic, fiberglass, or any other suitable material.
[0033] Referring again to FIGS. 1 - 3 , the first sash 14 defines a first opening 46 formed by a first sash header 48 , a first sash sill 50 spaced away from the first sash header 48 and oriented substantially parallel to the first sash header 48 , a first sash jamb 52 connected to one end of the first sash header 48 and one end of the first sash sill 50 , and a second sash jamb 54 spaced away from the first sash jamb 52 and is oriented substantially parallel to the first sash jamb 52 , and is connected to the other end of the first sash header 48 and the other end of the first sash sill 50 . The first insulated glass unit 18 is received in the first opening 46 defined by the first sash header 48 , the first sash sill 50 , the first sash jamb 52 , and the second sash jamb 54 . The first insulated glass unit's 18 construction is conventional, such as two panes of spaced-apart glass, two panes of spaced-apart safety glass, or two or three panes of spaced-apart coated glass, with any of the panes connected together by a peripheral seal to form an insulation air space between the panes of glass. Single panes of insulated glass may also be used. As shown in FIG. 2, weather stripping 56 may be positioned along peripheral edges of the first sash 14 . One half of a conventional window locking device 58 A may also be provided on the first sash sill 50 .
[0034] Referring again to FIGS. 2 and 3, the second sash 16 is similar to the first sash 14 . The second sash 16 defines a second opening 60 formed by a second sash header 62 , a second sash sill 64 spaced away from the second sash header 62 and oriented substantially parallel to the second sash header 62 , a third sash jamb 66 connected to one end of the second sash header 62 and one end of the second sash sill 64 , and a fourth sash jamb 68 spaced away from the third sash jamb 66 and is oriented substantially parallel to the third sash jamb 66 and is connected to the other end of the second sash header 62 and the other end of the second sash sill 64 . The second insulated glass unit 20 is received in the second opening 60 defined by the second sash header 62 , the second sash sill 64 , the third sash jamb 66 , and the fourth sash jamb 66 . The second insulated glass unit 20 is also conventional. Weather stripping 56 may be positioned along peripheral edges of the second sash 16 . Another half of a conventional locking device 58 B may also be provided on the second sash header 62 .
[0035] As shown in FIG. 4A, a first sash retaining arm 70 is positioned at an intersection of the first sash jamb 52 and the first sash sill 50 . A second sash retaining arm 72 is positioned at an intersection of the second sash jamb 54 and the second sash sill 64 . Likewise, as shown in FIG. 4B, a third sash retaining arm 74 is positioned at an intersection of the third sash jamb 68 and the second sash sill 64 . A fourth sash retaining arm 76 is positioned at an intersection of the fourth sash jamb 68 and the second sash sill 64 .
[0036] As shown in FIG. 5, the first sash header 48 has one or more conventional spring clips 78 which retract and protrude from intersections formed by the first sash header 48 and the first sash jamb 52 and the first sash header 48 and the second sash jamb 54 . The first and second frame jambs 38 , 40 each define a first balance track 80 and a second balance track 82 . As shown in FIGS. 5 - 7 , included in the second balance track 82 of the first frame jamb 38 and in the second balance track 82 the second frame jamb 40 is the jamb retainer clip 30 , a shoe balance 84 , and a balance anchor 86 . The jamb retainer clip 30 , also shown in FIG. 1, is preferably made from polycarbonate, commercially available under the BAKELITE tradename, but may also be made from metal, wood, vinyl or any other suitable material.
[0037] The shoe balance 84 is preferably a pretensioned balance known to those skilled in the art. In general, as shown in FIG. 7, the shoe balance 84 includes a balance housing 88 , a wheel 90 that is rotatable with respect to the balance housing 88 and defines a sash retaining arm orifice 92 , and a pretensioned, coiled strip 94 of metal or other suitable material that is encased in the balance housing 88 . One end of the coiled strip 94 is attached to the balance anchor 86 that is rigidly attached in the second balance track 82 defined by the first frame jamb 38 . The same is also true for a shoe balance 84 positioned in the second balance track 82 defined by the second frame jamb 40 , a shoe balance 84 positioned in the first balance track 80 of the first frame jamb 38 , and a shoe balance 84 positioned in the first balance track 80 of the second frame jamb 40 .
[0038] As a shoe balance 84 slides in its corresponding balance track 80 , 82 , indicated by arrow A 1 , the pretensioned, coiled strip 94 unrolls from the balance housing 88 . Accordingly, as the balance housing 88 is moved further away from its corresponding balance anchor 86 , the length of the pretensioned, coiled strip 94 that extends from the balance housing 88 increases. Conversely, if the balance housing 88 is moved toward its corresponding balance anchor 86 , indicated by arrow A 2 , the length of the pretensioned, coiled strip 94 that extends from the balance housing 88 decreases. The tension provided by the coiled strip 94 creates a restoring force that is calculated to approximately counterbalance the combined approximate weight of a sash and a double pane of glass.
[0039] As shown in FIGS. 4A, 4B, and 7 , the sash retaining arms 70 , 72 , 74 , 76 positioned on the first and second sashes 14 , 16 are received in a corresponding sash retaining arm orifice 92 defined by wheel 90 of a corresponding shoe balance 84 . For example, FIG. 7 shows that the second sash 16 is installed in the window frame 12 by inserting the fourth sash retaining arm 76 in the sash retaining arm orifice 92 defined by the wheel 90 of the shoe balance 84 positioned in the second balance track 82 of the first frame jamb 38 . Similarly, but not shown in FIG. 7, the third sash retaining arm 74 is inserted into the sash retaining arm orifice 92 defined by the wheel 90 of the shoe balance 84 positioned in the second balance track 82 defined by the second frame jamb 40 of the window frame 12 . As shown in FIGS. 5 - 7 , when the first and second sashes 14 , 16 are installed in the window frame 12 via the shoe balance 84 , the first and second sashes 14 , 16 can be moved within the confines of the window frame 12 , indicated by arrows A 1 and A 2 or pivoted in a direction away from the window frame 12 and opposite to the framed screen 44 , if installed, as shown by arrows A 3 .
[0040] Referring generally to FIG. 8, the reinforcement member 22 is preferably encased in the second sash header 62 . The reinforcement member 22 is preferably a hollow, double I-beam made from metal or other suitable material. The reinforcement member 22 preferably extends along an entire length of the second sash header 62 , but may also be segmented into two sections. A spring clip 78 is received in a cavity defined by the second sash header 62 , as is convention, and the pin lever 28 is connected to the spring clip 78 and to the reinforcement pin 28 . As shown in FIG. 9, the reinforcement pin 24 and the spring clip 78 are oriented coincident with an imaginary longitudinal axis L extending along the second sash header 62 , and positioned at an intersection of the second sash header 62 and the fourth sash jamb 68 . Both the reinforcement pin 24 and the spring clip 78 are biased by the spring 26 shown in phantom in FIG. 1. Another reinforcement pin 24 and another spring clip 78 , each also biased by a spring 26 , may also be oriented coincident with the imaginary longitudinal axis L extending along the second sash header 62 and positioned at an intersection of the second sash header 62 and the third sash jamb 66 .
[0041] When the first and second sashes 14 , 16 are in a closed position, as shown in FIGS. 1 - 3 , forces acting on the window panes 18 , 20 and the sashes 14 , 16 are transferred along the reinforced second sash 16 via the reinforcement member 22 , through the reinforcement pins 24 , through the jamb retainer clips 30 , and into the first and second frame jambs 38 , 40 of the window frame 12 . It has been found that this arrangement provides strength to the replacement window 10 .
[0042] To clean the first and second insulated glass units 18 , 20 , as shown generally in FIG. 9, the second sash 16 is pivoted by retracting the spring clip 78 and reinforcement pin 28 combinations into the second sash header 62 , as indicated by opposing arrows A 4 . The retraction moves the opposed reinforcement pins 24 from their corresponding reinforcement pin orifices 32 , while simultaneously allowing the spring clips 78 to clear the second balance track 82 . The second sash 16 may then be pivoted in the direction indicated by arrows A 3 . The first sash 14 can then be moved in the direction indicated by arrow A 1 and then pivoted in the direction of arrow A 3 after the spring clips 78 are retracted into the first sash header 48 .
[0043] Three double-hung windows, made as described above with dimensions of 44 inches wide by 60 inches high with a 4 inch deep frame (upper vent 39{fraction (3/16)} inches wide by 28¾ inches high and lower vent 40{fraction (3/16)} inches wide by 29¾ inches high) were tested according to Dade County (Florida) Protocols PA 201 (the Missile Impact Test) and PA 203 (Cyclic Wind Pressure Test).
[0044] In the Missile Impact Test, a 9 lb., 2 inch×4 inch×96 inch #2 Southern Yellow Pine stud was propelled at the three test windows at a velocity of 50 ft./sec. (34 mph). The location of the test impact points for each window is shown in FIG. 10 as A and B for window Example 1, shown C and D for window Example 2, and shown as E and F for window Example 3. In each instance, no penetration of the stud was observed.
[0045] Next, each of the windows was subjected to the cyclic wind pressure test. This test is conducted after the Missile Impact Test has been completed. By simulating the forces applied to a window by repeated severe wind gusts, this test exposes possible weaknesses in the window assembly created by the missile impacts. In this test, the window assembly is installed in a chamber, and pressures are applied for only a few seconds and repeated several hundred times. The deflection of the components and the anchorage system are examined. The three window examples were exposed to the following conditions:
Pressure Duration Number of Pressure Cycles (fps) (seconds) Positive Pressure Cycles 3500 +29 1 300 +35 1 600 +47 1 100 +58 1 Negative Pressure Cycles 50 −67 2 1050 −54 1 50 −41 2 3350 −34 1
[0046] The three sample windows were structurally intact, operable, and all parts were securely in place at the conclusion of the tests. These results indicate that the replacement window of the present invention meets the strict building code requirements of Dade County (Florida) PA 201 and PA 203, and other such building codes requiring rigorous performance standards in hurricane prone areas.
[0047] As is described above, the present invention transmits forces applied to the windows and sashes of a replacement window, such as a double-hung replacement window, through a reinforced sash, reinforcement pins, and jamb retainer clips. The force is then more evenly distributed through the frame jambs. This allows a replacement window according to the present invention to withstand violent replacements.
[0048] The invention has been described with reference to the preferred embodiment. Obvious modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
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A replacement window having a window frame, the window frame having a window header, a window sill, a first frame jamb, and a second frame jamb, wherein the first frame jamb and the second frame jamb each connect the window header to the window frame and the window header, the window sill, and the first frame jamb and the second frame jamb define a window frame opening. A sash having a reinforced sash header may be movably positioned in the window frame opening. A reinforcement pin may be positioned adjacent to the reinforced first sash header of the sash, and a jamb retainer clip may be positioned adjacent to the first frame jamb, the jamb retainer clip defining a reinforcement pin orifice, wherein the reinforcement pin orifice receives the reinforcement pin.
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RELATED APPLICATIONS
This application is a divisional application of U.S. Ser. No. 12/282,152 filed May 26, 2009 entitled “EXTRACORPOREAL REMOVAL OF MICRO VESICULAR PARTICLES” which is the U.S. National Phase under 35 U.S.C. §371 of International Application No. PCT/US2007/006101 filed Mar. 9, 2007 which claims the benefit of U.S. Provisional Application No. 60/780,945 filed Mar. 9, 2006, the contents of which are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
The present invention relates to the field of therapeutic methods and devices for the extracorporeal removal of microvesicular particles, useful, for example, for reversing immune suppression in a subject in need thereof (e.g., a cancer patient) through extracorporeal means.
BACKGROUND OF THE INVENTION
Immunological control of neoplasia has been a topic of intense investigation dating back to the days of William Coley, who at the beginning of the 20 th century reported potent induction of tumor remission through administration of various non-specific immune stimulatory bacterial extracts which came to be known as “Coley's Toxins” (1). Suggestions of the ability to induce anti-cancer immunological responses also came from experiments in the 1920s demonstrating that the vaccination with non-viable tumor cells mounts a specific “resistance” to secondary challenge, although at the time, the concept of MHC matching was not known and it was possible that the secondary resistance was only a product of allogeneic sensitization (2). Although the field of cancer immunotherapy has been very controversial throughout the 20 th Century, with some authors actually claiming that immunological responses are necessary for tumor growth (3), the age of molecular biology has demonstrated that indeed immune responses are capable of controlling tumors from initiating, as well as in some cases inhibiting the growth of established tumors.
Originally demonstrated in the murine system, the concept of a productive anti-tumor response was associated with a cytokine profile termed Th1, whereas an ineffective anti-tumor response was associated with Th2. The prototypic method of assessing Th1 activity was by quantitation of the cytokine IFN-γ (4). At an epigenetic level it is known that the chromatin structure of Th1 and Th2 cells is distinct, thus providing a solid foundation that once a naïve T cell has differentiated into a Th1 or Th2 cell, the silenced and activated parts of the chromatin are passed to progeny cells, thus the phenotype is stable (5). Associated with such chromatin changes is the activation of the multi-gene inducing transcription factors GATA-3 (6), STAT6 (7, 8) in Th2 cells, and T-bet (9), and STAT4 (10) in Th1 cells. Accordingly studies have been performed using STAT6 knockout mice as a model of an immune response lacking Th2 influences, thus predominated by Th1. Tumors administered to STAT6 knockout animals are either spontaneously rejected (11), or immunity to them is achieved with much higher potency compared to wild-type animals (12). Furthermore immunologically mediated increased resistance to metastasis is observed (13). In agreement with the Th1/Th2 balance, mice lacking STAT4 develop accelerated tumors in a chemically-induced carcinogenesis model (14).
In the clinical situation correlation between suppressed immune responses and a higher incidence of cancer is well established. For example, natural immune deficiency such as the congenital abnormality Chediak-Higashi Syndrome, in which patients have abnormal natural killer cell function, is associated with an overall weakened immune response. In this population, the overall incidence of malignant tumors is 200-300 times greater than that in the general population (15). In another example, a specific polymorphism of the IL-4 receptor gene that is known to be associated with augmented Th2 responses was investigated in an epidemiological study. Multivariate regression analysis showed that the specific genotype of the IL-4R associated with augmented Th2 activity was an independent prognostic factor for shorter cancer survival and more advanced histopathological grade (16). In addition to inborn genetic abnormalities, the immune suppressive regimens used for post-transplant antirejection effect are associated with a selective inhibition of Th1 responses (17-19). In support of the concept that suppression of Th1 immunity is associated with cancer onset, the incidence of cancer in the post-transplant population is markedly increased in comparison to controls living under similar environmental conditions (20-25). In terms of disease associated immune suppression, HIV infected patients also have a marked predisposition to a variety of tumors, especially, but not limited to lymphomas, as a result of immunodeficiency (26).
Although the above examples support a relation between immune suppression (or Th2 deviation) and cancer, the opposite situation, of immune stimulation resulting in anticancer response, is also documented. Numerous clinical trials using antigen specific approaches such as vaccination with either tumor antigens alone (27, 28), tumor antigens bound to immunogens (29, 30), tumor antigens delivered alone (31) or in combination with costimulatory molecules by viral methods (32), tumor antigens loaded on dendritic cells ex vivo (33-35), or administration of in vitro generated tumor-reactive T cells (36), have all demonstrated some clinical effects. Unfortunately, to date, there is no safe, reproducible, and mass-applicable method of therapeutically inducing regression of established tumors, or metastasis via immunotherapy. Approved immunotherapeutic agents such as systemic cytokine administration are associated with serious adverse effects, as well as mediocre responses and applicability to a very limited patient subset.
Accordingly, there is a need in the art to develop successful immunotherapy capable of stimulating specific immune responses that only target neoplastic tissue, or components of the host tissue whose activity is necessary for the progression of neoplasia (ie endothelium). The development of such a successful immunotherapy is hindered by suppression of the host immune system by the cancer. Experiments in the 1970s demonstrated the existence of immunological “blocking factors” that antigen-specifically inhibited lymphocyte responses. Some of this early work involved culturing autologous lymphocytes with autologous tumor cells in the presence of third party healthy serum. This culture resulted in an inhibition of growth of the autologous tumor as a result of the lymphocytes. Third party lymphocytes did not inhibit the growth of the tumor. Interestingly when autologous serum was added to the cultures the lymphocyte mediated inhibition of tumor growth was not observed. These experiments gave rise to the concept of antigen-specific “blocking factors” found in the body of cancer patients that incapacitate successful tumor immunity (37-39).
More recent demonstration of tumor-suppression of immune function was seen in experiments showing that T cell function is suppressed in terms of inability to secrete interferon gamma due to a cleavage of the critical T cell receptor transduction component, the TCR-zeta chain. Originally, zeta chain cleavage was identified in T cells prone to undergo apoptosis. Although a wide variety of explanations have been put forth for the cleavage of the zeta chain, one particular cause was postulated to be tumor-secreted microvesicles.
Microvesicles secreted by tumor cells have been known since the early 1980s. They were estimated to be between 50-200 nanometers in diameter and associated with a variety of immune inhibitory effects. Specifically, it was demonstrated that such microvesicles could not only induce T cell apoptosis, but also block various aspects of T cell signaling, proliferation, cytokine production, and cytotoxicity. Although much interest arose in said microvesicles, little therapeutic applications developed since they were uncharacterized at a molecular level.
Research occurring independently identified another type of microvesicular-like structures, which were termed “exosomes”. Originally defined as small (i.e., 80-200 nanometers in diameter), exosomes were observed initially in maturing reticulocytes. Subsequently it was discovered that exosomes are a potent method of dendritic cell communication with other antigen presenting cells. Exosomes secreted by dendritic cells were observed to contain extremely high levels of MHC I, MHC II, costimulatory molecules, and various adhesion molecules. In addition, dendritic cell exosomes contain antigens that said dendritic cell had previously engulfed. The ability of exosomes to act as “mini-antigen presenting cells” has stimulated cancer researchers to pulse dendritic cells with tumor antigens, collect exosomes secreted by the tumor antigen-pulsed dendritic cell, and use these exosomes for immunotherapy. Such exosomes were seen to be capable of eradicating established tumors when administered in various murine models. The ability of dendritic exosomes to potently prime the immune system brought about the question if exosomes may also possess a tolerance inducing or immune suppressive role. Since it is established that the exosome has a high concentration of tumor antigens, the question arose if whether exosomes may induce an abortive T cell activation process leading to anergy. Specifically, it is known that numerous tumor cells express the T cell apoptosis inducing molecule Fas ligand.
Fas ligand is an integral type II membrane protein belonging to the TNF family whose expression is observed in a variety of tissues and cells such as activated lymphocytes and the anterior chamber in the eye. Fas ligand induces apoptotic cell death in various types of cells target cells via its corresponding receptor, CD95/APO1. Fas ligand not only plays important roles in the homeostasis of activated lymphocytes, but it has also been implicated in establishing immune-privileged status in the testis and eye, as well as a mechanisms by which tumors escape immune mediated killing. Accordingly, given the expression of Fas ligand on a variety of tumors, we and others have sought, and successful demonstrated that Fas ligand is expressed on exosomes secreted by tumor cells (40).
Due to the ability of exosomes to mediate a variety of immunological signals, the model system was proposed that at the beginning of the neoplastic process, tumor secreted exosomes selectively induce antigen-specific T cell apoptosis, through activating the T cell receptor, which in turn upregulates expression of Fas on the T cell, subsequently, the Fas ligand molecule on the exosome induces apoptosis. This process may be occurring by a direct interaction between the tumor exosome and the T cell, or it may be occurring indirectly by tumor exosomes binding dendritic cells, then subsequently when T cells bind dendritic cells in lymphatic areas, the exosome actually is bound by the dendritic cell and uses dendritic cell adhesion/costimulatory molecules to form a stable interaction with the T cell and induce apoptosis. In the context of more advanced cancer patients, where exosomes reach higher concentrations systemically, the induction of T cell apoptosis occurs in an antigen-nonspecific, but Fas ligand, MHC I-dependent manner.
The recent recognition that tumor secreted exosomes are identical to the tumor secreted microvesicles described in the 1980s (41), has stimulated a wide variety of research into the immune suppressive ability of said microvesicles. Specifically, immune suppressive microvesicles were identified not only in cancer patients (42, 43), but also in pregnancy (44-46), transplant tolerance (47, 48), and oral tolerance (49, 50) situations.
Previous methods of inducing anti-cancer immunity have focused on stimulation of either innate or specific immune responses, however relatively little work has been performed clinically in terms of de-repressing the immune functions of cancer patients. Specifically, a cancer patient having tolerance-inducing exosomes has little chance of mounting a successful anti-tumor immune response. This may be one of the causes for mediocre, if not outright poor, results of current day immunotherapy.
Others have attempted to de-repress the immune system of cancer patients using extracorporeal removal of “blocking factors”. Specifically, Lentz in U.S. Pat. No. 4,708,713 describes an extracorporeal method of removing proteins approximately 200 kDa, which are associated with immune suppression. Although Lentz has generated very promising results using this approach, the approach is: a) not-selective for specific inhibitors; b) theoretically would result in loss of immune stimulatory cytokines; c) is not applicable on a wide scale; and d) would have no effect against tumor-secreted microvesicles which are much larger than 200 kDa.
The recently discovered properties of microvesicles in general, and tumor microvesicles specifically, have made them a very promising target for extracorporeal removal. Properties such as upregulated expression of MHC I, Fas ligand, increased affinity towards lectins, and modified sphingomyelin content allow for use of extracorporeal devices to achieve their selective removal. Additionally, the size of microvesicles would allow for non-selective removal either alone or as one of a series of steps in selective removal.
SUMMARY OF THE INVENTION
In accordance with the present invention, there are provided methods of immune stimulation and/or immune de-repression using extracorporeal techniques to remove microvesicles from circulation.
In one aspect, the present invention relates to methods of removing microvesicles from the circulation of a subject in need thereof (e.g., cancer patients), thereby de-repressing immune suppression present in said subjects. Accordingly, the present invention teaches the use of various extracorporeal devices and methods of producing extracorporeal devices for use in clearing microvesicle content in subjects in need thereof. Said microvesicles may be elaborated by the tumor itself, or may be generated by non-malignant cells under the influence of tumor soluble or contact dependent interactions. Said microvesicles may be directly suppressing the host immune system through induction of T cell apoptosis, proliferation inhibition, incapacitation, anergy, deviation in cytokine production capability or cleavage of the T cell receptor zeta chain, or alternatively said microvesicles may be indirectly suppressing the immune system through modification of function of other immunological cells such as dendritic cells, NK cells, NKT cells and B cells. Said microvesicles may be suppressing the host antitumor immune response either in an antigen-specific or an antigen-nonspecific manner, or both.
One of the objects of the present invention is to provide an effective and relatively benign treatment for cancer.
Another object is to provide an adjuvant, and/or neoadjuvant therapy to be used in conjunction with currently used cancer treatments that require a functional immune response for efficacy.
Another object is to provide an adjuvant, and/or neoadjuvant therapy to be used in conjunction with currently used cancer treatments that stimulate the immune response of a subject in need thereof in an antigen-specific manner.
Another object is to provide an adjuvant, and/or neoadjuvant therapy to be used in conjunction with currently used cancer treatments that stimulate the immune response of a subject in need thereof in an antigen-nonspecific manner.
Another object is to provide improvements in extracorporeal treatment of cancer through selecting the novel target of tumor associated microvesicles.
Another object is to provide beads or other types of particles that can form a matrix outside of a hollow fiber filter, said matrix component having a size greater than pores of said hollow fiber filter, and said beads or other types of particles being bound to agents that capture microvesicles.
Another object is to provide improvements in extracorporeal treatment of cancer through selecting the novel target of tumor associated microvesicles containing unique properties that are not found on microvesicles found in non-cancer patients.
Another object is to provide improved specific affinity devices, particularly immunoadsorption devices, and methods useful for removal of cancer associated microvesicles from cancer patients. Specifically, immunoadsorption devices use proteins with affinity to components of the tumor associated microvesicles. Said proteins include antibodies such as antibodies to Fas ligand, MHC I, MHC II, CD44, placental alkaline phosphatase, TSG-101, MHC I-peptide complexes, MHC II-peptide complexes, or proteins found to be present on the exterior of microvesicles contributing to immune suppression found in a cancer patient. Contemplated within the invention are proteins that act as ligands for the microvesicular proteins, said proteins may be currently in existence, or may be generated by in silico means based on known qualities of microvesicle-specific proteins.
In accordance with one particular aspect of the present invention, methods and devices for treating cancer are provided that are based on the utilization of specific affinity adsorption of microvesicles that are associated with the cancerous state. The affinity adsorbents utilized in accordance with the present invention are both immunoadsorbents and non-immune-based specific affinity chemical adsorbents. More specifically, adsorption can be accomplished based on specific properties of the cancer associated microvesicles, one said property is preferential affinity to lectins and other sugar-binding compounds.
In one particular embodiment, the invention provides a device for extracorporeal treatment of blood or a blood fraction such as plasma. This device has a sorbent circulation circuit, which adheres to and retains microvesicles, and a blood circulation circuit through which blood cells flow unimpeded. The device may be constructed in several variations that would be clear to one skilled in the art. Specifically, the device may be constructed as a closed system in a manner that no accumulating reservoir is needed and the sorbent circulation system accumulates the microvesicles, while non-microvesicle matter is allowed to flow back into the blood circulation system and subsequently returned to the patient. Alternatively, the device may use an accumulator reservoir that is attached to the sorbent circulation circuit and connected in such a manner so that waste fluid is discarded, but volume replenishing fluid is inserted back into the blood circulation system so the substantially microvesicle purified blood that is reintroduced to said patient resembles a hematocrit of significant homology to the blood that was extracted from said patient.
DETAILED DESCRIPTION OF THE INVENTION
For the purposes of advancing and clarifying the principles of the invention disclosed herein, reference will be made to certain embodiments and specific language will be used to describe said embodiments. It will nevertheless be understood and made clear that no limitation of the scope of the invention is thereby intended. The alterations, further modifications and applications of the principles of the invention as described herein serve only as specific embodiment, however one skilled in the art to which the invention relates will understand that the following are indeed only specific embodiments for illustrative purposes, and will derive similar types of applications upon reading and understanding this disclosure.
In accordance with one aspect of the present invention, there are provided methods of removing microvesicular particles from a subject in need thereof, said methods comprising:
a) establishing an extracorporeal circulation system which comprises contacting the whole blood or components thereof with a single or plurality of agents capable of binding microvesicles found within said blood or components thereof; and
b) returning said blood or components thereof into the original blood, said blood or blood components containing substantially less immune suppressive particles in comparison to the blood or blood components originally residing in the blood.
Invention methods are useful, for example, for de-repressing immune response, which includes restoration of one or more of the following: T cell, natural killer (NK) cell, natural killer T (NKT) cell, gamma-delta T cell, and B cell function. Presently preferred applications of invention methods include restoration of one or more of the following: T cell, natural killer (NK) cell, natural killer T (NKT) cell, gamma-delta T cell, and B cell function includes prevention of apoptosis; it is especially preferred that restoration of one or more of the following: T cell, natural killer (NK) cell, natural killer T (NKT) cell, gamma-delta T cell, and B cell function includes restoration and/or endowment of activity capable of inhibiting cancer progression.
Inhibiting cancer progression as contemplated herein is accomplished in a variety of ways, e.g., by one or more of the following: direct cytolysis of tumor cells, direct induction of tumor cell apoptosis, induction of tumor cell cytolysis through stimulation of intrinsic host antitumor responses, induction of tumor cell apoptosis through stimulation of intrinsic host antitumor responses, inhibition of tumor cell metastasis, inhibition of tumor cell proliferation, and induction of senescence in the tumor cell.
Exemplary tumor cells contemplated for treatment herein are selected from the group of cancers consisting of: soft tissue sarcomas, kidney, liver, intestinal, rectal, leukemias, lymphomas, and cancers of the brain, esophagus, uterine cervix, bone, lung, endometrium, bladder, breast, larynx, colon/rectum, stomach, ovary, pancreas, adrenal gland and prostate.
Agents capable of binding microvesicles contemplated for use herein are selected from the group consisting of one or more of the following: a) a singular or plurality of antibody species; b) a singular or plurality of proteins (e.g., lectins); c) a singular or plurality of aptamers, d) a surface that selectively restricts microvesicles from passage, and e) a surface with selective adhesion to microvesicles.
Antibodies contemplated for use herein have a specificity for proteins selected from the group consisting of one or more of the following: Fas ligand, MHC I, MHC II, CD44, placental alkaline phosphatase, TSG-101, MHC I-peptide complexes, MHC II-peptide complexes, and proteins found to be present on the exterior of microvesicles contributing to immune suppression found in a cancer patient. Presently preferred antibodies are specific to Fas ligand, MHC I, and the like.
Binding proteins contemplated for use herein are selected from the group comprising consisting of one or more of the following: Fas, T cell Receptor, protein extracts isolated from T cells, protein extracts isolated from dendritic cells, and proteins found to possess affinity for binding proteins found on microvesicles associated with immune suppression.
Surfaces contemplated for use herein that selectively restrict passage of said microvesicles typically have pore sizes in the range of about 20-400 nanometers in size, with surfaces having pore sized in the range of about 40-300 nanometers in size being preferred, with surfaces having a pore size in the range of about 50-280 nanometers in size being especially preserved.
Surfaces with selective adhesion to microvesicles contemplated for use herein can be coated with a single compound, or a plurality of compounds that bind particles that are enriched in sphingomyelin and with a lower level of phosphatidylcholine as found in the cellular membranes of non-malignant cells.
In accordance with another aspect of the present invention, agents capable of binding microvesicles are immobilized on a porous hollow fiber membrane. For example, agents capable of binding microvesicles are immobilized on the porous exterior of the hollow fiber membrane.
In accordance with another aspect of the present invention, existing methods and devices of extracorporeal treatment of blood can be integrated (in whole or in part) with the above-described methods to augment ex vivo clearance of microvesicles in a physiologically applicable manner. For example, existing methods for extracorporeal treatment of blood can be selected from one or more of the following: a) hemofiltration; b) hemodialysis; and c) hemodiafiltration. A presently preferred existing method for extracorporeal treatment of blood comprises apheresis followed by filtration.
In accordance with another embodiment of the present invention, there are provided medical devices useful for the removal of cancer associated microvesicles from the blood of a cancer patient, said device comprising:
a) an intake conduit through which blood of a cancer patient in need of treatment enters;
b) a single or plurality of matrices capable of adhering to microvesicles causative of cancer associated immune suppression; and
c) a system for reintroduction of said blood into the patient in need thereof, whereby said blood is reintroduced under physiologically acceptable conditions.
In one aspect of the above-described medical device, the matrices surround a plurality of hollow fiber filters. Preferably, the hollow fiber filters have a diameter of sufficient size to allow passage of blood cells through the lumen, and diffusion of particles between 80-300 nanometers in size.
In another aspect of the above-described medical device, a microvesicle binding agent is chemically reacted with a high-molecular weight substrate and placed on the exterior of said hollow fibers so as to bind non-blood cell liquids permeating through the pores of said hollow fibers. Exemplary microvesicle binding agents include one or more of the following: a) a singular or plurality of antibody species; b) a singular or plurality of proteins (e.g., lectins); c) a singular or plurality of aptamers, d) a surface that selectively restricts microvesicles from passage, and e) a surface with selective adhesion to microvesicles.
Exemplary antibodies contemplated for use herein have a specificity for proteins selected from the group consisting of one or more of the following: Fas ligand, MHC I, MHC II, CD44, placental alkaline phosphatase, TSG-101, MHC I-peptide complexes, MHC II-peptide complexes, and proteins found to be present on the exterior of microvesicles contributing to immune suppression found in a cancer patient. Presently preferred antibodies are specific to Fas ligand, MHC I, and the like.
Exemplary proteins contemplated for use in the invention device are selected from the group consisting of one or more of the following: Fas, T cell Receptor, protein extracts isolated from T cells, protein extracts isolated from dendritic cells, and proteins found to possess affinity for binding proteins found on microvesicles associated with immune suppression.
In accordance with another embodiment of the present invention, there are provided methods of potentiating the immunologically mediated anticancer response elicited by vaccination to tumor antigens, said methods comprising:
a) immunizing a subject in need thereof using a single or combination of tumor antigens;
b) removing immunosuppressive microvesicles from the sera of said subject by extracorporeal means; and
c) adjusting the amount of removal of immune suppressive microvesicles based on immune stimulation desired.
In accordance with yet another embodiment of the present invention there are provided methods of enhancing the immune response of a subject in need thereof through the removal of microvesicular particles found in systemic circulation of said subject, said methods comprising:
a) establishing an extracorporeal circulation system which comprises contacting the whole blood or components thereof with a single or plurality of agents capable of binding microvesicles found within said blood or components thereof; and
b) returning said blood or components thereof into the subject, said blood or blood components containing substantially less immune suppressive particles in comparison to the blood or blood components originally residing in said subject.
Enhancing immune response as contemplated herein includes one or more of the following: upregulation of T cell, natural killer (NK) cell, natural killer T (NKT) cell, gamma-delta T cell, and B cell function. In a presently preferred embodiment, upregulation of one or more of T cell, natural killer (NK) cell, natural killer T (NKT) cell, gamma-delta T cell, and B cell function includes prevention of apoptosis. In yet another preferred embodiment, upregulation of one or more of T cell, natural killer (NK) cell, natural killer T (NKT) cell, gamma-delta T cell, and B cell function includes enhancing and/or endowment of activity capable of inhibiting cancer progression.
Inhibiting cancer progression contemplated herein is accomplished in a variety of ways, e.g., by direct cytolysis of tumor cells, direct induction of tumor cell apoptosis, induction of tumor cell cytolysis through stimulation of intrinsic host antitumor responses, induction of tumor cell apoptosis through stimulation of intrinsic host antitumor responses, inhibition of tumor cell metastasis, inhibition of tumor cell proliferation, and induction of senescence in the tumor cell.
Tumor cells contemplated for treatment in accordance with the present invention are selected from the group of cancers consisting of soft tissue sarcomas, kidney, liver, intestinal, rectal, leukemias, lymphomas, and cancers of the brain, esophagus, uterine cervix, bone, lung, endometrium, bladder, breast, larynx, colon/rectum, stomach, ovary, pancreas, adrenal gland and prostate.
Agents capable of binding microvesicles contemplated for use herein are selected from the group consisting of one or more of the following: a) a singular or plurality of antibody species; b) a singular or plurality of proteins (e.g., lectins); c) a singular or plurality of aptamers, d) a surface that selectively restricts microvesicles from passage, and e) a surface with selective adhesion to microvesicles.
Antibodies having specificity for proteins contemplated for use herein are selected from the group consisting of one or more of the following: Fas ligand, MHC I, MHC II, CD44, placental alkaline phosphatase, TSG-101, MHC I-peptide complexes, MHC II-peptide complexes, and proteins found to be present on the exterior of microvesicles contributing to immune suppression found in a cancer patient. Presently preferred antibodies are specific to Fas ligand, MHC I, and the like.
Proteins contemplated for use herein are selected from the group consisting of one or more of the following: Fas, T cell Receptor, protein extracts isolated from T cells, protein extracts isolated from dendritic cells, and proteins found to possess affinity for binding proteins found on microvesicles associated with immune suppression.
Surfaces that selectively restrict passage of said microvesicles contemplated for use herein typically have a pore size in the range of about 20-400 nanometers in size, with pores sizes in the range of about 40-300 nanometers in size being preferred, and pore sizes in the range of about 50-280 nanometers in size being especially preferred.
Surfaces with selective adhesion to microvesicles contemplated for use herein are coated with a variety of agents, e.g., a single compound, or plurality of compounds that bind particles that are enriched in sphingomyelin and with a lower level of phosphatidylcholine as found in the cellular membranes of non-malignant cells.
In one aspect, the above-described agents capable of binding microvesicles are immobilized on a porous hollow fiber membrane, e.g., on the porous exterior of the hollow fiber membrane.
In another aspect of the invention, existing methods and devices of extracorporeal treatment of blood are integrated (in whole or in part) for augmenting ex vivo clearance of microvesicles in a physiologically applicable manner. Exemplary existing methods for extracorporeal treatment of blood are selected from one or more of the following: a) hemofiltration; b) hemodialysis; and c) hemodiafiltration. A presently preferred existing method for extracorporeal treatment of blood comprises apheresis followed by filtration.
In accordance with yet another embodiment of the present invention, there are provided methods of enhancing the immune response of a subject in need thereof through the removal of microvesicular particles found in systemic circulation of said subject, said methods comprising:
a) establishing an extracorporeal circulation system which comprises contacting the whole blood or components thereof with a single or plurality of agents capable of binding microvesicles found within said blood or components thereof, said agents being in turn bound to a plurality of objects;
b) performing a filtration step such that said objects of a defined size are captured within said extracorporeal circulation system; and
c) returning said blood or components thereof into the subject, said blood or blood components containing substantially less immune suppressive particles in comparison to the blood or blood components originally residing in said subject.
Enhancing immune response contemplated herein includes one or more of the following: upregulation of T cell, natural killer (NK) cell, natural killer T (NKT) cell, gamma-delta T cell, and B cell function. It is presently preferred that upregulation of one or more of T cell, natural killer (NK) cell, natural killer T (NKT) cell gamma-delta T cell, and B cell function includes prevention of apoptosis. It is also presently preferred that upregulation of one or more of T cell, natural killer (NK) cell, natural killer T (NKT) cell gamma-delta T cell, and B cell function includes enhancing and/or endowment of activity capable of inhibiting cancer progression.
Inhibiting cancer progression contemplated herein is accomplished by one or more of the following: direct cytolysis of tumor cells, direct induction of tumor cell apoptosis, induction of tumor cell cytolysis through stimulation of intrinsic host antitumor responses, induction of tumor cell apoptosis through stimulation of intrinsic host antitumor responses, inhibition of tumor cell metastasis, inhibition of tumor cell proliferation, and induction of senescence in the tumor cells.
Tumor cells contemplated for treatment in accordance with the present invention are selected from the group of cancers consisting of: soft tissue sarcomas, kidney, liver, intestinal, rectal, leukemias, lymphomas, and cancers of the brain, esophagus, uterine cervix, bone, lung, endometrium, bladder, breast, larynx, colon/rectum, stomach, ovary, pancreas, adrenal gland and prostate.
Agents capable of binding microvesicles contemplated for use herein are selected from the group consisting of one or more of the following: a) a singular or plurality of antibody species; b) a singular or plurality of proteins (e.g., lectins); c) a singular or plurality of aptamers, d) a surface that selectively restricts microvesicles from passage, and e) a surface with selective adhesion to microvesicles.
The plurality of objects contemplated for use herein comprise beads manufactured to a specific size or range of sizes in a manner so that said agents capable of binding microvesicles may be conjugated to said plurality of objects. Preferably such beads have a defined size range to restrict their movement out of said extracorporeal circulation system, e.g., the beads are of a size range larger than pores of hollow fibers used in extracorporeal systems so as to restrict their movement out of said extracorporeal systems. In one aspect, such beads possess properties responsive to an electromagnetic field, such that subsequent to said beads contacting said microvesicles, said beads may be removed or sequestered by said electromagnetic field in order to substantially prevent movement of said beads out of said extracorporeal system.
Examples of beads contemplated for use herein are MACS™ beads alone or conjugated with compounds in order to allow said beads to form complexes with said agents capable of binding microvesicles, Dynal™ beads alone or conjugated with compounds in order to allow said beads to form complexes with said agents capable of binding microvesicles, and the like.
Antibodies contemplated for use herein have a specificity for proteins selected from a group consisting of one or more of the following: Fas ligand, MHC I, MHC II, CD44, placental alkaline phosphatase, TSG-101, MHC I-peptide complexes, MHC II-peptide complexes, and proteins found to be present on the exterior of microvesicles contributing to immune suppression found in a cancer patient. Presently preferred antibodies are specific to Fas ligand, MHC I, and the like.
Proteins contemplated for use herein are selected from the group consisting of one or more of the following: Fas, T cell Receptor, protein extracts isolated from T cells, protein extracts isolated from dendritic cells, and proteins found to possess affinity for binding proteins found on microvesicles associated with immune suppression.
Surfaces that selectively restrict passage of said microvesicles typically fall in the range of about 20-400 nanometers in size, with microvesicles falling in the range of about 40-300 nanometers in size being presently preferred, and microvesicles in the range of about 50-280 nanometers in size being especially preferred.
Exemplary surfaces with selective adhesion to microvesicles are coated with a single compound, or plurality of compounds that bind particles that are enriched in sphingomyelin and with a lower level of phosphatidylcholine as found in the cellular membranes of non-malignant cells.
In accordance with another aspect of the invention, agents capable of binding microvesicles can be immobilized on a porous hollow fiber membrane, e.g., on the porous exterior of the hollow fiber membrane.
In accordance with still another aspect of the present invention, existing methods and devices of extracorporeal treatment of blood can be integrated (in whole or in part) with the above-described methods to augment ex vivo clearance of microvesicles in a physiologically applicable manner. Exemplary methods contemplated for use herein include: a) hemofiltration; b) hemodialysis; and c) hemodiafiltration, with a preferred method including apheresis followed by filtration.
In accordance with various aspects of the present invention, extracorporeal removal of microvesicles can be performed through selective adhesion of said microvesicles to matrices or substrates that are conjugated to agents possessing higher affinity to microvesicles with a high sugar content, in comparison to microvesicles of a lower sugar content.
In accordance with yet another embodiment of the present invention, there are provided methods of extracorporeally removing microvesicles from a subject in need thereof, said method comprising passing said subject's whole blood, or separated blood components, through a system capable of selectively binding and retaining microvesicles based on one or more of size, charge, affinity towards lectins, or affinity towards molecules that are known to be present on said microvesicles.
In accordance with a further embodiment of the present invention, there are provided methods of extracorporeally removing microvesicles from a subject in need thereof, said methods comprising passing said subject's whole blood, or separated blood components, through a system capable of non-selectively binding and retaining microvesicles based on one or more of size, charge, affinity towards lectins, or affinity towards molecules that are known to be present on said microvesicles.
In accordance with a still further embodiment of the present invention, there are provided methods of extracorporeally removing microvesicles from a subject in need thereof, said methods comprising passing said subject's whole blood, or separated blood components, through a system capable of selectively binding and retaining microvesicles based on similarities between properties of microvesicles and membranes of cancer cells.
In accordance with yet another embodiment of the present invention, there are provided methods of extracorporeally removing microvesicles from a subject in need thereof, said methods comprising passing said subject's whole blood, or separated blood components, through a system capable of non-selectively binding and retaining microvesicles based on similarities between properties of microvesicles and membranes of cancer cells.
When carrying out the above-described methods, the similarities between cancer associated microvesicles and membranes of cancer cells include ability to bind a lectin or plurality of lectins. Reference to lectins herein includes GNA, NPA, Conconavalin A and cyanovirin, with a presently preferred lectin being Conconavalin A.
One embodiment of the present invention relates to methods that can be used for extracorporeal treatment of blood or a blood fraction for the removal of microvesicles associated with immune suppression in a cancer patient. Blood is run through an extracorporeal circulation circuit that uses a hollow fiber cartridge with the membranes of said hollow fibers having sufficient permeability for the microvesicles found in the blood to be removed through the membrane of the hollow fibers and into an area outside of the fibers containing a substrate that is bound to a single or plurality of agents capable of adhering to said microvesicles in a manner such that said microvesicles are attached to said agent and do not substantially re-enter the hollow fibers. Within the knowledge of one skilled in the art are available numerous types of hollow fiber systems. Selection of said hollow fiber system is dependent on the desired blood volume and rate of passage of said blood volume through the hollow fiber system. Specifically, hollow fiber cartridges may be used having lengths of 250 mm and containing 535 hollow fibers supplied by Amicon, and having the fiber dimensions: I.D. 180 micron and O.D. 360 micron, and the total contact surface area in the cartridge is 750 cm 2 . Alternatively, the “Plasmaflux P2” hollow fiber filter cartridge (sold by Fresenius) or Plasmart PS60 cartridges (sold by Medical srl) may be used. These and other hollow fiber systems are described by Ambrus and Horvath in U.S. Pat. No. 4,714,556 and incorporated herein by reference in its entirety. Hollow fiber cartridges such as described by Tullis in United States Patent Application 20040175291 (incorporated by reference herein in its entirety) may also be used. Furthermore, said hollow fiber cartridges and affinity cartridges in general are thought in U.S. Pat. Nos. 4,714,556, 4,787,974 and 6,528,057, which are incorporated herein by reference in their entirety.
Regardless of hollow fiber system used, the concept needed for application of the present invention, is that said hollow fiber filters are required to allow passage of blood cells through the interior of said hollow fiber, and allow diffusion of microvesicles to the exterior. In order to allow such diffusion, the pores on the membrane of the hollow fiber need to be of a diameter sufficient to allow particles ranging from the size of 20 nanometers to 500 nanometers in diameter. More specifically, the pores on the membrane of the hollow fiber need to be of a diameter sufficient to allow particles ranging from the size of 50 nanometers to 300 nanometers in diameter. Even more specifically, the pores on the membrane of the hollow fiber need to be of a diameter sufficient to allow particles ranging from the size of 80 nanometers to 200 nanometers in diameter. During experimentation with different hollow fibers, one skilled in the art would find it useful to utilize particles of similar size ranges as the microvesicles in order to calibrate and quantitate the ability of various pore sizes of hollow filters. One method of performing this is through the utilization of commercially available MACS™ Beads (Milteny Biotech), which have a size of 60 nanometers. Fluorescent, spherical latex beads ranging in size from 25 to 1000 nm are also available for this purpose (e.g., from Duke Scientific (Palo Alto, Calif.)).
The substrate or matrix to be used in practicing the present invention needs to allow sufficient permeation of flow so that non-cellular blood components that enter the space exterior to the hollow fiber are distributed throughout the substrate or matrix material, so that substantial contact is made between the microvesicles permeating the hollow fiber filter and the microvesicle-binding agent that is attached to the substrate or matrix. Suitable substrates or matrices are known to one skilled in the art. Said substrates or matrices include silica gel, dextran, agarose, nylon polymers, polymers of acrylic acid, co-polymers of ethylene and maleic acid anhydride, aminopropylsilica, aminocelite, glass beads, silicate containing diatomaceous earth or other substrates or matrices known in the art. Examples of such are described in the following patents, each of which are incorporated by reference herein in their entirety: Lentz U.S. Pat. No. 4,708,713, Motomura U.S. Pat. No. 5,667,684, Takashima et al U.S. Pat. No. 5,041,079, and Porath and Janson U.S. Pat. No. 3,925,152. The agents that are attached to said substrate are chosen based on known affinity to cancer associated microvesicles. Said agents may be capable of non-specifically binding to said microvesicles, in that binding occurs both from non-tumor associated microvesicles, and from tumor associated microvesicles, or conversely, said agents may display a certain degree of selectivity for exosomes derived from tumors.
In one embodiment said agents non-specifically bind all microvesicles due to common expression of molecules such as MHC I on microvesicles that are associated with conditions of neoplasia, and microvesicles that are not. Specifically, an agent that would bind both types of microvesicles would be an antibody specific to the non-polymorphic regions of MHC I. Therefore, in the embodiment of the invention in which non-selective removal of microvesicles is sought, anti-MHC I antibodies would be bound to said substrate chosen, and the combination would be placed to reside outside of the hollow fiber filters in order to allow binding of said microvesicles to the substrate, however blood cells and other components of the blood would not be removed during the passage of blood through the encased system containing said hollow fiber filters, exterior substrate, and microvesicle binding agent.
In order to achieve non-specific removal of microvesicles, another embodiment of the invention is the use of hollow fiber filters of sufficient size of the pores on the side of the hollow fiber filter for microvesicles to exit, while not allowing blood cells to exit, and passing a continuous solution over said hollow fiber filters in order to clear said microvesicles leaking through the sides of the hollow fiber filters. In such a situation it would be critical to re-introduce the other blood components that escaped the hollow fiber filter, such as albumin, back into the microvesicle purified blood, before returning of the blood to the subject.
Alternatively, the hollow-fiber cartridge may be sealed as described in Ambrus. In such a system, both diffusion and convection cause blood fluids (exclusive of blood cells) to pass through the pores in the hollow fibers and into contact with the capture molecules bound to the solid phase matrix. The fluids (e.g. plasma) pass back into the circulation at the distal end of the cartridge through a process known as Starling flow. In this system, there is no significant loss of blood fluids and therefore no need for blood component replacement.
In the situations where a substantially specific removal of microvesicles associated with tumors is desired, the said agent bound to said substrate outside of said hollow fiber filters possesses affinity to molecules specifically found on said microvesicles associated with tumors. Said agent may be an antibody to the molecule Fas Ligand, may be a recombinant Fas protein, or may be directed to MHC I, MHC II, CD44, placental alkaline phosphatase, TSG-101, MHC I-peptide complexes, MHC II-peptide complexes, and proteins found to be present on the exterior of microvesicles contributing to immune suppression found in a cancer patient. Another embodiment of the invention takes advantage of the similarity of tumor membranes with tumor microvesicles and the known high concentration of mannose and other sugars on tumor membranes compared to membranes of non-malignant cells.
In a situation where microvesicles associated with tumors are meant to be withdrawn with a certain degree of selectivity from the systemic circulation of a subject in need thereof, said agent binding the matrix or substrate may be a lectin. Specific methodologies for use of lectins in removal of viruses are described by Tullis in United States Patent Application 20040175291 (incorporated by reference herein in its entirety) and these methodologies may also be used in part or in whole for practicing the present invention. In various embodiments of the invention, it is important that said systems include means for maintaining the blood at conditions similar to that found in the host, so that upon returning said blood to the host, no adverse reactions occur. In other words, it is within the scope of the invention to use technologies that are known to one skilled in the art to maintain blood at physiological ion concentrations, osmolality, pH, hematocrit, temperature, and flow in order to avoid harm being caused to the subject subsequent to reinfusion of blood treated as disclosed herein. Said technologies are well known to one skilled in the art.
In another embodiment of the invention a system for extracorporeal clearance of microvesicles; either selectively removing tumor associated microvesicles, or non-selectively microvesicles that are found in healthy subjects as well as tumor bearing subjects. The invention comprises several interacting components whose primary purpose is the formation of a functional circuit capable of depleting microvesicles in order to de-repress, or in some cases augment the immune response of a cancer patient. More specifically, a means for separating blood from a subject in need thereof (e.g., a cancer patient) into plasma and cellular elements is used. Appropriate means for such separation are available commercially, and well-known to the skilled artisan. They include, for example, the Exorim System, the Fresenius Hemocare Apheresis system, and the Gambo Prisma System. Plasma purified through said separation means is then run over an array of filtration means, said filtration means possessing a higher affinity towards tumor associated microvesicles in comparison to other molecules. Said filtration means includes, in some embodiments, microvesicle binding agents immobilized to a substrate.
Said microvesicle binding agents include but are not limited to antibodies, proteins, or compounds with selective affinity towards microvesicles associated with the cancer or not associated. Examples of such agents include antibodies to Fas ligand, MHC I, MHC II, CD44, placental alkaline phosphatase, TSG-101, MHC I-peptide complexes, MHC II-peptide complexes, or proteins found to be present on the exterior of microvesicles contributing to immune suppression found in a cancer patient, as well as lectins such as conconavalin A, phytohemagluttanin, GNA, NPA, and cyanovirin. Said substrate is selected from known substrates previously used in the are, these include, for example SEPHAROSE™ made by Amersham-Biosciences, Upsala, Sweden, as well as acrylamide and agarose particles or beads. The substrates used should have the properties of being able to tightly bind the microvesicle binding agent, the ability to be produced in a sterile means, and be compatible with standard dialysis/extracorporeal tubings.
In other embodiments, the agent capable of binding the tumor associated or non-tumor associated microvesicles is immobilized to a filter membrane or capillary dialysis tubing, where the plasma passes adjacent to, or through, the membranes to which said agent capable of binding the tumor associated or non-tumor associated microvesicles are bound. Suitable filters include those mentioned previously with respect to separation of blood components. These may be the same filters, having immobilized agents capable of binding microvesicles (either tumor associated or non-associated, or may be arranged in sequence, so that the first filter divides the blood components and the secondary, tertiary and additional filter removes one or more of the components of said cancer associated microvesicles. Conjugation of the agent capable of binding the tumor associated or non-associated microvesicle to said substrate may be accomplished by numerous means known in the art. Said means include avidin-streptavidin, cynanogen bromide coupling, the use of a linker such as a polyethylene glycol linker. A means of returning the blood together with plasma substantially cleared of tumor associated microvesicles back to said subject is also provided in the invention. Preferred means are chosen by one of skill in the art based on the desired application, extent of microvesicle removal desired, patient condition, extracorporeal method chosen, and microvesicle-binding agent chosen.
In one embodiment of the invention, extracorporeal removal of microvesicles is performed in a cancer patient in order to accelerate the rate of tumor-specific T cell proliferation and activation. It is known in the art that tumors contain antigens that are specific to the tumor (e.g. the bcr-abl product p210 in CML), expressed on other tissues but overexpressed on cancer cells (e.g. tyrosinase), or expressed embryonically and re-expressed in the cancer (e.g. telomerase). Vaccination to such antigens has been demonstrated to induce immune response, and in some cases generation of cytotoxic T lymphocytes (CTL). Unfortunately, despite much effort in development of cancer vaccines, clinical translation has been slow, with most cancer vaccines not demonstrating efficacy in the double-blind setting. In order to increase efficacy of cancer vaccines, it is important that the cancer patient has an immunological environment in which proper T cell activation may occur. It is known that high numbers of microvesicles are present in the circulation of patients with a wide variety of histologically differing tumors including melanoma (52), ovarian (53), colorectal (54), and breast (55). Importantly, such microvesicles are known to induce suppression of immunity via direct mechanisms such as induction of T cell death via FasL expression (52), through indirect mechanisms such as stimulation of myeloid suppressor cell activity (54). Indeed, numerous mechanisms are known for suppression of T cell immunity by cancer-secreted microvesicles (56-59). Accordingly, in one embodiment a cancer patient is treated with a therapeutic cancer vaccine either prior to, concurrently, or subsequent to undergoing extracorporeal removal of exosomes. Said cancer vaccine may be used for stimulation of immune responses to antigens that are found either exclusively on the tumor, to antigens found on non-malignant tissues but at higher concentration on the tumor, or antigens whose presence is required for tumor functionality. In a specific embodiment of the invention, tumor vaccination is performed to peptides, polypeptides, glycoproteins, peptidomimetics, or combinations thereof. Tumor vaccination may be performed in the context of a cell therapy, such as, for example, administration of dendritic cells that are pulsed with tumor antigens or tumor lysates. Tumor vaccines are commonly known in the art and are described in the following reviews, which are incorporated by reference (60-64). Examples of tumor antigens that may be used in the practice of the current invention include CDK-4/ma MUM-1/2, MUM-3, Myosin/m, Redox-perox/m, MART-2/m, Actin/4/ma, ELF2-M, CASP-8/ma, HLA-A2-R17OJ, HSP70-2/ma, CDKN2A, CDC27a, TPI, LDLR/FUT Fibronectin/m, RT-PTP-K/ma, BAGE, GAGE, MAGE, telomerase, and tyrosinase, and fragments thereof.
In one specific embodiment, a patient with ovarian cancer is selected for treatment with cancer vaccination. Said patient plasma is assessed for exosomal content based on methods known in the art, as for example described in the following study and incorporated herein by reference (65). In specific method involves the following procedure: ETDA treated plasma is purified from peripheral blood by centrifugation at 500 g for half-hour. Separation of cellular debris is accomplished by a second centrifugation at 7,000 g for an additional half-hour. Exosomes are subsequently collected by centrifugation at 100,000 g for 3 hours, followed by a washing step in PBS under the same conditions. Using this procedure, approximately 0.5-0.6 ug/ml of exosomal protein is detected from healthy volunteers as visualized by the Bradfort Assay (Bio-Rad, Hercules, Calif.) (66). In contrast, the plasma of cancer patients typically contains a higher exosomal yield, ranging between 200-500 ug/ml. This is in agreement with studies describing high concentrations of “membrane vesicles” found systemically circulating in cancer patients (65). For the practice of the invention patients with high exosomal content compared to healthy volunteers are selected. For example, patients with exosomal content above two fold the concentration of exosomes in healthy volunteers may be treated by the invention. In another embodiment, patients with exosomal contented 10-fold higher than exosomal content of healthy volunteers are treated. In another embodiment of the invention, patients with higher exosomal content than healthy volunteers which have spontaneous T cell apoptosis present are selected for treatment. Protocols for assessment of spontaneous T cell apoptosis are known in the art and described, for example by Whiteside's group and incorporated here by reference (67). Assessment of exosome immune suppressive activity may be quantified by culture of exosomes purified from patient plasma with a Fas expressing T cell line such as the Jurkat clone E6.1 (ATCC Manassas, Va.). These cells may be cultured in standard conditions using the method described by Andreola et al and incorporated herein by reference (52) in order to develop a standardized assay. Briefly 10 6 /ml Jurkat cells are seeded in 24-well plates in 10% FBS RPMI 1640 and co-cultured with escalating concentrations of exosomes from healthy volunteers, as well as cancer patients. Apoptosis of Jurkat cells may be quantified by assessment of Annexin-V staining using flow cytometry.
Patients displaying elevated numbers of exosomes, and/or apoptotic T cells, and/or possessing exosomes capable of inducing T cell apoptosis are selected for extracorporeal removal of said exosomes. In one preferred embodiment, patent blood is passaged over an extracorporeal circuit for a time sufficient to substantially reduce exosome burden. Reduction of exosome burden is quantified as described above. Correlation can be made between exosome concentration and spontaneous T cell apoptosis. When reduction of both plasma exosome concentration and spontaneous T cell apoptosis is achieved, said patient may be immunized with a tumor vaccine. Alternatively, patients may have exosome removal performed without immunization with a tumor vaccine so as to allow for endogenous antitumor responses to be derepressed. Alternatively patients may be treated with a non-specific immune stimulator, said immune stimulator may be a small molecule (e.g. muramyl dipeptide, thymosin, 7,8-disubstituted guanosine, imiquimod, detoxified lipopolysaccharide, isatoribine or alpha-galactosylceramide), a protein (e.g. IL-2, IL-7, IL-8, IL-12, IL-15, IL-18, IL-21, IL-23, IFN-a, b, g, TRANCE, TAG-7, CEL-1000, bacterial cell wall complexes, or LIGHT), or an immunogeneic nucleic acid (e.g. short interfering RNA targeting the mRNA of immune suppressive proteins, CpG oligonucleotides, Poly IC, unmethylated oligonucleotides, plasmid encoding immune stimulatory molecules, or chromatin-purified DNA). Said non-specific immune stimulants are known in the art and in some cases are already in clinical use. Said non-specific immune stimulants in clinical use include interleukin-2, interferon gamma, interferon alpha, BCG, or low dose cyclophosphamide.
In another embodiment extracorporeal removal of exosomes is performed in conjunction with chemotherapy in order to derepress immune suppression caused by exosomes, while at the same time allowing said chemotherapy to perform direct tumor inhibitory functions. Alternatively, extracorporeal removal of exosomes may be utilized to remove increased exosomes caused by tumor cell death during chemotherapy use. Numerous types of chemotherapies are known in the art that may be utilized in the context of the present invention, these include: alkylating agents such as thiotepa and cyclosphosphamide (CYTOXAN™); alkyl sulfonates such as busulfan, improsulfan and piposulfan; aziridines such as benzodopa, carboquone, meturedopa, and uredopa; ethylenimines and methylamelamines including altretamine, triethylenemelamine, triethylenephosphoramide, triethylenethiophosphoramide and trimethylolomelamine; nitrogen mustards such as chlorambucil, chlomaphazine, cholophosphamide, estramustine, ifosfamide, mechlorethamine, mechlorethamine oxide hydrochloride, melphalan, novembichin, phenesterine, prednimustine, trofosfamide, uracil mustard; nitrosureas such as carmustine, chlorozotocin, fotemustine, lomustine, nimustine, ranimustine; antibiotics such as aclacinomysins, actinomycin, authramycin, azaserine, bleomycins, cactinomycin, calicheamicin, carabicin, carminomycin, carzinophilin, chromomycins, dactinomycin, daunorubicin, detorubicin, 6-diazo-5-oxo-L-norleucine, doxorubicin, epirubicin, esorubicin, idarubicin, marcellomycin, mitomycins, mycophenolic acid, nogalamycin, olivomycins, peplomycin, potfiromycin, puromycin, quelamycin, rodorubicin, streptonigrin, streptozocin, tubercidin, ubenimex, zinostatin, zorubicin; anti-metabolites such as methotrexate and 5-fluorouracil (5-FU); folic acid analogues such as denopterin, methotrexate, pteropterin, trimetrexate; purine analogs such as fludarabine, 6-mercaptopurine, thiamiprine, thioguanine; pyrimidine analogs such as ancitabine, azacitidine, 6-azauridine, carmofur, cytarabine, dideoxyuridine, doxifluridine, enocitabine, floxuridine, 5-FU; androgens such as calusterone, dromostanolone propionate, epitiostanol, mepitiostane, testolactone; anti-adrenals such as aminoglutethimide, mitotane, trilostane; folic acid replenishes such as frolinic acid; aceglatone; aldophosphamide glycoside; aminolevulinic acid; amsacrine; bestrabucil; bisantrene; edatraxate; defofamine; demecolcine; diaziquone; elfornithine; elliptinium acetate; etoglucid; gallium nitrate; hydroxyurea; lentinan; lonidamine; mitoguazone; mitoxantrone; mopidamol; nitracrine; pentostatin; phenamet; pirarubicin; podophyllinic acid; 2-ethylhydrazide; procarbazine; PSK®; razoxane; sizofiran; spirogermanium; tenuazonic acid; triaziquone; 2,2′,2″-trichlorotriethylamine; urethan; vindesine; dacarbazine; mannomustine; mitobronitol; mitolactol; pipobroman; gacytosine; arabinoside (“Ara-C”); cyclophosphamide; thiotepa; taxanes, e.g. paclitaxel (TAXOL®, Bristol-Myers Squibb Oncology, Princeton, N.J.) and docetaxel (TAXOTERE®, Rhone-Poulenc Rorer, Antony, France); chlorambucil; gemcitabine; 6-thioguanine; mercaptopurine; methotrexate; platinum analogs such as cisplatin and carboplatin; vinblastine; platinum; etoposide (VP-16); ifosfamide; mitomycin C; mitoxantrone; vincristine; vinorelbine; navelbine; novantrone; teniposide; daunomycin; aminopterin; xeloda; ibandronate; CPT-11; topoisomerase inhibitor RFS 2000; difluoromethylomithine (DMFO); retinoic acid; esperamicins; and capecitabine.
In one embodiment, frequency and length of extracorporeal treatment is performed based on the amount of time (or blood volume) needed for reduction of exosome concentration to a level significant to correlate with reduction in spontaneous T cell apoptosis. In one embodiment a reduction of spontaneous T cell apoptosis by approximately 20% in comparison to pre-extracorporeal treatment values is judged as sufficient. In another embodiment a reduction of spontaneous T cell apoptosis by approximately 50% in comparison to pre-extracorporeal treatment values is judged as sufficient. In another embodiment a reduction of spontaneous T cell apoptosis by approximately 90% in comparison to pre-extracorporeal treatment values is judged as sufficient.
Although assessment of spontaneous T cell apoptosis is used in some embodiments for judging the frequency, and/or time, and/or blood volume needed for extracorporeal treatment, other means of measuring immune responses may be used. For example restoration of cytokine production (68), T cell proliferation (69), or TCR-zeta chain expression (70) are all known in the art and described in the references incorporated herein.
One skilled in the art will appreciate that these methods and devices are and may be adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The methods, procedures, and devices described herein are presently representative of preferred embodiments and are exemplary and are not intended as limitations on the scope of the invention. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the disclosure. It will be apparent to one skilled in the art that varying substitutions and modifications may be made to the invention disclosed herein without departing from the scope and spirit of the invention.
EXAMPLES
There are numerous methods of conjugating antibodies to substrates that are used for packing the Hollow Fiber Cartridge. In the examples, the binding of proteins and other chemical binding agents is generally performed using variations of the glutaraldehyde techniques described by Ambrus and Horvath in U.S. Pat. No. 4,714,556 (incorporated herein by reference in its entirety).
Example 1
Preparation of GNA Covalently Coupled to Agarose Using Cyanogen Bromide
Cyanogen bromide (CNBr) activated agarose was used for direct coupling essentially according to Cuatrecasas, et al (Cuatracasas, Wilchek and Anfinsen. Proc Natl Acad Sci USA 61(2): 636-643, 1968). In brief, 1 ml of GNA at a concentration of 10 mg/ml in 0.1M NaHCO 3 pH 9.5 is added to 1 ml CNBr activated agarose (Sigma, St. Louis, Mo.) and allowed to react overnight in the cold. Care must be taken to maintain alkaline pH to prevent the potential release of HCN gas. When the reaction is complete, unreacted materials are aspirated and the lectin coupled agarose washed extensively with sterile cold PBS. The lectin agarose affinity matrix is then stored cold until ready for use. Alternatively, GNA agarose is available commercially from Vector Labs (Burlingame, Calif.)
Example 2
Preparation of an Antibody Covalently Coupled to Glass Beads Via Schiff's Base and Reduction with Cyanoborohydride
The affinity matrix was prepared by a modification of the method of Hermanson (Hermanson. Bioconjugate Techniques: 785, 1996). Anti-HIV monoclonal antibody dissolved to a final protein concentration of 10 mg/ml in 0.1M sodium borate pH 9.5 is added to aldehyde derivatized silica glass beads (BioConnexant, Austin Tex.). The reaction is most efficient at alkaline pH but will go at pH 7-9 and is normally done at a 2-4 fold excess of protein over coupling sites. To this mixture is added 10 ul 5M NaCNBH 3 in 1N NaOH (Aldrich, St Louis, Mo.) per ml of coupling reaction and the mixture allowed to react for 2 hours at room temperature. At the end of the reaction, remaining unreacted aldehyde on the glass surfaces are capped with 20 ul 3M ethanolamine pH 9.5 per ml of reaction. After 15 minutes at room temperature, the reaction solution is decanted and the unbound proteins and reagents removed by washing extensively in PBS. The matrix is the stored in the refrigerator until ready for use.
Example 3
Preparation of an Exosome Specific Antibody Covalently Coupled to Chromosorb (Diatomaceous Earth) Using Glutaraldehyde
Preparation of aminated diatomaceous earth is accomplished using γ-aminopropyl triethoxysilane (GAPS) (Sigma Chemical, St. Louis, Mo.) and Chromosorb 60/80 mesh. Although other grades of diatomaceous earth may be used, Chromosorb of this mesh size (200-300 microns in diameter) is often used to prevent small particulates from entering the sample through the largest available pore sizes found in hollow-fiber cartridges used for plasma separation (˜0.5 micron).
Amino Chromosorb was prepared by suspension in an excess of 5% aqueous solution of GAPS in an overnight reaction. Aminated-Chromosorb was washed free of excess reagent with water and ethanol and dried overnight in a drying oven to yield an off white powder. One gram of the powder was then suspended in 5 ml 5% glutaraldehyde (Sigma) for 30 minutes. Excess glutaraldehyde was then removed by filtration and washing with water until no detectable aldehyde remained in the wash using Schiff's reagent (Sigma Chemical). The filter cake was then resuspended in 5 ml of Sigma borohydride coupling buffer containing 2-3 mg/ml of the antibody and the reaction allowed to proceed overnight at 4 degrees C. At the end of the reaction, excess antibody is washed off and the remaining aldehyde reacted with ethanolamine as described. After final washing in sterile PBS, the material was stored cold until ready for use.
Example 4
Preparation of an AntiFas-Ligand Specific Antibody Covalently Coupled to Polyacrylate Beads Using Glutaraldehyde and Azide
Anti-Fas Ligand antibody (NOK-1 mouse anti-human as described by Kayagaki et al in U.S. Pat. No. 6,946,255 and incorporated herein by reference in its entirety) is dissolved in a concentration of 50-200 mg./ml. with human serum albumin in a phosphate-buffered aqueous medium of pH 7.0. Glutaraldehyde at a concentration of 0.05-10% is added to the solution which is then incubated for 1-24 hours, but preferably 12 hours, at 4.degree. C. Excess glutaraldehyde that remains in the reaction mixture is removed by addition of glycine, or other suitable compounds known in the art, to the solution at the end of incubation. This solution is then diafiltered through a membrane having a minimal retentively value of 500,000 molecular weight. The diafiltered antibody-bearing product is dissolved in saline or dialysis fluid. To obtain a reactive polymer to act as a substrate for said anti-Fas Ligand antibody, polyacrylic acid polymer beads (micron in diameter) are activated by the azide procedure (51). The ratios of antibody to reactive polyester are selected to avoid excessive reaction. If this ratio is appropriately adjusted, the spacing of the antibody along the polymer chain will allow a binding of the antibody with the antigen found on microvesicle without untoward steric hindrances and the antibody conjugate is intended to remain soluble.
Said antiFas Ligand antibody conjugates are subsequently loaded into a hollow fiber filter cartridge, on the exterior of said hollow fibers. The external filling ports are then sealed. This allows for passage of blood cell components through the lumen of said hollow fibers. Blood plasma containing the microvessicles, convects and diffuses through pores in the hollow fibers into the extralumenal space where it contacts the antibody-polyacrylate conjugates. Treated plasma inside the cartridge diffuses back into the general circulation leaving the microvesicles attached to the insolublized anti-FAS Ligand antibody.
Example 5
Patient Treatment Using AntiFas-Ligand Specific Antibody Covalently Coupled to Polyacrylate Beads from Example 4
A patient with stage IV unresectable colorectal cancer presents with a suppressed ability to produce interferon-gamma subsequent to ex vivo stimulation of peripheral blood mononuclear cells with anti-CD3. In order to de-repress the ability of said patients immune response to produce interferon gamma, said patient is treated with an extracorporeal device capable of removing microvesicles that contribute, at least in part, to the suppressed production of interferon gamma. Said medical device is manufactured as in Example 4:
The modified hollow fiber filter is connected to a veno-venous dialysis machine and connected to the circulation of said patient for a time period necessary to remove microvesicles associated with suppression of interferon gamma production. Vascular access is obtained via a double-lumen catheter in the subclavian or femoral vein. For this specific application the hollow fiber hemofilter is connected to a flow-controlled blood roller pump, the blood flow rate (Q b ) is set at 100 to 400 ml/min, (more preferably at 200 to 300 ml/min depending on the cardiovascular stability of the patient). The dialysis circuit is anticoagulated with a continuous heparin infusion in the afferent limb. The activated clotting time (ACT) is measured every hour, and the heparin infusion is adjusted to maintain the ACT between 160 and 180 seconds. Said patient is monitored based on the concentration of microvesicles expressing Fas Ligand in circulation, as well as by ability of said patient lymphocytes to produce interferon gamma in response to mitogenic or antibody stimulation.
Upon upregulation of interferon gamma production, said patient can be administered a tumor vaccine with the goal of antigen-specifically stimulating host immune responses in an environment conducive to immune-mediated clearance of the primary and/or metastatic tumors.
Example 6
Removal of Exosomes from Blood Using Plasmapheresis
Selective removal of exosomes from blood may be accomplished using plasmapheresis combined with affinity capture using any of the matrices described in Examples 1-5. Plasmapheresis is done using either centrifugal separation or hollow-fiber plasma separation methods. The blood circuit is anticoagulated with a continuous heparin infusion in the afferent limb. The activated clotting time (ACT) is measured every hour, and the heparin infusion is adjusted to maintain the ACT between 160 and 180 seconds.
The plasma obtained from the patient may be discarded and replaced with a combination of normal saline and fresh plasma from healthy donors (i.e. plasma exchange). Alternatively, the plasma containing the microvesicles can be pumped at 60-100 ml/min over the affinity matrix which captures the exosomes. The cleaned plasma may then be reinfused into the patient. A similar system (the Prosorba column) has been described for the removal of immunoglobulin complexes from patients with drug refractory rheumatoid arthritis (71, 72). The clearance of the microvesicles may be monitored based on the concentration of microvesicles expressing Fas Ligand remaining in circulation.
Example 7
Direct Coupling of an Aptamer Specific for Tumor Exosomes to the Hollow-Fibers
In hollow-fiber based devices, more intimate contact with the blood is obtained by direct coupling of the capture agent to the hollow-fibers. Aptamers are short pieces of synthetic DNA and its chemical derivatives which bind to specific antigens (i.e. DNA antibodies). The process for generating aptamers is described in detail in U.S. Pat. No. 5,567,588 (1996; issued to Gold et al.; incorporated herein by reference in its entirety). In this example the isolation of Fas Ligand protein specific DNA aptamers and the production of hollow-fiber coupled aptamer affinity matrices are described. Purified Fas Ligand protein is chemically coupled to agarose using Amino-Link agarose (Pierce Chemical Co.). AminoLink Coupling Gel is a 4% crosslinked beaded agarose support, activated to form aldehyde functional groups which develops a stable bond, in the form of a secondary amine, between the gel and the protein with coupling efficiencies of 85% between pH 4-10. In this example 2 ml Fas Ligand protein (1 mg/ml in coupling buffer) is applied to the Aminolink gel for 7 hours at 4 degrees C. Unreacted protein is then washed off with 25 volumes of phosphate buffered saline (PBS) and the product material stored cold until ready for use.
Next DNA oligonucleotides, typically 80 nucleotides long are prepared containing the following elements. First a PCR primer site of 20 nucleotides on both the 5′ and 3′ ends and a 40 base segment in the middle of the molecule prepared with a random mixture of bases. This generates a very large number of DNA species from which the specific aptamer (i.e. DNA antibody) may be selected. The DNA capable of binding selectively to the target protein Fas Ligand is then selected by multiple rounds of binding to the immobilized Fas Ligand interspersed with polymerase chain reaction (PCR) amplification on the recovered fragments. The final material with high selectivity for Fas Ligand may then be cloned and sequenced to yield a consensus sequence. Copies of the consensus sequence are then chemically synthesized with 5′ or 3′ terminal amino groups and coupled to a solid phase such as described in Example 3.
In this specific example, the chemically synthesized FasL specific aptamer containing a terminal amine is to be coupled directly to polysulfone hollow-fibers in situ in a plasma separator cartridge. To accomplish this, the cartridge is first exposed to a solution of 4% human serum albumin (HSA) reacted overnight at 4 degrees C. The adsorbed HSA is then cross-linked with glutaraldehyde. Excess glutaraldehyde is then briefly washed out with water. The cartridge is then filled with Sigma cyanoborohydride coupling buffer containing 2-3 mg/ml of the aminated FasL aptamer and reacted overnight at 4 degrees C. At the end of the reaction, excess aptamer is washed off and the remaining unreacted aldehyde reacted with ethanolamine. After final washing in sterile PBS, the cartridge was dried in sterile air, packaged and sterilized using gamma-irradiation (25-40 kGy) and stored in a cool, dark area until ready for use.
Those skilled in the art recognize that the aspects and embodiments of the invention set forth herein may be practiced separate from each other or in conjunction with each other. Therefore, combinations of separate embodiments are within the scope of the invention as disclosed herein. All patents and publications mentioned in the specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference. The invention illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations which is not specifically disclosed herein. Thus, for example, in each instance herein any of the terms “comprising,” “consisting essentially of” and “consisting of” may be replaced with either of the other two terms. The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention that in the use of such terms and expressions indicates the exclusion of equivalents of the features shown and described or portions thereof. It is recognized that various modifications are possible within the scope of the present invention. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the disclosure.
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The invention described herein teaches methods of removing microvesicular particles, which include but are not limited to exosomes, from the systemic circulation of a subject in need thereof with the goal of reversing antigen-specific and antigen-nonspecific immune suppression. Said microvesicular particles could be generated by host cells that have been reprogrammed by neoplastic tissue, or the neoplastic tissue itself. Compositions of matter, medical devices, and novel utilities of existing medical devices are disclosed.
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BACKGROUND
[0001] The invention relates generally to take-up frames and similar structures for rotating machinery bearings. In particular, the invention relates to a load indicating system for take-up frames.
[0002] In rotating equipment, such as conveyor belts, chain drives or other systems, bearing assemblies are provided for securing a rotating element, such as a shaft, with respect to support or stationary components. Typically, one end of the system is fixed in position, while the opposite end is moveable. For example, the fixed end may be supported on a pillow block, while structures such as take-up frames are provided on the moveable end to allow for tension adjustment.
[0003] Take-up frames have a framework for supporting a moveable bearing set. Specifically, the framework may include glides, or guiding rails which support the bearing set while allowing it to move within the framework. A tension or compression adjustment member, such as a threaded rod may be supported by a threaded nut. Special bearing sets may be employed, including housings adapted to receive the tension or compression adjustment member. The position of the bearing assembly is adjusted by turning the thread rod or the nut to slide the bearing set into the desired location, hereby adjusting the tension on a belt, chain, or other component supported by the take-up frame bearing.
[0004] Such take-up frames and bearing sets are employed to maintain tensile or compressive forces within machine systems. Upon installation, the take-up frames are situated generally parallel to the forces to be regulated, such that adjustment of the bearing set position will tend to tighten or relax a machine component fitted around an associated rotated member. For example, in belt conveyors and the like, take-up frames are often positioned on either side of a pulley. In chain drives, take-up frames may be positioned on one or both sides of an endless chain. Changes in the initial installed tensile or compressive forces may cause premature wear and require frequent component repair or replacement. Moreover, it is often difficult to judge the force or tension set via adjustment of the take-up frame both during initial installation and subsequently, as the system relaxes or wears.
[0005] There is a need, therefore, for arrangements that will permit measurement or feedback of forces exerted by a take-up frame. There is a particular need for relatively simple, mechanical systems that can provide such feedback in a reliable manner.
BRIEF DESCRIPTION
[0006] The present invention provides a technique for regulating forces applied to a take-up frame. The technique may be used in systems in which the take-up frame is positioned either in tension or compression, providing feedback on forces exerted on the bearing sets in either case.
[0007] In accordance with one aspect of the present invention a bearing take-up frame assembly is provided comprising a bearing housing configured to move within a take-up frame framework, and a force transmission member coupled to the bearing housing. The force transmission member is configured to apply force to the bearing housing. A spring member is to be compressed as force is applied by the transmission member to the bearing housing. A load indicating apparatus mechanically measures the displacement of the spring member and indicates the amount of force being applied.
[0008] In accordance with another embodiment of the present invention a take-up frame system is provided comprising a rotating component supported by first and second bearing sets, a first take-up frame and a second take-up frame supporting the first and second bearing sets, respectively. The take-up frames each include force transmission members coupled to the bearing sets, and spring members having an axis of displacement parallel to a longitudinal axis of the force transmission member. Force indicating mechanisms are configured to indicate the displacement of the spring members.
[0009] In accordance with another aspect of the invention, a method of operating a take-up frame is provided comprising reading a force indication that is obtained and provided through mechanical means. The amount of force applied is then adjusted to achieve a desired amount of force.
DRAWINGS
[0010] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0011] FIG. 1 illustrates a take-up frame assembly in accordance with an exemplary embodiment of the present invention;
[0012] FIG. 2 is a side view of the take-up frame of FIG. 1 , configured to provide force feedback to a user in accordance with an exemplary embodiment of the present invention;
[0013] FIG. 3 illustrates a load indicating plate for use in the arrangement of FIGS. 1 and 2 , in accordance with an exemplary embodiment of the present invention; and
[0014] FIG. 4 illustrates steps in an exemplary method for operating a force indicating take-up frame of the type shown in the previous FIGS. in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
[0015] The techniques and apparatus described herein allow a user to reach and maintain proper tensile or compressive forces on a bearing assembly or transmission component supported by the bearing assembly. The maintenance of proper tensile or compressive forces helps to reduce unnecessary maintenance and downtime that may result from an improper or unbalanced loading of bearing housings. Proper adjustment also enhances the normal operation of components such as belt conveyors, chain drives, and so forth.
[0016] Turning to the drawings, and referring first to FIG. 1 , a take-up frame assembly is illustrated as applied to lateral sides of a belt conveyor and is generally designated by reference numeral 10 . Assembly 10 includes a shaft 12 supported on both ends by bearing assemblies 14 . To maintain appropriate loading on the bearing assemblies 14 and, consequently, also the shaft 12 , each bearing assembly 14 is positioned inside a take-up frame 16 . The take-up frame 16 is mounted on a support structure 18 . The support structure 18 may be any appropriate machine support such as a stand or a support framework.
[0017] The take-up frame 16 provides a framework that allows the bearing assembly 14 to move linearly in order to adjust the tensile forces applied to the bearing assembly 14 . As will be appreciated by those skilled in the art, through appropriate adjustment of the take-up frame 16 , and consequent movement of bearing assemblies 14 on either side of the shaft 12 , the tension on belt 22 may be adjusted to a level appropriate for the anticipated loading of the take-up frame assembly 10 and the belt. Additionally, appropriate adjustment of the take-up frame 16 helps to properly situate the belt 22 on pulley 20 and avoids lateral creep.
[0018] In the presently disclosed technique, visual feedback of applied force allows a user to readily discern proper adjustment. Specifically, as will be described in greater detail below, a mechanical apparatus is provided to indicate force exerted on a bearing assembly 14 .
[0019] As mentioned earlier, each bearing assembly 14 is mounted in a take-up frame 16 so that it is able to move to adjust the tensile or compressive forces on the belt 22 . A force transmission member 24 , such as a threaded rod, for example, is attached to the bearing assembly 14 . A hex nut 26 supports the force transmission member 24 within the take-up frame 16 . As the hex nut 26 or the transmission member 24 is turned, tensile or compressive forces are adjusted. Specifically, as the hex nut 26 is tightened on the forced transmission member 24 , the bearing assembly 14 may move within the take-up frame in order to apply force to the belt 22 . Alternatively, the hex nut 26 can be loosened in order to reduce the tensile forces applied to the bearing assembly 14 and the belt 22 . Movement of the bearing assembly 14 towards the hex nut 26 is limited by an end plate 28 . The end plate 28 prevents the bearing assembly 14 from exiting the take-up frame 16 .
[0020] As the take-up frame 16 may be used in harsh environments, such as in food processing plants or in mining operations, a cover 30 is provided to prevent debris from coming into contact with parts of the take-up frame 16 . The cover 30 is secured to the take-up frame 16 by a slotted guidepost 32 which fits over the threaded rod and is held in place by the hex nut 26 . The cover 30 and slotted guidepost 32 may be welded together at a 90 degree angle. Additionally, a lower guide 36 and an upper guide 38 hold the cover in place, as can be seen in FIG. 2 . A position indicating piece, such as a cone point set screw 40 is attached to the cover 30 in order to indicate movement of the cover 30 relative to the take-up frame 16 , as will be discussed in detail below.
[0021] A side view of the take-up frame 16 is illustrated in FIG. 2 in accordance with an exemplary embodiment of the present invention. As can be seen in this view, the cone point set screw 40 protrudes through the cover 30 so that the cone point is directed at a load indicating plate 42 mounted on the take-up frame 16 . Movement of the cone point set screw 40 relative to the load indicating plate 42 indicates the amount of force being applied by the force transmission member 24 to the bearing assembly 14 . Specifically, the cone point set screw 40 points to imprinted or inscribed numbers on a load indicating plate 42 .
[0022] The load indicating plate 42 is attached to the take-up frame 16 and may have numbers imprinted, etched, or otherwise placed on it. Alternatively, markings may be made directly to the take-up frame 16 itself, however, such an embodiment may be limited in its ability to be calibrated. As illustrated, the numbers may increase in steps of 400, or in any other incremental step (typically depending upon the range of force that can be applied to the take-up frame, and the reasonable subdivisions of the range). Alternatively, the load indicating plate 42 may simply have markings to indicate relative displacement of the cover 30 to the take-up frame 16 . Furthermore, the load indicating plate 42 may have markings to indicate an ideal load level or a range of acceptability for a particular application.
[0023] The numbers or markings on the load indicating plate 42 correspond to an amount of tensile or compressive force applied to the bearing assembly 14 by the force transmission member 24 . As such, units corresponding to the numbers may be in Newtons, or pounds-force, for example.
[0024] The amount of force applied can result from, and be approximated through the use of a spring mechanism such as Belleville washers 44 . As will be appreciated by those skilled in the art, the force applied to the bearing assembly will depend upon the effective aggregate spring constant of the Belleville washers, and the compression (i.e., change in aggregate length) of the collection of washers, according to the force equation: F=Kx, where F is force, K is the aggregate spring constant, and x is the compression of the set of washers or displacement of the bearing set. The Belleville washers 44 may be positioned on the force transmission member 24 between an outboard washer 46 and an inboard washer 48 . The outboard washer 46 may be placed on the end plate 28 of the take-up frame 16 , while the inboard washer 48 is on the opposite side of the slotted guidepost 34 from the hex nut 26 . The Belleville washers 44 have specific spring constants k that can be obtained from their manufacturer. Moreover, the spring constant k can vary according to the stacking orientations of the washers. For example, the washers can be stacked in the same direction to provide a stiffer spring and maintain the constant k. The washers may also be stacked by alternating their orientation to provide a lower spring constant and greater displacement or deflection for the same applied force. Using such stacking techniques allows for specific spring constants and deflection characteristics to be achieved. The effective aggregate constant K, then is generally the combination (e.g., average) of the constants k, and is selected, along with the overall length of the collection of washers, to provide the desired tension and length adjustability ranges for the take-up frame assembly.
[0025] Once the spring constant K is known, the displacement of the Belleville washers 44 is all that is needed to calculate the force applied to the bearing assembly. Accordingly, an approximation of the amount of force applied to the bearing assembly 14 can be obtained by measuring the aggregate deflection or displacement of the Belleville washers 44 . Because the end plate 28 of the take-up frame 16 is fixed, and the cover 30 is attached to the opposite end of the washer stack, the aggregate displacement of the washers may be determined by measuring the amount of movement of the cover 30 relative to the take-up frame 16 .
[0026] It should be noted that any suitable tension or compression arrangement may be used in place of the Belleville washers shown in the figures and described here. These might include both tension and compression springs, compression members of various types (e.g., fluid cylinders), and so forth.
[0027] An initial calibration may be necessary to ensure accurate approximation of the force. Specifically, when installing the take-up frame assembly 10 the cone point set screw 40 and the load indicating plate 42 may need to be properly aligned. As illustrated in FIG. 3 , the load indicating plate has adjustment slots 50 configured to allow movement of the load indicating plate 42 . Adjustment screws 52 are provided to secure the load indicating plate 42 to a take-up frame 16 . To calibrate the load indicating take-up frame, the load indicating plate 42 is moved so that the cone point set screw 40 is aligned with the zero position on the load indicating plate 42 , with the washers under substantially no compression.
[0028] Operation of the take-up frame assembly 10 includes the tightening or loosening of the hex nut 26 . Initially, the tightening of the hex nut 26 will only move the bearing assembly within the take-up frame 16 . Specifically, the bearing assembly will move towards the end plate 28 and remove slack from the belt 22 , or any other component supported by the bearing assembly. Eventually, the slack is removed from the belt and tightening of the hex nut 26 provides tension force to the bearing assembly 14 (i.e., preloading). As the Belleville washers 44 are compressed between the outboard washer 46 and the inboard washer 48 , displacement occurs. The displacement of the Belleville washers 44 allows the cover 30 to move parallel to the take-up frame 16 . Consequently, the cone point set screw 40 moves relative to the load indicating plate 42 and a user can easily obtain an estimation of the forces being applied to the bearing assembly.
[0029] Turning to FIG. 4 , a technique of operation for a load indicating take-up frame is shown and generally indicated by the reference numeral 60 . The technique 60 includes an initial calibration as indicated at box 62 . The calibration may include moving a load indicating plate 42 into alignment with a cone point set screw as discussed above, with no preload on the assembly.
[0030] Once the take-up frame has been calibrated, a hex nut 28 can be tightened on a force transmission member 24 to provide tension, as indicated at block 64 . Initially, the tightening of the hex nut 26 will remove slack from a conveyor belt, chain assembly, or other system component. Once the slack is removed, tensile or compressive forces will be applied to a bearing assembly 14 within the take-up frame 16 . As the tension increases, a spring member, such as Belleville washers 44 , deforms or is displaced from an initial position. A cover 30 coupled to the spring member is displaced relative to the take-up frame 16 a distance corresponding to the displacement of the spring member.
[0031] A user can consult the load indicating plate 42 and obtain an approximation of the amount of tension being applied to the bearing assembly 14 in the take-up frame 16 , as indicated at block 66 . Specifically, a user can read a number value from the load indicating plate 42 that corresponds to the position of a cone point set screw 40 as discussed above. The number value correlates with the amount of force being asserted by the force transmission member 24 to the bearing assembly 14 . Because the force feedback is purely mechanical, the feedback is instant, and requires no connection to any external power source or network.
[0032] The ability to read the tension from the load indicating plate 42 allows a user to adjust the tension to a desired load, as indicated at box 68 . Specifically, it may be necessary to have the tension in a take-up frame 16 be equal to the tension of another take-up frame supporting a common belt or chain assembly. As discussed above, imbalance in loading may cause premature wear on parts necessitating repair or replacement. As such, the technique 60 helps to reduce downtime and repair expenses by allowing proper and balanced loading. Similarly, over time, the system components (e.g., a conveyor belt) may wear or stretch, and proper force adjustment of the system will be facilitated by the same steps summarized above.
[0033] While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
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A method of operating a take-up frame is disclosed herein. Specifically, a method of operating a take-up frame is disclosed which includes reading a force indication, wherein the force indication is obtained and provided through mechanical means. Additionally, the method includes adjusting the amount of force applied to achieve a desired amount of force.
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This invention relates to a modular system to install various crotch belt assemblies and/or shoulder belt retractor assemblies into a given type of child seat. More particularly this invention relates to a universal mounting pan to which various crotch belt assemblies and/or shoulder belt retractor assemblies are attached, which can then be mounted in a given child seat that has been adapted to receive the mounting pan.
BACKGROUND OF THE INVENTION
In currently available child seats, the restraint system is comprised of three subassemblies: the shoulder belt assembly, the crotch belt assembly, and the shoulder belt adjuster assembly. These three subassemblies are shipped to and installed by the child seat manufacturer independently from one another, and the child seat manufacturer must make provisions for the attachment of each assembly to the child seat. As various restraint component options are considered, the child seat manufacturer must make changes to these attachment provisions to insure that new component configurations are compatible with the child seat. As the number of component options increases, the ability to mate all variations with a single child seat reaches a practical limit.
What is needed is a modular system, which allows the child seat manufacturer to combine the installation of several of these subassemblies without the need for changes to the child seat. This invention is one answer to that need.
SUMMARY OF THE INVENTION
In one aspect, this invention is a module for use with a child seat that has a shoulder harness, an interengageable combination of a tongue and seat belt buckle, and has a seat portion that has been adapted to receive the module. The module, itself, has a pan that is mountable within the seat portion of the child seat, a belt retractor fixedly attached to the bottom of the pan, and a crotch assembly that may be attached to either the buckle or the tongue of the seat belt harness.
In another aspect, this invention is a child seat harness for installation in an automobile. The child seat harness includes a child seat that is adapted to receive a module in its seat area, a harness mounted to the child seat, which is extendable over the child to secure the child within the child seat, an interlocking tongue and seat belt buckle mounted to said child seat, which is interlockable with the harness, and a universal module. The universal module includes a pan that is mountable within the seat of the child seat, a belt retractor that is attached to the pan; and a crotch assembly that is attached to either the tongue or the buckle of the harness.
An advantage of this invention is that it simplifies the installation of a restraint into a child seat.
Another advantage of this invention is that it allows child seat manufacturers to make a single provision in all models of its child seats for installation of the restraining harness, regardless of the configuration of the particular components, i.e. the crotch belt assembly or the belt retractor assembly or the means for controlling the belt retractor assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a child seat incorporating one alternative embodiment of the modular system according to the invention disclosed in this specification.
FIG. 2 is a rear view of the seat of FIG. 1 .
FIG. 3 is a fragmentary view left side view of a child seat incorporating one alternative embodiment of the modular system according to the invention disclosed in this specification.
FIG. 4 is an enlarged perspective view of one alternative embodiment of the pan used in the modular system according to the invention disclosed in this specification.
FIG. 5 is a front view of the pan of FIG. 4 .
FIG. 6 is a side view of the pan of FIG. 4 .
FIG. 7 is an enlarged perspective view of one alternative embodiment of the pan used in the modular system according to the invention disclosed in this specification that includes a belt retractor and a push button to operate the belt retractor.
FIG. 8 is a rear view of the pan of FIG. 7 .
FIG. 9 is a side view of the pan of FIG. 7 .
FIG. 10 is an enlarged perspective view of one alternative embodiment of the pan used in the modular system according to the invention disclosed in this specification that includes a crotch stalk.
FIG. 11 is a front view of the pan of FIG. 10 .
FIG. 12 is a side view of the pan of FIG. 10 .
FIG. 13 is an enlarged perspective view of one alternative embodiment of the pan used in the modular system according to the invention disclosed in this specification that includes a crotch stalk, a push button, and a belt retractor.
FIG. 14 is a front view of a child seat incorporating one alternative embodiment of the modular system according to the invention disclosed in this specification.
FIG. 15 is an enlarged perspective view of one alternative embodiment of a modular system according to the invention disclosed in this specification.
FIG. 16 is a side view of FIG. 15 .
FIG. 17 is a rear view of FIG. 15 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the purpose of promoting an understanding of the principles of this invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein are contemplated as would normally occur to one of average skill in the art to which the invention relates.
Referring now to the drawings, in FIG. 1 there is shown a child seat 10 , which includes an outer frame 11 having a pair of downwardly extending arms 12 and 13 with a seat area 14 and a back supporting area 15 located therebetween. A plurality of conventional tubing 35 (FIG. 2) forms a rear frame 36 . Tubing 35 may be utilized to secure child seat 10 to an automobile seat by any suitable means such as by extending the automobile seat belts securely around tubing 35 . In the seat area 14 , there is provided a seat belt buckle 17 . In back supporting area 15 there is provided a first set of slots 26 - 28 and a second set of slots 29 - 31 . Belts 23 and 24 have ends 8 and 9 (FIG. 2) secured to conventional T-bar or belt connector 25 with the belts then extending each through a slot formed in back supporting area 15 . In the embodiment shown in FIG. 1, belts 23 and 24 extend slidably through slots 26 and 29 which are arranged to accommodate a large size child as compared to accommodating a smaller sized child when the belts extend through slots 28 and 31 .
Belts 23 and 24 extend slidably respectively through slots 37 and 38 of tongues 39 and 40 , which having tongued blades are releasably lockable with buckle 17 . Tongues 39 and 40 are identical to the buckle tongues disclosed in the commonly owned U.S. Pat. Nos. 5,023,981 or 5,182,837 or D364124. Likewise, buckle 17 is identical to the buckle disclosed in the commonly owned U.S. Pat. Nos. 5,023,981 or 5,182,837 or D364124, which are hereby specifically incorporated into this specification by reference. Buckle 17 is provided with a push button 18 to allow the user to unlock the buckle relative to tongues 39 and 40 . Once belts 23 and 24 extend through slots 37 and 38 , the belts 23 and 24 then diverge and extend through a pair of apertures 42 and 43 formed in the sides of arms 12 and 13 . Belts 23 and 24 are integrally joined together by intermediate portion 20 (FIG. 2) which extends across the bottom of the seat. Thusly configured, belts 23 and 24 are joined together in a single belt configuration. Belts 23 and 24 extend across the bottom of the seat, pass through apertures 42 and 43 , pass through slots 37 and 38 of tongues 39 and 40 , and then pass through the pair of slots 26 and 29 . Belts 23 and 24 connect to belt connector 25 , in such a fashion to allow the belts to be removed from the belt connector in the event the belts are to be changed and extended through either slots 27 and 30 or slots 28 and 31 .
Referring now to FIGS. 2 and 3, a third belt 50 has a distal end 51 fixedly secured to belt connector 25 , with the proximal end of belt 50 being wrappingly mounted onto belt retractor 53 . The belt-buckle-retractor system and the child seat as described so far are presently conventional and are currently available in the marketplace from a variety of sources. The present invention is the inclusion of such belt-buckle-retractor systems in a module that can be interchanged from one model of a child seat to another model of a child seat. Referring now to FIG. 1, child seat 10 also includes mounting pan 100 . Pan 100 is the basis of the present invention for a modular system that allows a child seat manufacturer to combine the installation of several components of the child restraint system in one step, rather than multiple steps. This, in turn, allows the child seat manufacturer to vary component options without having to make changes in the child seat.
An isolated perspective view of pan 100 is shown in FIG. 4, of which a front and a side view are respectively shown in FIGS. 5 and 6. Pan 100 has a channel 101 defined by sides 102 and 103 , wall 104 , floor 105 , and open end 99 . Openings 106 and 107 reside in sides 102 and 103 , and as shown, may also include a portion of floor 105 . The upper edges of side 102 , side 103 , and wall 104 are fixedly attached to the internal edges, respectively 112 , 113 , and 114 , of base 108 that surrounds channel 101 . The upper edges of channel 101 at the distal ends 109 and 110 of its sides 102 and 103 are tapered to meet floor 105 . Base 108 is similarly attached to the upper edges of distal ends 109 and 110 as base 108 is attached to the rest of sides 102 and 103 . So being, base 108 follows the tapers in distal ends 109 and 110 , curves around open end 99 , and is then fixedly attached to distal end 111 of floor 105 at internal edge 115 of base 108 . As a result, channel 101 generally forms a compartment 116 in top face 117 of base 108 .
Besides top face 117 , pan 100 also preferably includes a front face 118 . Front face 118 is formed from base 108 by continuing base 108 down past compartment 116 , in a fashion that preferably complements the curve in child seat 10 in which it is to be placed. Front face 118 creates additional surface area in base 108 , which increases the length of external edge 119 of base 108 . A pan 100 with a larger external edge 119 may be easier for some child manufacturers to mount into their child seat. But besides possibly assisting installation, front face 118 also provides a location where the practitioner of this invention may mount controls or options for the operation of the child seat. Accordingly, it is preferable that front face 118 in pan 100 also has one or more hole(s) 120 in which to mount such options or controls, as the need may arise.
An isolated perspective view of one preferred embodiment of pan 100 is shown in FIG. 7, of which a front and a side view are respectively shown in FIGS. 8 and 9. In this embodiment, conventional belt retractor 53 is mounted to the bottom of pan 100 , underneath compartment 116 , and optionally over reinforcing members 121 and 122 that reinforce floor 105 . A belt 50 (not shown in this figure) is wrappingly attached to belt retractor 53 as previously presented. A push button 123 is mounted in hole 120 of pan 100 to operate belt retractor 53 . In one method of operation, conventional retractor 53 is normally locked to prevent both tightening and lengthening of belt 50 . To place a child in seat 10 , push button 123 is actuated to extract belt 50 and lengthen straps 23 and 24 . Button 123 is then released while the child is secured, and once secured, button 123 is again actuated so that belt retractor 53 can remove any excess webbing in the system. In a second method of operation, conventional retractor 53 is normally locked to prevent lengthening of belt 50 . To place a child in the seat, push button 123 is actuated to extract belt 50 and lengthen straps 23 and 24 . Button 123 is then again released while the child is secured, but once secured, belt retractor 53 removes any excess in the system automatically without pushing button 123 . An example of this type of control of a belt retractor can be found in commonly owned U.S. Pat. No. 5,380,066 to Wiseman et al., the disclosure of which is specifically incorporated into this specification by reference.
Besides push button 123 , other means for actuating retractor 53 are contemplated by this invention. For example, pan 100 may include a rotary knob, a lever, or a strap 140 (FIG. 14) that is mechanically connected to retractor 53 . Or the actuation means may be more complex such as actuation caused by the insertion of the blades of tongues 39 and 40 into buckle 17 . An example of this latter type of control can be found in commonly owned U.S. Pat. No. 5,511,856 to Merrick et al., the disclosure of which is specifically incorporated into this specification by reference. Or retractor 53 may be operated by the movement of a rigid or semi-rigid stalk that is pivotally mounted in pan 100 , in a position that would reside between the child's legs upon securing pan 100 in child seat 10 .
In FIG. 1, buckle 17 is shown mounted at the distal end of a conventional webbing strap 125 . The proximal end of webbing strap 125 is then pivotally secured around a transverse pin (not shown) that runs both through pan 100 at openings 106 and 107 , and optionally through the metal frame of child seat 10 . But something more than a conventional webbing strap, shown in FIG. 1, can be used to secure buckle 17 to pan 100 .
An isolated perspective view of another embodiment of this invention is shown in FIG. 10, of which a front and a side view are respectively shown in FIGS. 11 and 12, and a cross-sectional view is shown in FIG. 3 . In this embodiment, a crotch stalk 130 is positioned within pan 100 and cooperates with tongues 39 and 40 , as well as, the rest of the harness system shown in FIG. 1 to restrain the child in the child seat. Buckle 17 is fixedly secured to the distal end of crotch stalk 130 . The proximal end of crotch stalk 130 is pivotally mounted by pin 131 , which passes through openings 106 and 107 in pan 100 , and optionally passes through the frame of the child seat. In one embodiment, the proximal end or lower portion of crotch stalk 130 extends below pivot pin 131 and mechanically engages retractor 53 . (FIG. 3) When crotch stalk 130 is pivoted forward, belt retractor 53 is unlocked, which allows straps 23 and 24 to lengthen or tighten as previously described in regard to push button 123 . An example of controlling a belt retractor with a pivotal stalk can be found in commonly owned U.S. Pat. No. 5,779,319 to Merrick, the disclosure of which is specifically incorporated into this specification by reference. An advantage of this particular design is that when the seat is not in use, it is contemplated that crotch stalk 130 can be positioned fully forward, within compartment 116 , to facilitate storage.
Another embodiment of this arrangement is shown in FIG. 13 . In FIG. 13, crotch stalk 130 is present, but another means is used to control belt adjuster 53 , such as previously described pushbutton 123 . In this arrangement, stalk 130 may be either pivotally secured or fixedly secured in the upright position to pan 100 .
Optionally, pan 100 can also include an adjustable webbing lock 141 (FIG. 14) operably coupled to straps 23 and 24 as shown in commonly owned U.S. Pat. No. 5,286,090 to Templin et al., the disclosure of which is specifically incorporated into this specification by reference. An adjustable webbing lock placed in one or both of these locations can provide additional means to control the tightness of the harness around the child. Likewise, webbing strap 125 may be mounted to the front of the child seat frictionally engaging strap 125 to tighten or loosen 125 .
An isolated perspective view of one preferred embodiment of pan 100 is shown in FIG. 15, of which a side and a rear view are respectively shown in FIGS. 16 and 17. In this embodiment, mounting pan 100 is combined with button 123 , crotch stalk 130 , and belt retractor 53 under cover 150 . Cover 150 has a back 151 , cover sides 152 and 153 , and an elliptically shaped bottom 154 . Cover 150 further includes an inverted tee-slot 161 in back 152 . Tee-slot 161 is of a size and shape to allow the passage of third belt 50 (not shown in this figure) and to belt retractor 53 . Cover 150 is joined to the underside of pan 100 along the distal edges of sides 152 and 153 , and bottom 154 . The distal edges of sides 152 and 153 , and bottom 154 attach to base 108 inside external edge 119 of pan 100 , creating flange 160 between cover 150 and outside edge 119 of pan 100 .
Typically, module 170 is installed in a child seat 10 that has been pre-configured to accept module 170 . For example, in one installation arrangement, seat portion 14 (FIG. 1) of child seat 10 has a cavity 200 with a shape that is complementary to the external dimensions of cover 150 , but not large enough to pass base 108 . Module 170 is then placed into cavity 200 , leaving flange 160 riding over the top of seat portion 14 . But in this regard, it is preferable for seat portion 14 to also have a mating flange (not shown) that is cut into the outside surface of seat portion 14 in the location where flange 160 makes contact with seat portion 14 . Such a mating flange will place the inside face of flange 106 below the face of seat portion 14 , and when the mating flange is sufficiently below the face of seat portion 14 , will also allow the outside surface of pan 100 to reside flush with seat portion 14 . Once in place, module 170 can then be attached to child seat 10 in most any conventional manner such as with screws, snaps, rivets, or the like.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
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A modular system that allows a child seat manufacturer to combine the installation of the crotch belt assembly and the shoulder belt adjuster assembly in one step, and which allows the child seat manufacturer to vary the type of components without having to alter the design of the child seat. A module for use with a child seat that has a shoulder harness, an interengageable combination of a tongue and seat belt buckle, and has a seat portion that has been adapted to receive the module. The module, itself, has a pan that is mountable within the seat portion of the child seat, a belt retractor fixedly attached to the bottom of the pan, and a crotch assembly that is designed to attach either to the buckle or the tongue of the seat belt harness.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. application Ser. No. 62/070,508, filed on Aug. 28, 2014, the disclosure of which is incorporated by reference herein.
BACKGROUND
[0002] Induced pluripotent stem cells iPSCs are adult cells that have been genetically reprogrammed to an embryonic stem cell-like state by being forced to express genes and factors important for maintaining the defining properties of embryonic stem cells. Although these cells meet the defining criteria for pluripotent stem cells, it is not known if iPSCs and embryonic stem cells differ in clinically significant ways. Mouse iPSCs were first reported in 2006, and human iPSCs were first reported in late 2007. Mouse iPSCs demonstrate important characteristics of pluripotent stem cells, including expressing stem cell markers, forming tumors containing cells from all three germ layers, and being able to contribute to many different tissues when injected into mouse embryos at a very early stage in development. Human iPSCs also express stem cell markers and are capable of generating cells characteristic of all three germ layers.
[0003] Although additional research is needed, iPSCs are already useful tools for drug development and modeling of diseases, and scientists hope to use them in transplantation medicine. In the original protocol, viruses were used to introduce the reprogramming factors into adult cells. In animal studies, the virus used to introduce the stem cell factors sometimes causes cancers. Researchers have now developed non-viral delivery strategies that are believed to have less chance of causing cancers.
[0004] This breakthrough discovery of iPSCs has created a powerful new way to “de-differentiate” cells whose developmental fates had been previously assumed to be determined. In addition, tissues derived from iPSCs will be a nearly identical match to the cell donor and thus probably avoid rejection by the immune system. The iPSCs strategy creates pluripotent stem cells that, together with studies of other types of pluripotent stem cells, will help researchers learn how to reprogram cells to repair damaged tissues in the human body.
[0005] However, creating viable large arrays of iPSCs for high throughput drug screening is problematic due to their sensitivity to environmental factors, available nutrients, fabrication techniques, handling, contamination, and dehydration, as well as the cells immediate three dimensional macro structure environment and the precision equipment necessary to dispense nano liter quantities of molecules of interest to specific array locations.
SUMMARY
[0006] The present disclosure provides a fabrication process that results in creating large arrays of living cells, e.g., stem cells, which are subsequently exposed to nanoliter quantities of compounds to test the efficacy on cellular metabolism. In one example, induced pluripotent stem cells iPS are mixed with a ultra violet curable hydrogel matrix, coated onto a support or substrate, then mated to an embossing master tool with a pre-defined micro geometric pattern in a N×N matrix array where N can range from 1 to 10,000, exposed to UV radiation to harden the gel, the embossing tool removed, and the patterned gel, cell, support structure then transferred to an incubation chamber to enhance cellular growth and viability. The N×N matrix of living cells is subsequently exposed to a drug compound delivery system that can address any N in the N×N matrix and dispense nano liter quantities of drug compounds to the site of interest.
[0007] In one embodiment, the present disclosure provides for the use of a micro embossing fabrication technology in combination with a nano liter dispensing system that can address individual locations within a cellular array, e.g., an iPSCs matrix array, to deliver drug candidates of interest, thereby providing large matrix arrays for high throughput drug screening.
[0008] In one embodiment, this disclosure provides a method of fabricating arrays by the use of micro embossing an ultraviolet curing gel that contains dispersed cells such as stem cells or iPSCs.
[0009] In one embodiment, this disclosure provides a method of fabricating cell s arrays by the use of micro embossing where distinct three dimensional micro structures are created that contain dispersed cells.
[0010] In one embodiment, this disclosure provides a method of fabricating cell arrays by the use of micro embossing where an array matrix is formed in an N x N pattern where N can range from 1 to 10,000.
[0011] In one embodiment, this disclosure provides for exposing arrays, such as those formed either on a film or microwell plate, as to a high precision nano liter dispensing system. In one embodiment, this disclosure provides for exposing arrays to a high precision nano liter dispensing system that can address individual location sites on a N×N iPSCs array.
BRIEF DESCRIPTION OF THE DRAWING
[0012] FIG. 1 shows a cross sectional view of one embodiment of the present invention that shows iPSCs dispersed into a hardened gel linear matrix.
DETAILED DESCRIPTION
[0013] In one embodiment, FIG. 1 shows a cross sectional view of one example of the present invention that uses iPSC cardiomyocyte cells 30 that have been dispersed and cured into an ultraviolet sensitive hydrogel 20 , that was deposited onto a support 10 . The support 10 can be comprised of a number of materials such as metal, glass, ceramic, polymer sheet or film and optionally may be a rigid support. The thickness of the support can range from about 12 microns to about 10 millimeters and in one embodiment, about 0.2 to about 1 millimeters. In most cases, the substrate is transparent to allow visual inspection of the contents of the fabricated array on the surface or to allow UV radiation to pass through the material in order to cure the hydrogel-cell mixture onto the surface. In one embodiment, a polymer substrate such as heat stabilized polyester film, polycarbonate, or 1 mm glass is employed. In addition, it may be desirable to have the substrate be porous in order to allow water and nutrients to diffuse into the bottom of the micro embossed 20 hydrogel array. Some porous materials that may be employed are Vycor glass made by Corning, open cell foam film and sheet, or micro porous polymer films that are readily available from multiple suppliers.
[0014] In one embodiment, a hydrogel 20 , such as one having methacrylate, e.g., gelatin methacrylate, that has iPSCs dispersed into the volume of the gel is coated onto the support 10 and then the gel is cured into the desired geometric shape. In the example of FIG. 1 , that shape is a linear array with dimensions of approximately 1.5 mm×1.5 mm×0.25 mm. The linear array shape can be fabricated by mask less direct write photolithography or by using a micro embossing template into which the inverse pattern has been created by diamond engraving, laser ablation, or photolithography, that is pressed into the gel and the gel cured with UV light through a transparent micro embossing template such as silicone or glass or a transparent polymer or glass support 10 . A N×N array can be formed onto the support where the number of discrete geometric shapes can range from 2 to over millions. N can have an integer value from 1 to 10,000 but for practical purposes an N×N where N=50 is sufficient and practical. In the present example a 1×16 linear array was fabricated.
[0015] In addition to the aforementioned method one skilled in the art can also take a pre-embossed film that has microstructures fabricated as in FIG. 1 then optionally depositing onto the surface an adhesion promoter such as fibronectin, gelatin, hyaluronic acid, carrageen, cellulose, polylysine, polyvinylprylidone, collagen, polyvinylalcohol, or polyethylene oxide or combinations of the aforementioned molecules including polymers thereof. Differentiated iPSCs can then be deposited onto the pre-embossed film and laminated to a N×N where N can range from 1 to 10,000, microplate to form an array.
[0016] After the iPSCs array is fabricated, the device is then placed in an incubation chamber at 37° C. with a 5% carbon dioxide gas atmosphere. A number of additives, such as RB+ and Rock inhibitor, that are well known in the art is/are added to a nutrient solution to nourish and prevent the cells from premature death. The cells may be incubated and nourished for up to 3 days or more prior to exposing them to a drug dosing procedure.
[0017] In one example, a Labcyte Echo Model 555 nano liter sonic dispensing system was used to deliver 2 heart drugs, Satolol an Antiarrhythmic drug and Isoproteronol a nitric oxide generating compound, to the fabricated array. The drugs were diluted to 2.25 uM in cell media nutrient solution to prevent dehydration. The Echo 555 liquid handler revolutionizes liquid handling with acoustic energy. Sound waves eject precisely sized droplets from a source onto a microplate, slide or other surface suspended above the source. This product does not use tips, pin tools or nozzles completely eliminating contact between the instrument and the liquid. Fluids are transferred in nanoliter increments. Larger volumes are transferred at the rate of hundreds of droplets per second. By using this non contact method it minimizes any contact that could damage or kill the cells as found in other dispensing methods. It also allows for the use of very small quantities thus allowing users to screen molecules that are scarce or difficult to manufacture thus reducing cost. In addition, the X and Y position of the dispensing head can be precisely located over the N×N array location of interest thereby allowing different locations to have a drug of interest administered.
[0018] The invention will be described by the following non-limiting example.
Example 1
[0019] Induced pluripotent stem cells: beating H9 embryonic stem cell derived cardiomyocytes were used on day 25 of differentiation. After disassociation a vial with 1 mL of suspension was produced. The concentration of the suspension was 1.38×10 6 mL total cells. Within those it was determined that 8.38×10 5 live cells were present with tryptan blue. The food solution provided was a 50 mL aliquot of RB+ medium (RPMI supplemented with B27 with insulin) for the cells after gel encapsulation. A single drop of Rock inhibitor was added to the nutrient solution. This drug is used to avoid cell death until the cells sense that they are attached to a substrate. The vial was used at a 10 mM concentration. The cells were centrifuged and mixed with GelMa a UV curable matrix and kept at 37° C. The GelMa cell mixture was them placed on a glass support and the area defined by hydrophobic tape. Then a TI DLP mirror chip was used in combination with UV light with a peak frequency of 370 nm to direct write a 1×16 linear array that was approximately 1.5 mm×1.5 mm by 0.25 mm high which takes about 10 seconds. The uncured GelMa was washed away. The support and array was placed in a petri dish and filled with nutrient solution and placed in an incubator at 37° C. in a 5% CO 2 atmosphere. Each day the nutrient solution is replaced with fresh media for up to 3 days. After 3 days the arrays were demonstrating a strong beating action and were ready for drug dosing. The array was placed in a Labcyte 555 sonic dispensing machine and the drug molecules precisely dispensed onto the beating cells. During this process the cells were observed with a Lumenera Camera with infinity capture software to visualize the beating cells during the drug dosing.
[0020] During the dosing with 10 nM of Satolol an increase in the heart cells beating by 30-40% was observed. During the dosing with Isoproteronol it was observed that the drug removed the refectory period (pause in beating) of some irregularly beating heart cells.
[0021] The invention herein is described by example and one particular way of practicing the invention has been described. However the invention as claimed herein is not limited to that specific embodiment are not limited to use therewith and may be used separately or in conjunction with other embodiments disclosed herein. For example, instead of using visual cameras to observe drug effects one can use electronic, magnetic, fluorescence, or fiber optic methods to examine cellular response to drug dosing. Equivalence to the description as hereinafter claimed is considered to be in the scope of protection of this patent. While particular embodiments of the method for fabricating cell micro arrays with subsequent drug dosing has been described it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects as set forth in the following claims.
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The present disclosure provides a fabrication process that results in creating large arrays of living cells, such as stem cells, which are subsequently exposed to nanoliter quantities of compounds to test the efficacy on cellular metabolism.
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BACKGROUND OF THE INVENTION
The field of the present invention is lubricated gearing; and more specifically lubricated gearing particularly adaptable to vehicle transmissions.
Gearing associated with vehicles and particularly exposed transmissions for motorcycles and the like can produce significant, objectionable noise. Gear noise resulting from the individual contact of gear teeth is often present due to backlash in the gears. Such noise may result from torque fluctuation to the drive gear. The gear teeth impacting noise may be reduced by reducing backlash. However, in doing so, a buzzing noise may be induced which is caused by the rubbing of the faces of the gear teeth. The remedies for the two sources of noise, gear tooth impacting and buzzing, are counterproductive. This condition makes it extremely difficult to minimize both noises.
In addressing the foregoing problem, two current solutions are illustrated in FIGS. 1 and 2. Looking first to FIG. 1, a driven gear is illustrated as being composed of two gear wheels which are arranged in juxtaposition to rotate together. One of the two wheels is angularly biased by a spring or the like such that the teeth are slightly angularly misaligned. This enables the driven gear to exert resilient pressure against the drive gear to reduce backlash noise without as much buzzing noise as might otherwise occur.
FIG. 2 illustrates another driven gear composed of two gear wheels. The two gear wheels are brought together with an angular friction force therebetween. The smaller of the two gear wheels has one less tooth than the larger, power transmission wheel. The friction force between the gears causes the exta gear to drag on the power transmission gear so as to cause positive meshing with the drive gear. As with the device of FIG. 1, backlash noise may be mechanically controlled. However, optimum buzzing noise is not achieved. As a result, neither solution is totally satisfactory. With substantial drive torque fluctuation in either system, an increased force between the two gears is necessary, spring force for the device of FIG. 1 and friction force for the device of FIG. 2. However, in increasing the relative force between gear wheels, a greater tendency to produce buzzing exists.
Naturally, lubricant has a tendency to reduce gear noise. However, conventional lubrication in power transmissions, particularly for motorcycles, employs the splashing of lubricant from one of the gears, see FIG. 3. The results are sufficient for lubrication but do not provide sufficient amounts of lubricant for noise reduction.
SUMMARY OF THE INVENTION
The present invention pertains to the reduction of noise in lubricated gears. To this end, increased lubricant is provided to the gear. In a first aspect of the present invention, this result is achieved by the use of walls adjacent to a gear wheel to inhibit lubricant flow away from the gear. In a second aspect of the present invention, an auxiliary vessel is employed for providing additional lubricant to the gear.
Accordingly, it is a principal object of the present invention to reduce gear noise by an improved lubricated gear system. Other and further objects and advantages will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a prior art drawing illustrating a gear mechanism in cross section in FIG. 1A and a side view thereof in FIG. 1B.
FIG. 2 is a cross-sectional view of yet another prior art gear mechanism.
FIG. 3 is a prior art schematic elevation illustrating splash lubrication.
FIG. 4 is a side view of a motorcycle engine employing the present invention with the side cover of the transmission removed for clarity.
FIG. 5 is a detailed view of the device of FIG. 4.
FIG. 6 is a cross-sectional plan view taken along line 6--6 of FIG. 4.
FIG. 7 is a detailed perspective of a gear of the present invention.
FIG. 8 illustrates a gear of the present invention including integral walls, FIG. 8a being a side view and FIG. 8b being a cross-sectional elevation.
FIG. 9 illustrates yet another embodiment of the present invention taken along line 6--6 of FIG. 4.
FIG. 10 is a cross-sectional elevation taken along line 10--10 of FIG. 5.
FIG. 11 schematically illustrates a side view of a gear of the present invention.
FIG. 12 is a more detailed view of the drive gear wheel of FIG. 11.
FIG. 13 is yet another embodiment illustrated in cross-sectional elevation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning in detail to the drawings, a first embodiment of the present invention is generally illustrated in FIG. 4 within the context of its environment in association with a motorcycle engine. The assembly includes a cylinder 10 in association with a crankcase 12 within which a gear is assembled. A drive gear wheel 14 is mounted to rotate with a crankshaft 16 and drive a driven gear wheel 18. Additionally illustrated is a kick gear 20, a timing chain 22, an oil pump 24 and a lubricant supply manifold 26 from the oil pump 24.
As illustrated in further detail in FIG. 6, the drive shaft 16 is supported by a bearing 28. A clutch 30 may also be included within the assembly.
Looking first to the drive gear wheel 14, it conventionally includes a hub with gear teeth positioned about the periphery thereof. It will be recognized by one of ordinary skill in the art that a variety of types of gear wheels and gear teeth may be employed in accordance with the teachings of the present invention. Positioned on either side of the gear wheel 14 are walls 32. In FIGS. 5, 6, 7 and 10, the walls 32 are illustrated to be fixed to the gear wheel 14 on either side thereof extending radially outwardly from adjacent the hub to past the teeth of the wheel 14. The two walls 32 are thus adjacent the gear teeth to form a barrier around the teeth for retaining lubricant in close proximity thereto. It can be seen in FIG. 6 that the walls 32 extend outwardly from the periphery of the gear wheel 14 by a convenient amount "h".
In the embodiment specifically illustrated in FIG. 6, plates are fastened to the sides of the gear teeth 14 to form the walls 32. Screws or rivets may be employed at the base of the gear teeth to fix these plates in position so as to avoid deflection. Additionally, the embodiment of FIG. 6 is shown to have the plates or walls 32 located on the drive gear. The drive gear in the context of this preferred embodiment is shown to be smaller than the driven gear. Provision of the plates on gear wheel 14 exhibits smaller plate deflection than might be exhibited were a larger plate required for the gear wheel 18. A clearance "d" is illustrated in FIG. 6 between each wall 32 and the mating side of the gear wheel 18. This clearance prevents interference between meshing of the gear teeth and the walls 32 as well as friction between these components.
Additional arrangements of the walls 32 are illustrated in FIGS. 8 and 9. In FIG. 8, the teeth 34 of the gear wheel 14, and indeed the hub, are shown to be integrally formed with the walls 32. Such a gear wheel may be produced by means of a sintering process.
In FIG. 9, a first enclosed wall 32 is positioned on one side of the gear wheel 14. A second wall 36 on the opposite side adjacent the gear wheel 14 is provided by means of the casing 12. Naturally, some clearance between the gear wheel 14 and the surface 36 of the casing 12 preferably exists to avoid friction losses and wear.
Looking then to the oil flow as constrained by the devices of FIGS. 4 through 10, reference is made to FIG. 7. In FIG. 7, arrows 38 and 40 illustrate the normal flow of lubricant from between meshing gear teeth absent the teachings of the present invention. As can be seen from the illustration, this flow is outwardly away from the gear where it generally would be recycled through the lubricant system before arriving back at the lubricated surfaces. With the walls 32 in position, the flow of lubricant is generally as indicated by arrow 42. The flow of lubricant can then only flow through the clearances d between the walls 32 and the gear wheel 18. This restriction to flow of the lubricant retains the lubricant in the area of meshing so as to absorb the shock of impacting tooth faces, even during torque fluctuation. In this way, buzzing noise and gear hitting noise can be reduced.
The effect of the employment of the walls 32 may be optimized by empherical study for any gear to obtain maximum noise attenuation with minimum loss of gear efficiency or the like. This may be accomplished by appropriately establishing the clearance d and by consideration of the extent of the radial projection of the walls 32 as measured by h.
To provide further lubricant to the meshing gear for noise reduction, a lubricant vessel 44 is employed to extend about a portion of the gear wheel 14. This lubricant vessel is shown to be elevated above the lubricant sump having a sump level at 46. Lubricant is supplied through the lubricant manifold 26 to passageway 48 which in turn delivers the lubricant to the vessel 44. The passageway 48 provides a feed line which directs lubricant at the gear wheel 14. As can be seen in FIG. 5, this feed line directs lubricant generally along a tangent line to the wheel 14 in the direction of gear rotation. Inded, the lubricant is directly conveyed to the meshing area of the gear. The level of the lubricant is, therefore, less critical, even under conditions of acceleration and tipping such as illustrated in FIG. 11.
The bottom surface 50 of the lubricant vessel 44 is arcuate to approximate the curve of the gear teeth as may best be seen in FIG. 5. This is believed to aid in the delivery of lubricant to the gear wheel 14.
In operation, lubricant is supplied by means of the oil pump 24 through the manifold 26 and passageway 48 into the lubricant vessel 44. The lubricant is directed somewhat tangentially to the gear wheel 14 both because of the direction of the passageway 48 and the bottom surface 50 of the lubricant vessel 44. The direction of such lubricant feed causes the lubricant to be directly supplied into the meshing area of the gear to both lubricate and attenuate noise. Oil is also preferably delivered to the meshing area by the conventional splashing from the sump lubricant. In cooperation with the walls 32, the introduced lubricant reduces noise and the impacting shock between intermeshing teeth.
Accordingly, a gear system is disclosed for a transmission which is designed to reduce noise through delivery of lubricant to the meshing area of the gear and through retention of the lubricant in that area. While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the appended claims.
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A system of lubricated gearing illustrated in the context of a motorcycle transmission. A lubricant vessel is provided to partially enclose the lower portion of the drive gear to deliver additional lubricant thereto. Walls extend radially outwardly adjacent to the drive gear to retain lubricant within the meshing area of the gears, reducing gear noise and impact shock between meshing gear teeth.
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This is a division of application Ser. No. 597,376, filed July 18, 1975, now Pat. No. 4,014,727 issued Mar. 29, 1977.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to improvements in check valves, and more particularly, but not by way of limitation, to fluid flow-actuated check valves for use in float collars or float shoes in well cementing operations.
2. Description of the Prior Art
The prior art contains a number of teachings of flow control check valves for use in floating equipment employed in the cementing of casing in oil wells. It is normally desirable to maintain the check valves in an open condition in the float shoes or float collars of the casing as the casing is being run into the well so that the casing can automatically fill from the bottom at a predetermined rate in order to save costly rig time which would otherwise be expended in manually filling the casing string from the surface as it is being run into the borehole. Currently available tool designs for such floating equipment are limited by some form of sacrificial mechanical part for maintaining the check valve in an open position such as shear plates, shear pins, extrusion rings, tension collars or the like. Such mechanical items must have a calculated strength such that the check valve is held open until a predetermined amount of pressure differential or a predetermined fluid flow rate acts upon the tool. The reliability of such prior art designs depends upon whether or not the materials being deformed or sheared perform in the predicted manner. If the materials do not perform in the predicted manner, the check valve member may either be released prematurely or may not be released at all. The elimination of sacrificial mechanical devices would be a distinct advantage.
It should also be noted that the currently available tool designs for automatically filling float shoes or float collars provide no means for reopening and reclosing the check valve employed therein after the deformation or shearing of the sacrificial mechanical part previously maintaining such check valve in an open position. This structural limitation in the prior art devices eliminates the possibility of testing the check valve mechanism for operability when in position down hole prior to commencing the actual cementing operation.
Those forms of automatic filling float shoes or float collars which require a ball or plug to be dropped through the casing string to seal in the valve mechanism of the float shoe or float collar to seal off the valve mechanism so that pressure can be applied thereto to release the locked open check valve through shearing or deformation of a sacrificial mechanical part are characterized by a disadvantageous time delay during which the ball or plug must fall through the fluid in the casing. Prior art mechanisms of this type are illustrated at pages 2412 and 2413 of the Halliburton Services Sales and Service Catalog No. 37.
It will be clearly seen that all forms of prior art tool designs discussed above prevent the possibility of reverse circulation through the check valve mechanism once release of the check valve has been obtained through shearing or extruding the sacrificial mechanical part previously maintaining the check valve in an open position.
U.S. Pat. Nos. 3,776,250 and 3,385,372, each granted to Lloyd C. Knox, and U.S. Pat. No. 3,385,370, granted to Lloyd C. Knox, et al., all of which are assigned to Halliburton Company, the assignee of the present invention, disclose various forms of prior art flow control valve structures employing frangible pins and otherwise deformable elements. A non-indexing automatic fill-up valve utilizing shear pins is shown on pages 2414 and 2415 of Halliburton Services Sales and Service Catalog No. 37.
SUMMARY OF THE INVENTION
The present invention contemplates a flow responsive fluid check valve for controlling forward and reverse fluid flow through a conduit. The valve comprises a valve body having a substantially longitudinally aligned passage therethrough and means for connecting the valve body in a conduit. A valve seat is disposed in the valve body facing in the direction of foward fluid flow therethrough. The valve further includes valve member means, movably disposed in the valve body for engaging the valve seat to close the valve to reverse fluid flow and, alternately, for disengaging from the valve seat to open the valve to reverse fluid flow. The valve also includes biasing means operatively engaging the valve member means for urging the valve member means into engagement with the valve seat. The valve further comprises flow responsive means operatively, mutually engaging the valve body and the valve member means for retaining the valve member means disengaged from the valve seat against the urging of the biasing means to thereby allow reverse fluid flow through the valve body, for releasing the valve member means for engagement with the valve seat under the urging of the biasing means in response to an application of forward fluid flow through the valve body to thereby prevent reverse fluid flow therethrough, and for again retaining the valve member means disengaged from the valve seat against the urging of the biasing means in response to another application of forward fluid flow through the valve body to thereby again allow reverse fluid flow therethrough.
Objects and advantages of the present invention will be readily apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A is a partial vertical cross-sectional view of an indexing J-slot automatic fill-up valve apparatus constructed in accordance with the present invention illustrating the valve member in the closed position.
FIG. 1B is a partial vertical cross-sectional view of the indexing J-slot automatic fill-up valve apparatus of FIG. 1A illustrating the valve member in the open position.
FIG. 2 is an enlarged vertical cross-sectional view of the J-slot insert of the automatic fill-up valve apparatus of FIG. 1A.
FIG. 3 is a horizontal cross-sectional view taken along line 3--3 of FIG. 2.
FIG. 4 is a horizontal cross-sectional view taken along line 4--4 of FIG. 2.
FIG. 5 is an enlarged vertical elevation view of the indexing sleeve of the fill-up valve apparatus of FIG. 1A.
FIG. 6 is a top plan view of the indexing sleeve of FIG. 5.
FIG. 7 is a planar projection of the continuous cam slot formed in the inner periphery of the J-slot insert of FIG. 2.
FIG. 8 is a vertical cross-sectional view of an alternate embodiment of the indexing J-slot automatic fill-up valve apparatus of the present invention.
FIG. 9 is a vertical cross-sectional schematic view illustrating a float collar constructed in accordance with the present invention installed in a casing string being lowered into a well bore.
FIG. 10 is a vertical cross-sectional schematic view illustrating the casing string of FIG. 9 positioned in the well bore and the testing of the indexing automatic fill-up float valve in the float collar.
FIG. 11 is a vertical cross-sectional schematic view similar to FIG. 10 illustrating the introduction of cement slurry through the float collar to cement the casing string in the well bore.
FIG. 12 is a vertical cross-sectional schematic view similar to FIG. 11 illustrating the completion of the cementing operation with the indexing automatic fill-up float valve in the closed position preventing reverse upward flow of the cement slurry through the casing string.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and to FIGS. 1A and 1B in particular, a float collar constructed in accordance with the present invention is illustrated and is generally designated by the reference character 10. The float collar 10 comprises an outer cylindrical housing 12 formed of a durable material such as steel. Centered within the housing 12 and supported by a drillable concrete filler portion 14 is a tubular valve body assembly 16 comprising an upper valve body 18 and a lower valve body 20 joined together by a releasable connection such as matching threads 22.
The lower valve body 20 includes a valve guide 24 formed as an integral part thereof and having a longitudinal passage 26 extending vertically therethrough coaxial with the tubular valve body assembly 16 and the housing 12. The valve guide 24 is supported by one or more vanes 28 extending between the valve guide 24 and the outer wall 30 of the lower valve body 20. The vanes 28 further define one or more flow ports 32 extending longitudinally through the lower valve body 20. A lower recessed central opening 34 is formed in the lower valve body 20 and communicates between the lower end face 36 and the flow ports 32 thereof. In the preferred embodiment, the lower valve body 20 comprises three equally circumferentially spaced vanes 28 defining three equally circumferentially spaced flow ports 32.
A valve body 38, comprising a plunger head 40, a valve stem 42 axially aligned with the tubular valve body assembly and an externally threaded portion 44 formed on the lower end of the valve stem 42, is longitudinally slidably supported within the valve body assembly 16 by the valve guide 24 with the valve stem 42 extending through the longitudinal passage 26. The plunger head 40 includes a substantially conical valve surface 46 which matches a downwardly facing upper valve seat 48 formed in the upper valve body 18. The conical valve surface 46 preferably carries an elastomeric covering to provide enhanced sealing engagement between the plunger head 40 and the valve seat 48.
The plunger head 40 further includes an integral collar 50 formed on the lower portion thereof coaxial with the valve stem 42 and having an outer diameter substantially equal to the outer diameter of the upper portion 52 of the valve guide 24. A compression coil spring 54 extends between the upper portion 52 of the valve guide 24 and the lower portion of the plunger head 40 to apply a constant upward biasing force to the valve member 38 urging the plunger head 40 thereof toward the valve seat 48 to achieve sealing engagement therebetween.
A first cylindrical outer surface 56 is formed on the valve stem 42 and extends upwardly from the threaded portion 44 thereof. The first cylindrical outer surface 56 communicates with a second cylindrical outer surface 58 formed on the valve stem 42 via an annular radial shoulder 60. A tubular indexing sleeve 62 is journaled on the first cylindrical outer surface 56 of the valve stem 42 intermediate the annular shoulder 60 and an internally threaded nut 64 threadedly secured to the externally threaded portion 44 of the valve stem 42. The tubular indexing sleeve 62 is adapted to freely rotate about the longitudinal axis of the valve stem 42.
As more clearly shown in FIGS. 5 and 6, the tubular indexing sleeve 62 includes a cylindrical bore 66 extending longitudinally therethrough communicating with the upper and lower end faces 68 and 70. Radially outwardly extending cam follower portuberances or lugs 72, 74 and 76 are formed on the cylindrical outer periphery 78 of the tubular indexing sleeve 62 and are equally circumferentially spaced about the outer periphery 78. The annular circumferential spacing between adjacent cam follower lugs is 120°.
The longitudinal passage 26 of the valve guide 24 includes an internally threaded portion 80 which extends upwardly from the lower end face 82 and communicates with an annular shoulder 84 formed in the longitudinal passage 26.
A tubular J-slot insert 86 having external threads 88 formed thereon is threadedly secured in the internally threaded portion 80 of the longitudinal passage 26 of the valve guide 24 with the upper end face 90 thereof abutting the annular shoulder 84 of the longitudinal passage 26.
As more clearly shown in FIGS. 2, 3 and 4, the J-slot insert 86 includes a substantially cylindrical inner surface 92 in which is formed a continuous cam slot 94. The cam slot 94 includes three longitudinally aligned portions 96, 98 and 100, which communicate with the upper end face 90, and three circumferentially equally spaced detent portions 102, 104 and 106. Inclined surface 108 interconnects longitudinal portion 96 and detent portion 102. Inclined surface 110 interconnects longitudinal portion 98 and detent portion 104. Inclined surface 112 interconnects longitudinal portion 100 and detent portion 106. Longitudinal surfaces 114, 116 and 118 extend downwardly from detent portions 102, 104 and 106, respectively. An inclined surface 120 interconnects longitudinal surface 114 and longitudinal portion 98 of the continuous cam slot 94. Inclined surface 122 interconnects longitudinal surface 116 and longitudinal portion 100. Inclined surface 124 interconnects longitudinal surface 118 and longitudinal portion 96. This structure is more clearly shown in the planar projection of the continuous cam slot 94 illustrated in FIG. 7.
The continuous cam slot 94 further includes three upwardly facing inclined surface 126, 128 and 130 positioned directly below the longitudinal portions 96, 98 and 100, respectively. The continuous cam slot 94 further includes three additional upwardly facing inclined surfaces 132, 134 and 136 positioned directly below the detent portions 102, 104 and 106, respectively. Longitudinal surfaces 138, 140, 142, 144, 146 and 148 interconnect the lower end face 150 of the J-slot insert 86 with the upwardly facing inclined surfaces 126, 128, 130, 132, 134 and 136, respectively.
The float collar 10 is advantageously employed in oil well cementing. Oil well cementing is a process involving the mixing of a cement-water slurry and the pumping of the slurry down through steel casing positioned with an oil well borehole to critical points located in the annulus between the casing and the borehole, in the open hole below the steel casing or in fractured formations. The strain on the derrick caused by the weight of the casing string as it is being inserted into the borehole can be minimized through the employment of one or more float collars and/or a float shoe in the casing string to partially float the casing string to the bottom of the well in the well fluids contained therein. Casing flotation is accomplished when the well or drilling fluid in the well bore is either prevented from flowing upwardly through the float valve in the casing or the fluid is allowed to flow through the float valve structure at a predetermined restricted rate to automatically fill the casing from the bottom as it is being run into the well.
In such cement operations, the float collar 10 is assembled as shown in FIG. 1B and is inserted in a casing string either at the lower end portion thereof or spaced one or two joints upwardly from the lower end portion thereof. FIG. 9 illustrates schematically a casing string 162 having a float collar 10 installed therein as it is being lowered into an oil well borehole 164 in which it is to be cemented. The casing string 162 includes a conventional guide shoe 166 mounted on the lower end thereof and a conventional casing centralizer 168 disposed about the casing string intermediate the guide shoe and the float collar 10. As the casing string is run into the well, the fluid in the barehole 164 passes upwardly through the guide shoe 166 and through the flow ports 32 in the tubular valve body assembly 16 of the float collar 10 at a predetermined rate dependent upon the cross-sectional area of the flow ports 32 and the hydrostatic head of the fluid in the borehole acting thereon.
It will be seen that as the casing string 162 is lowered into the borehole 164, the plunger head 40 of the valve member 38 is retained or locked out of engagement with the valve seat 48 thereby opening the tubular valve body assembly 16 to upward reverse fluid flow therethrough. The float collar 10 is maintained in this open position against the upward bias of the compressed compression coil spring 54 through the engagement of the cam follower lugs 72, 74 and 76 with the detent portions 102, 104 and 106 of the continuous cam slot 94 as shown in FIG. 1B and in FIG. 7 at the position indicated at A.
If, at any time during or after the descent of the casing string 162 into the borehole fluid, it is desired to close the valve apparatus of the float collar 10, this may be done by flowing displacement fluid 169 downwardly through the casing string 162 in a forward direction from reservoir 170 and pump 172 through the tubular valve body assembly 16 at a sufficient flow rate to move the valve member 38 downwardly from its retained open position, as shown in FIG. 10, thereby causing the cam follower lugs 72, 74 and 76 to engage the upwardly facing inclined surfaces 132, 134 and 136 of the cam slot 94 causing resulting rotation of the tubular indexing sleeve 62 relative to the valve stem 42 to the position indicated at B in FIG. 7. When fluid is no longer flowing downwardly through the casing string 162 at a rate sufficient to compress the coil spring 54, the coil spring 54 extends moving the valve member 38 upwardly until the plunger head 40 is free to sealingly engage the valve seat 48 and the cam follower lugs 72, 74 and 76 move upwardly along the longitudinal ports 98, 100 and 96 to the position indicated at C. The valve structure of the float collar 10 is then in the condition illustrated in FIG. 1A and operates as a check valve preventing upward reverse fluid flow through the tubular valve body assembly 16 while permitting downward forward fluid flow therethrough against the upward bias of the compression coil spring 54.
When it is again desired to position the valve structure of the float collar 10 in the locked open position with the valve member 38 retained against the bias of the compression coil spring 54, fluid is again flowed downwardly through the casing string 162, as shown in FIG. 10, at a flow rate sufficient to overcome the upward bias of the coil spring 54 thereby forcing the valve member 38 downwardly within the tubular valve body 16 until the cam follower lugs 72, 74 and 76 of the tubular indexing sleeve 62 engage the upwardly facing inclined surfaces 128, 130 and 126 thereby rotating the tubular indexing sleeve 62 relative to the valve stem 42 until the cam follower lugs and the tubular indexing sleeve 62 assume the position indicated at D. When downward fluid flow through the casing string 162 is stopped, the coil spring 54 extends and moves the valve member 38 upwardly within the tubular valve body 16 and the cam follower lugs 72, 74 and 76 of the indexing sleeve 62 engage the inclined surfaces 110, 112 and 108 of the cam slot 94 causing a resulting rotation of the tubular indexing sleeve 62 relative to the valve stem 42 until the cam follower lugs again engage the detent portions 102, 104 and 106 again, as shown at position A, thereby retaining the valve member 38 is an open position with the plunger head 40 out of engagement with the valve seat 48 thus permitting upward reverse fluid flow through the tubular valve body assembly 16 of the float collar 10. Such opening and closing of the valve structure of the float collar 10 may be repeated as many times as desired prior to commencing the cementing operation.
When the cementing operation commences, the cement slurry 175 is pumped downwardly through the casing string 162 from reservoir 174 by pump 176 behind bottom plug 178, as shown in FIG. 11, at a rate sufficient to again force the valve member 38 downwardly relative to the tubular valve body 16 causing the cam follower lugs 72, 74 and 76 to move from their retained positions at A to the positions indicated at B. When the bottom plug 178 abuts the float collar 10, differential pressure ruptures a diaphragm formed therein permitting the cement slurry 175 to pass therethrough. The rate of flow of the cement slurry through the tubular valve body 16 is sufficient to maintain the valve member 38 in its lowermost position compressing the coil spring 54 and thus maintaining the valve structure in an open position. A top plug 180 is inserted in the casing string 162 and follows the cement slurry 175, separating it from displacement fluid 182 pumped from reservoir 170 by pump 172 which forces the cement slurry downwardly until the top plug 180 engages the ruptured bottom plug 178 stopping further flow. When cement flow is stopped, the compression spring 54 urges the plunger head 40 of the valve member 38 into sealing engagement with the valve seat 48 thereby closing the tool against reverse upward flow of cement through the tubular valve body assembly 16 of the float collar 10 caused by the hydrostatic pressure applied by the column of cement in the annulus between the casing string 162 and the wall of the oil well borehole 164, as shown in FIG. 12.
FIG. 8 illustrates a slightly modified float collar 10a in which an insert 152 includes a plurality of radially inwardly extending lugs 154. The insert 152 is threaded into the internally threaded portion 80 of the valve guide 24 in a manner as described above for the tubular J-slot insert 86.
A J-slot indexing sleeve 156 is journaled on the valve stem 42 in a manner identical to that previously described for the tubular indexing sleeve 62. The J-slot indexing sleeve 156 includes a continuous cam slot 158 formed in the substantially cylindrical outer periphery 160 thereof. The configuration of the continuous cam slot 158 is substantially identical to, but radially inverted from the continuous cam slot configuration illustrates at 94 in the tubular J-slot insert 86.
It will be readily understood that the relative operation between the cam slot 158 of the J-slot indexing sleeve 156 and the inwardly extending lugs 154 of the insert 152 is substantially identical to that previously described above for the tubular indexing sleeve 62 and the tubular J-slot insert 86.
The operation of the float collar 10a is clearly evident from the operation of the float collar 10 described in detail above and, therefore, need not be explained again.
The advantages achieved in the employment of either embodiment of this invention are believed readily apparent in that operational control of the valve structure of the float collars 10 and 10a is accomplished without necessitating the shearing or deformation of materials with the accompanying inherent unreliability of such shearing or deformation. The present invention requires only the action of downward forward fluid flow against the upward bias of a compression coil spring to alternately lock the check valve structure in a retained open position and release the check valve structure to seal against any reverse upward fluid flow through the float collar. Further, both embodiments of the present invention permit a recycling of the valve structure from a locked open position, to a closed position, and back to a locked open position an unlimited number of times. Such flexibility of operation is not achievable by any of the known prior art float shoes or collars.
All of the parts of the present invention within the housing 12 may be constructed of easily drilled materials such as concrete, plastic, rubber, aluminum, cast iron and brass, to allow the collar to be drilled out after a cementing operation has been completed and the cement has set. The drilling out leaves a full-open passage through the collar to pass other tools down the casing for further work, production or testing.
Although specific preferred embodiments of the present invention have been described in the detailed description above, the description is not intended to limit the invention to the particular forms or embodiments disclosed herein, since they are to be recognized as illustrative rather than restrictive and it will be obvious to those skilled in the art that the invention is not so limited. For instance, it is contemplated that different numbers of vanes could be used between the valve guide and the lower body to vary the number and size of the ports through the collar. It would also be possible to employ the valve structure disclosed herein in the construction of a float shoe for installation on the lower end of a casing string.
In a similar manner, it will be understood that the valve structure of the present invention could be modified to employ a single J-slot and a single lug or any other number of J-slots and lugs, depending on the particular size of the tool. Further, the configuration of the J-slots could be modified so as to provide a locked-closed position, two consecutive closed positions, two consecutive open positions, or any other combination of open and closed positions desired in view of the particular well bore operations to be performed.
It will also be understood that the valve stem of the valve structure disclosed herein may be splined to the valve body to positively prevent any relative rotation therebetween. Additionally, those skilled in the art will perceive that various other forms of valve structures could be employed in the present invention, such structures including a ball valve member, a sleeve valve member, a flapper valve member or other suitable type of valve member if desired.
The invention is declared to cover all changes and modifications of the specific examples of the invention herein disclosed for purposes of illustration, which do not constitute departures from the spirit and scope of the invention.
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A valve for repetitively allowing and preventing upward fluid flow through a casing string. The valve is convertible from a locked open position permitting reverse upward fluid flow therethrough to a check valve position preventing upward fluid flow therethrough by flowing fluid downwardly through the casing to actuate an indexing J-slot mechanism interconnecting the spring-loaded valve member and the valve body assembly. The valve may be recycled to the locked open position from the check valve position an unlimited number of times through the flowing of fluid in a forward direction downwardly through the casing string.
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BACKGROUND OF THE INVENTION
This invention relates to an improved method of combining or intermixing the contents of two (2) containers which can be flexible wall containers, rigid wall containers, or semirigid wall containers. The containers can contain sterile contents or nonsterile contents. The contents can be liquid and/or powders. The containers can be joined to the attaching elements of the invention at one time and at a later time the device can be activated and the contents can be mixed without effecting the sterility or the cleanliness of the contents. The attaching elements of the invention are capable of being attached to the rigid, semirigid or flexible wall container that has clamping or threaded attaching means. The elements are capable of functioning with the containers sealed with resilient stoppers or with bonded membrane members or any combination of seals. The elements of this invention allow the passageway for intermixing the contents to be almost as large as the exit or inlet port of the containers. They also allow the flow of the contents to go in either or both directions, that is, into either container. The elements also can lock the containers to the elements so that they or the device must be destroyed in order to separate the containers.
Prior patents which show a method for mixing two materials include Nos. 4,614,267, to Larkin; 4,703,864 to Larkin; 4,614,515 to Tripp; 4,610,684 to Knox; 3,532,254 to Bork; 3,290,017 to Davies; and 2,176,923 to Nitardy. These devices are deficient in that they do not enable the intermixing to occur between rigid, semirigid or flexible containers. U.S. Pat. No. 4,614,267, although providing for sterile mixing, must utilize a flexible bag for one of the containers. The flexible bag is necessary since the operation of removing the seal plugs must be done from the outside of the flexible bag which is very cumbersome and time consuming.
It is therefore a principle object of this invention to provide an improved means to intermix two sterile materials without breaking sterility.
It is another object of this invention to provide a means to intermix two materials simply by moving the containers from the first assembled position to the second activating position.
It is another object of this invention to provide a means to intermix two materials when needed while enabling the two containers to be joined awaiting mixing for any length of time for storage.
It is another object of this invention to provide a means to intermix materials regardless of whether the materials are packaged in containers with rigid walls, semirigid walls or flexible walls.
It is another object of this invention to provide a means for intermixing materials from two containers and preventing the containers from being separated without destruction to prevent reuse of the components.
It is another object of this invention to provide for intermixing material from two containers with a minimum of obstruction to the flow of the materials.
It is another object of this invention to provide for intermixing material from two containers which utilize as few parts as possible and which is low in cost to produce.
These and other objects of this present invention will become apparent from the following drawings and description.
SUMMARY OF INVENTION
This invention provides for the advantages cited above by utilizing two elements, a first element that can be attached to a rigid, semirigid, or flexible container while that container still holds its contents in a sealed, clean, or even sterile condition. The second element of the invention can be assembled to a second rigid, semirigid, or flexible container while it still holds its contents in a sealed, clean, or sterile condition. When it is desired to mix the contents of the two containers, movement of the first element with respect to the second element removes the seals from both containers and provides a large passageway for the flow of the contents from one container to the other. It allows this flow to occur while still maintaining cleanliness and sterility for the contents.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross section showing the combination of a rigid container with a threaded top attached to the transfer member of the invention and a flexible container attached to the ingress member of the invention with an adhesive or shrink fit attachment.
FIG. 2 is a cross section showing the combination of a rigid container with a flanged top attached to the transfer member of the invention and a rigid container attached to the ingress member of the invention with a thread attachment.
FIG. 3 is a cross section showing the combination of a flexible material container sealed with an adhesive seal or heat shrink seal attached to the transfer member of the invention and a flexible container attached to the ingress member of the invention with an adhesive or shrink seal attachment.
FIG. 4 is a cross section showing the combination of a flanged rigid container attached to the transfer member of the invention and a flanged rigid container attached to the ingress member of the Invention.
FIG. 5 is a cross section substantially along lines 1--1 of FIG. 2 showing the transfer member fingers passing through the ingress member.
FIG. 6 is a cross section showing the combination of a flanged container attached to a transfer member of the invention sealed with a diaphragm seal and a threaded container attached to an ingress member sealed with a diaphragm.
FIG. 7 is a cross section showing a vial with a resilient plug stopper and a cap over the stopper.
FIG. 8 is a partial sectional view showing the detenting of the transfer member of the invention engaging a detent groove of the ingress member of the Invention.
FIG. 9 is a partial cross section after the stopper in one container is removed.
FIG. 10 is a view of a flange type of seal for the containers.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to FIG. 1, a rigid container 101 is provided at its open end with threads 102 as is common in normal bottle production. Thread 102 is attached to a mating thread 103 molded as part of a hollow tube member 104 which is part of transfer member 110. Inside tube member 104 is a second tube member 105. At the external end of tube member 105 is a flexible seal member 106 which can be a flexible member formed as part of tube member 105 or it could be a resilient member such as a rubber "O" ring or rubber cap fastened to the external end of tube member 105. As a result, when the container 101 is threaded together to transfer member 110, the top of the container 101 engages the seal and produces a sealed fit when the container is screwed tight. A third tube called the external tube 107 also is part of transfer member 110. External tube 107 is provided with an external tapered ring 108 see FIG. 8, and an upstanding container guide flange 109. Guide flange 109 is provided to give added support to container 101. Before the container 101 is threaded into transfer member 110 a diaphragm seal or a cap, not shown, can cover the open end of the guide flange 109 to seal the transfer member 110 from particles if the guide member is used in clean applications or the seal can provide a means to retain sterility for sterile applications.
As shown in FIG. 8, tooth 108 is designed with a shape that allows transfer member 110 to move only in one direction.
A second container 120 is fabricated from flexible material and bonded or heat sealed to a flange 121 of an ingress member 115. Ingress member 115 comprises a tube 122 upstanding from a base 123. Attaching flange 121 can be secured to tube 122 anywhere along its length but in FIG. 1 it is shown in alignment with base 123. Base 123 is provided with a second tube member 124. A resilient material stopper 125 is inserted into tube 124 resulting in sealing contents 126 in container 120. Base 123 is provided with opening 127 through which arms 111 pass. Arms 111 after passing through opening 127 engage the resilient material stopper 125. Tube 122 surrounds external tube 107 and is in sliding engagement with it. On the internal surface of tube 122 are two grooves 128 and 129. Groove 129, FIG. 8, engages the tapered ring 108 and retains the transfer member 110 in a nonactive condition with ingress member 115. Internal of opening 127 is an extending tube member 130 which is concentric with tube 122. Extending tube member 130 is sized to fit inside the opening 112 of container 101. A second resilient material plug 113 is used to seal the opening 112 of container 101. The outer end of tube member 130 is provided with fingers 131 which engage the resilient material plug 113, just touching the resilient material plug 113 when the transfer member ring 108 is engaged with groove 129. A resilient member 132, a pump type gland 133 and/or an adhesive seal ring or heat seal ring 134 can provide a seal between transfer member 110 and ingress member 115 during storage before the unit is activated.
In order to enable the contents 135 of container 101 to mix with the contents 126 of container 120 the seal ring 134 if it is made of rigid material must be removed. After removal, pressure applied on container 101 in the direction towards container 120 will move the transfer member 110 inwardly into ingress member 115. Tapered ring 108 will disengage from groove 129 and engage into groove 128. After engaging the groove 128, the transfer member cannot move back again into groove 129 due to the shape of the groove and tooth. This locking condition prevents the reuse of the components. The walls of tube 107 will deflect inwardly slightly and the wall of tube 122 will deflect outwardly to allow the tapered ring 108 to move to groove 128 position. In moving from groove position 129 to groove position 128, the fingers 131 of upstanding tube member 130 push the resilient material plug 113 inwardly into container 101. As shown in FIG. 9 fingers 131 prevent the resilient material plug from reentering the opening 112 of container 101 while allowing the contents to flow into tube member 130 and then into container 120. Arms 111 of transfer member 110 push the resilient stopper 125 into container 120. With both resilient material members removed, a large clear passage is available for the contents 126 and 135 to flow in either direction into either container.
When the tapered ring 108 is engaged in groove 128, the parts are positioned so that a second flexible seal 136 of ingress member 115 is deflected by a pad 114 on transfer member 110. As a result, the passageway between both containers is sealed to prevent any leaking.
In this particular combination, container 120 is provided with an exit port 137 with a cap 138 through which the mixed contents can be removed.
As shown in FIG. 2, container 220 is made of a rigid material such as glass or a semirigid material such as a plastic molded bottle. The inlet port into the container is provided with a threaded portion 250. The ingress member 215 is provided with a mating threaded tube 260 depending from base 223. As a result, ingress member 215 can be secured and sealed to container 220 by screwing the container 220 into the ingress member 215. Container 201 is not provided with the threaded port 102 as shown in FIG. 1 but is provided with a flanged top 202. Flange top 202 can be sealed with a ring seal over a stopper or a ring seal over a line seal as is well known in the art of sealing vials. After removing the ring seal and the line seal or stopper, the container 202 is still sealed by the resilient neck stopper 213 in the same manner as the stopper 113 of FIG. 1. In order to secure container 201 to the transfer member 210, the top of tube 204 is provided with a hook end 203 which latches over the flange top 202. The distance between the hook end 203 and the seal member 206 is less than the thickness of the flange top 202 thus compressing the seal member 206. As a result, the container 201 is sealed to transfer member 210. If the deflection force to deflect the hook member 203 over the flange 202 is too great, the hook member 203 can be slit lengthwise in the tube 204 thus producing a plurality of hook members 203 with lower deflecting force than that of a single ring hook member. After container 220 is secured to the ingress member, the unit functions in the same manner as the unit with the parts shown in FIG. 1.
As shown in FIG. 3 container 301 is made from a flexible material such as a plastic bag 301. Plastic bag 301 is secured by an adhesive or by heat binding or other methods known in the art to an attaching member 350. Attaching member 350 can be provided with flange member 302 similar to bottle flange 202 of FIG. 2. It could also be made with threads similar to threads 102 of FIG. 1. As a result as shown in FIG. 3, a flexible member containing contents can be connected to another flexible member with contents so that activation of the transfer member 310 will act in the same manner as previously described in relation to FIG. 1, namely, tube 330 will remove stopper 313 from container 301 and arms 311 will remove stopper 325 from container 320 so that the contents in either container can be transferred to the other for intermixing.
In reference to FIG. 4, container 420 can be made of a rigid or a semirigid material. The top of container 420 is made with a flange 450. Stopper 425 is used as the sealing member for container 420. The container 420 and the ingress member 415 are joined together by means of hook member 451 projecting inwardly from tube 452. An inner tube 453 is constructed similar to the tube 205 of FIG. 2 to provide the seal between the ingress member 410 and flange 450; as a result the seal functions in the same manner as inner tube 205 with seal 206 sealing against flange 202. Stoppers 425 and 413 are removed on movement of the transfer member as previously described. As a result, contents of container 401 and contents of container 420 can be transferred and mixed.
In certain applications, it may be desirable to provide a stopper for the containers which has a top sealing surface as well as a cylindrical seal. As shown in FIG. 10, the stopper comprises a top flange 1010 which is relatively thin in thickness. The thickness is thick enough to provide a seal and thin enough to be deflected as shown by the dotted line configuration. The fingers 1031, which are the same as fingers 131 of FIG. 1, can still push the stopper into the container. The fingers 1031 are displayed inwardly from the position of fingers 131 of FIG. 1 in order to allow for the thickness of the stopper flange 1010 to pass freely between the fingers 1031 and the inside of the container opening. As a result, the stopper 1013 can function in the same manner as the stopper 113 of FIG. 1.
In many applications of intermixing contents sterility is not required but cleanliness and interlocking of containers is desirable. As shown in FIG. 6, the containers 601 and 620 are sealed with a paper or similar type of diaphragm seal 650 and 651. Diaphragm seals 650 and 651 are secured to the container in one of the many known methods such as adhesive, heat sealing, shrink wrapping or mechanical gripping. In place of removing stopper or plugs as previously described for other combinations, diaphragm seals 650 and 651 are cut open or torn. Extending tube member 630 is provided with a cutting edge 631 which is capable of cutting out a flap or the entire diaphragm 651 as required for the application. Transfer member 610 is provided with a tube element 611 which is adjacent to tube member 630 and surrounds it a distance required to make the desired cut opening in diaphragm 650. The cut in diaphragm 650 will form a flap which drops into the neck of container 620. As a result, containers 601 and 620 are opened to permit the contents of container 601 and 620 to mix.
Although various combinations of container types have been shown, it is obvious that anyone skilled in the art can make other combinations. For example, combinations could include flexible containers each or both having threaded attaching means.
From the foregoing, it is seen that the present invention provides a combination of elements that allow each element to be connected to a sealed container such that movement of one container towards the other container under control of the elements allows the elements to open the seal of the other container and provide a connected path for the flow of either direction of the contents of the containers. The flow path is substantially the same as the size of the ports of the containers. The combinations shown are extremely simple in construction, low in cost and accomplish the desired objectives without departing from the spirit of the invention.
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A device capable of joining, holding, and opening a pair of sealed containers with contents. Each container is attachable to one of a pair of container opening parts movable with respect to each other. While in the attaching position the containers are maintained in sealed condition and are held in this position with respect to each other. The containers can remain in this position indefinitely or the containers can be moved to a different position from the attaching position. During this movement between the two positions, each of the pair of container opening parts opens a container and forms a passageway almost equal to the area of the seals for the contents of the containers to flow into either container to mix the contents of both containers.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a crystal structure, and more particularly to the crystal structure of glutaminyl cyclase (QC).
[0002] The formation of N-terminal pGlu is an important posttranslational or co-translational event in the processing of numerous bioactive neuropeptides, hormones, and cytokines during their maturation in the secretory pathway. The N-terminal pGlu is necessary in the formation of the proper conformation of these regulatory peptides for binding to their receptors and/or for protecting the N-termini of these peptides from exopeptidase degradation (Van Coillie et al., Biochemistry 37: 12672-12680 (1998); Hinke et al., J. Biol. Chem. 275: 3827-3834 (2000)). The N-terminal pyroglutamate (pGlu) is formed by the N-terminal cyclization of its glutaminyl precursor. And the glutaminyl cyclases (QCs) are the catalysts responsible for this posttranslational modification (Fischer et al., Proc. Natl. Acad. Sci. USA 84: 3628-3632 (1987); Busby et al., J. Biol. Chem. 262: 8532-8536 (1987)).
[0003] QCs (EC 2.3.2.5) are acyltransferases identified in both animal and plant sources (Fischer et al., Proc. Natl. Acad. Sci. USA 84: 3628-3632 (1987); Busby et al., J. Biol. Chem. 262: 8532-8536 (1987); Oberg et al., Eur. J. Biochem. 258: 214-222 (1998)). QCs are abundant in mammalian neuroendocrine tissues, such as hypothalamus and pituitary (Busby et al., J. Biol. Chem. 262: 8532-8536 (1987); Sykes et al., FEBS Lett. 455: 159-161 (1999)), and are highly conserved from yeast to human. Animal QCs were shown to have distinct structure and protein stability from plant QCs in spite of their similar molecular masses, i.e., 33-40 kDa (Oberg et al., Eur. J. Biochem. 258: 214-222 (1998); Schilling et al., Biochemistry 41: 10849-10857 (2002)). While no bacterial QCs have been reported thus far, the mammalian QCs had been predicted to exhibit remarkable homology to the bacterial double-zinc aminopeptidases (Schilling et al., J. Biol. chem. 278: 49773-49779 (2003); Booth et al., BMC biol. 2: 2 (2004)).
[0004] Several of human genetic diseases, e.g., osteoporosis that is a multifactorial hormonal disease characterized by reduced bone mass and microarchitectual deterioration of bone tissue (Stewart et al., J. Endocrinol. 166: 235-245 (2000)), appear to result from mutations of the QC gene. The gene encoding QC (QPC7) lies on chromosome 2p22.3. Within the region, thirteen single nucleotide polymorphisms (SNPs) were analyzed and shown a striking correlation with osteoporosis susceptibility in adult women (Ezura et al., J. Bone Miner. Res. 19: 1296-1301 (2004)). Of these SNPs, the R54W presents, statistically, the most prominent association with osteoporosis, which was proposed to affect the pathogenesis through the hypothalamus-pituitary-gonadal axis (Ezura et al., J. Bone Miner. Res. 19: 1296-1301 (2004)).
[0005] Interestingly, QC also catalyzes the N-terminal glutamate cyclization that leads to the formation pGlu (Schilling et al., FEBS Lett. 563: 191-196 (2004)). This reaction is probably related to the formation of several plaque-forming peptides, such as amyloid-β (Aβ) peptides and CLAC (collagen-like Alzheimer amyloid plaque component), which play a pivotal role in Alzheimer's disease (Morgan et al., Prog. Neurobiol. 74: 323-349 (2004); Hashimoto et al., EMBO J. 21: 1524-1534 (2002)). Peptides containing N-terminal pGlu, e.g., pGlu 3 -Aβ peptides, are major fractions of the Aβ peptides within the core of neuritic plaques (Saido et al., Neuron 14: 457-466 (1995); Kuo et al., Biochem. Biophys. Res. Commun. 237: 188-191 (1997); Russo et al., J. Neurochem. 82: 1480-1489 (2002)). The N-terminal pGlu could enhance the hydrophobicity, proteolytic stability and neurotoxicity of these peptides (Russo et al., J. Neurochem. 82: 1480-1489 (2002); Harigaya et al., Biochem. Biophys. Res. Commun. 276: 422-427 (2000)), probably causing a profused accumulation of pGlu-Aβ peptides in several senile plaques, and thus accelerating the progression of neurodegenerative disorders.
[0006] To date, there remain several theories concerning the properties and structures of human and animal QCs. The present invention offers the crystal structure of QC in free form, the structures of the active sites or catalytic centers of the QC, the method for identifying an inhibitor of glutaminyl cyclase (QC), and provides a structural basis for the rational design of new inhibitors against QC-associated disorders.
BRIEF SUMMARY OF THE INVENTION
[0007] An aspect of the invention provides a crystalline structure of glutaminyl cyclase (QC).
[0008] In another example, the present invention provides crystalline compositions of a complex comprising at least one QC molecule and another molecule that ligates, interacts with, or otherwise binds to the QC molecule.
[0009] Another aspect of the invention provides a method for identifying an inhibitor of glutaminyl cyclase (QC). The method comprises the steps of: (a) preparing QC protein, preferably a polypeptide with an amino acid sequence from amino acid residues 33 to 361 of SEQ ID NO:1, wherein the polypeptide has an active site comprising one zinc ion tetrahedrally coordinated to amino acid residues 159, 202, and 330 of SEQ ID NO:1, and a water molecule; (b) contacting the polypeptide with a candidate inhibitor for forming a QC/inhibitor complex; (c) generating a three-dimensional model of the QC/candidate inhibitor complex obtained in step (b); wherein the candidate inhibitor having an imidazole nitrogen bound to the zinc ion is identified as the inhibitor of QC.
[0010] A further aspect of the invention provides a method of making a QC crystal. The method comprises the steps of: (a) expressing a QC protein; (b) purifying the QC protein; and (c) crystallizing the QC protein to form the QC crystal.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawings will be provided by the Office upon request and payment of the necessary fee.
[0012] The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
[0013] In the drawings:
[0014] FIG. 1 is a list of X-ray coordinates of the human QC crystal structure at pH 6.5;
[0015] FIG. 2 is a list of X-ray coordinates of the human QC crystal structure at pH 8.0;
[0016] FIG. 3A is an overall view of the structure of human QC;
[0017] FIG. 3B is a schematic diagram illustrating a topology of the human QC structure;
[0018] FIG. 3C is a stereo view of the human QC catalytic region;
[0019] FIG. 4 is a list of X-ray coordinates of the crystal structure of human QC in complex with glutamine t-butyl ester;
[0020] FIG. 5A depicts the active-site structure of a human QC in free form;
[0021] FIG. 5B depicts the active-site structure of a human QC bound to 1-vinylimidazole at a 1.68 Å resolution;
[0022] FIG. 5C depicts the active-site structure of a human QC bound to 1-benzylimidazole at a 1.64 Å resolution; and
[0023] FIG. 5D depicts the active site structure of a human QC bound to N-ω-acetylhistamine at a 1.56 Å resolution.
DETAILED DESCRIPTION OF THE INVENTION
[0024] To facilitate the understanding of the invention, a number of terms are defined below.
[0025] The term “active site” refers to a specific region (or atom) in a molecular entity that is capable of entering into a stabilizing interaction with another molecular entity. In certain embodiments, the term also refers to the reactive parts of a macromolecule that directly participate in its specific combination with another molecule. In other embodiments, a binding site may be comprised or defined by the three dimensional arrangement of one or more amino acid residues within a folded polypeptide.
[0026] The term “analogue” refers to a drug or chemical compound whose structure is related in some way to that of another drug or chemical compound, but whose chemical and biological properties may be similar or different.
[0027] The term “coordinate” or “structural coordinates” refers to Cartesian coordinates derived from the mathematical equations related to the patterns obtained on diffraction of a monochromatic beam of X-ray by the atoms of a protein or protein complex in crystal form. The diffraction data are used to calculate an electron density map of the repeating units of the crystal. The electron density maps are then used to establish the positions of the individual atoms of the molecule or molecular complex.
[0028] The term “homologue” means a protein, polypeptide, oligopeptide, or portion thereof, having an amino acid sequence identity with QC as described in SEQ ID No: 1, or any active site described herein, or any functional or structural domain of binding protein. SEQ ID No:1 is a partial amino acid sequence of human QC.
[0029] The term “substrate” refers to any molecule, which is acted upon by an enzyme. According to the invention, the substrate binds with an active site of QC to form a QC-substrate-complex.
[0030] The term “mature domain” refers to a portion or segment of the QC protein or homologue that comprises an active or catalytic site; that is, the polypeptide with an amino acid sequence of amino acid residues 33 to 361 of SEQ ID NO:1.
[0031] The term “root mean square deviation” refers to the square root of the arithmetic mean of the squares of the deviations from the mean. It is a way to express the deviation or variation from a trend or object.
[0032] The term “variants” in relation to the polypeptide sequence in SEQ ID NO:1 include any substitution of, variation of, modification of, replacement of, deletion of, or addition of one or more amino acids from or to the sequence providing a resultant polypeptide sequence for a protein having QC activity.
[0033] The following amino acid abbreviations are used throughout this disclosure:
[0034] A=Ala=Alanine; T=Thr=Threonine; V=Val=Valine; C=Cys=Cysteine; L=Leu=Leucine; Y=Tyr=Tyrosine; I=Ile=Isoleucine; N=Asn=Asparagine; P=Pro=Proline; Q=Gln=Glutamine; F=Phe=Phenylalanin; D=Asp=Aspartic Acid; W=Trp=Tryptophan; E=Glu=Glutamic Acid; M=Met=Methionine; K=Lys=Lysine; G=Gly=Glycine; R=Arg=Arginine; S=Ser=Serine; H=His=Histidine.
[0035] A. Cloning, Expression and Purification
[0036] The nucleotide sequence encoding QC, or functional fragment, derivatives thereof, can be inserted into an appropriate expression vector that contains the necessary elements for the transcription and translation of the inserted protein-coding sequence. The vectors are then introduced into the desired host cells by methods known in the art.
[0037] For detailed descriptions of ways for cloning, expression, and purification of QC, please refer to U.S. patent application Ser. No. 11/331,704, the disclosure of which is hereby incorporated herein by reference.
[0038] B. Crystal Structure
[0039] X-ray structure coordinates define a unique configuration of points in space. Those skilled in the art understand that a set of structure coordinates for a protein or an enzyme/substrate complex define a set of points that, in turn, define a configuration in three dimensions. A similar or identical configuration can be defined by an entirely different set of coordinates, provided the distances and angles between atomic coordinates remain essentially the same.
[0040] Three-dimensional data generation may be provided by an instruction or set of instructions, such as a computer program or commands for generating a three-dimensional structure or graphical representation from structure. The graphical representation can be generated or displayed by commercially available software programs, such as SOLVE, RESOLVE (Terwilliger et al., Methods Enzymol. 374: 22-37 (2003)), O (Jones et. al., Acta Crystallogr. A47: 110-119 (1991)), PROCHECK (Laskowski et al., J. Appl. Crystallogr. 26: 283-291 (1993)), MOLSCRIPT (Kraulis et al., J. appl. crystallogr. 24: 946-950 (1991)), Raster3D (Merrit & Bacon et al., Methods Enzymol. 277: 505-524 (1997)) and GRASP (Nicholls et al., Proteins 11: 281-296 (1991)), which are incorporated herein by reference.
[0041] The present invention provides a crystalline structure of a QC polypeptide, the polypeptide comprising a QC protein, preferably a polypeptide an amino acid sequence spanning amino acid residues 33 to 361 of SEQ ID NO: 1. One embodiment of the present invention provides crystalline composition of QC that is derived from a mammal. In another embodiment, the present invention provides a crystal structure of QC that is derived from a human being.
[0042] The present invention further provides a crystal structure of human QC that comprises a three-dimensional structure characterized by the atomic structure coordinates according to FIG. 1 . And in accordance with another embodiment, the present invention provides a crystal structure of human QC, that has a space group of H32 so as to form a unit cell of dimensions of a=b=119.03 Å, c=332.94 Å. In yet another embodiment, the present invention provides a crystal as characterized above, wherein the crystal diffracts x-rays for determination of atomic coordinates of the crystal to a resolution of about 1.66 Å.
[0043] The present invention further provides a crystal structure of human QC that comprises a three-dimensional structure characterized by the atomic structure coordinates of FIG. 2 . In another embodiment, the present invention provides a crystal structure of human QC, that has a space group of H32 so as to form a unit cell of dimensions of a=b=118.99 Å, c=332.26 Å. In yet another embodiment, the present invention provides a crystal as characterized above, wherein the crystal diffracts x-ray for determination of atomic coordinates of the crystal to a resolution of about 2.35 Å.
[0044] In one embodiment, the present invention provides a QC crystal comprising two QC molecules. In accordance with another embodiment, the invention provides the crystal as characterized above, wherein the two QC molecules have a root mean square deviation of about 0.386 Å for all C α atoms between the two QC molecules.
[0045] The mature domain (amino acid residues 33-361 of SEQ ID NO: 1) of human QC was shown to possess glutaminyl and glutamyl cyclase activities on the putative physiological substrate of human QC. The asymmetric unit of the crystals, grown at pH 6.5, contains two human QC molecules with a root mean square deviation of 0.386 Å (for all C α atoms) between them. The globular structure reveals a mixed α/β fold with a size of 63×58×41 Å 3 . There are up to 36% and 16% of the amino acid residues involved in α-helix and β-sheet, respectively, with 6% in the 3 10 -helix regions.
[0046] FIG. 3A is an overall view of the structure of human QC. The central six β-strands are colored orange. The α helices located on the top, bottom, and edge are colored cyan, magenta, and yellow, respectively. The zinc ion is shown as a yellow sphere. The zinc-coordinated residues, Arg54, and a sulfate ion are depicted with a ball-and-stick model. The coils and loops adjacent to the catalytic center are colored green, whereas those distant from the active site are colored gray. Gray dots further represent the disordered region of residues 183 to 188 of SEQ ID NO: 1. FIG. 3B is a schematic diagram illustrating a topology of the human QC structure. The color codes for secondary structural elements are identical to those in FIG. 3A .
[0047] Referring to both FIGS. 3A and 3B , the structure has an open-sandwich topology comprising a central six-stranded β-sheet surrounded by two α-helices (α7 and α9) and six additional (α2, α3, α4, α5, α6 and α10) α-helices on opposite sides, and flanked by two other α-helices (α1 and α8) at one edge of the β-sheet ( FIG. 3A ). This twisted β-sheet is formed by two antiparallel strands (β1 and β2) and four parallel strands (β3, β4, β5 and β6), constituting the hydrophobic core of the molecule. The coil and loop regions of the structure represent 42% of the total residues; about half of them are major components of the active site ( FIG. 3B ). The structures at pH 6.5 and pH 8.0 are essentially similar, and the structure at pH 8.0 has a root mean square deviation of 0.155 Å (for all C α atoms) between the QC molecules.
[0048] C. QC/QC Substrate Complex
[0049] In another aspect, this invention provides a crystal of a complex comprising QC and a QC substrate bound to QC.
[0050] In one embodiment, the crystal of the QC/QC substrate complex comprises: (a) a polypeptide with an amino acid sequence from residues 33 to 361 of SEQ ID NO:1, or a homologue, analogue or variant thereof, and (b) a QC substrate, such that the crystal effectively diffracts X-rays for the determination of atomic coordinates of the QC/QC substrate complex to a resolution of 2.22 Å.
[0051] Another embodiment of this invention provides a QC/QC substrate complex that comprises a three-dimensional structure characterized by the atomic coordinates according to FIG. 4 .
[0052] In yet another embodiment, this invention provides a QC/QC substrate complex that has a space group of H32, so as to form a unit cell of dimensions a=b=119.14 Angstroms, and c=332.61 Angstroms.
[0053] Similarly, the three-dimensional data of the crystal of the QC/QC substrate complex may be generated by an instruction or set of instructions, such as a computer program or commands for generating a three-dimensional structure or graphical representation from structure. The graphical representation can be generated or displayed by commercially available software programs, such as those described in the method for determining the QC crystal structure.
[0054] D. Identification of Inhibitor of QC
[0055] To use the structure coordinates generated for QC, homologues, thereof, or one of its active site, it is at times necessary to convert them into a three-dimensional shape or to extract three-dimensional structural information from them. One of ordinary skill in the art would know that this can be achieved through the use of commercially or publicly available software that is capable of generating a three-dimensional structure, or a three-dimensional representation, of molecules or portions thereof from a set of structure coordinates.
[0056] The present invention provides a method for identifying a inhibitor of glutaminyl cyclase (QC), comprising the steps of:
[0057] (a) preparing a polypeptide with an amino acid sequence from amino acid residues 33 to 361 of SEQ ID NO:1, wherein the polypeptide has an active site comprising one zinc ion tetrahedrally coordinated to amino acid residues 159, 202, and 330 of SEQ ID NO:1, and a water molecule;
[0058] (b) contacting the polypeptide with a candidate inhibitor for forming a QC/candidate inhibitor complex;
[0059] (c) generating a three-dimensional model of the QC/candidate inhibitor complex obtained in step (b);
[0060] wherein the candidate inhibitor having an imidazole nitrogen bound to the zinc ion is identified as the inhibitor of QC.
[0061] The active site may further comprise amino acid residues 201, 207, 248, 305, 325, and 329 of SEQ ID NO: 1.
[0062] In accordance with one embodiment, the active site of QC comprises a water molecule, a zinc ion tetrahedrally coordinated to amino acid residues 159, 202, and 330 of SEQ ID NO: 1, and the amino acid residue 160 of SEQ ID NO: 1, the amino acid residue 160 of SEQ ID NO: 1 forming a peptide bond with the amino acid residue 159 of SEQ ID NO: 1. In another embodiment, such peptide bond is stabilized by a plurality of hydrogen bonds and is cis-configured.
[0063] In yet another embodiment, the active site of QC further comprises a hydrophobic pocket lined by amino acid residues 144, 146, 154, 249, 303, 321, 325, and 329 of SEQ ID NO: 1. Additionally, the active site may further comprise a sulfate ion adjacent to the hydrophobic pocket, wherein the sulfate ion is hydrogen-bonded to the amino acid residues 144, 206, 207, and 330 of SEQ ID NO: 1, and at least two water molecules.
[0064] Similarly, the three-dimensional data of the QC/candidate inhibitor complex may be generated by an instruction or set of instructions, such as a computer program or commands for generating a three-dimensional structure or graphical representation from structure. The graphical representation can be generated or displayed by commercially available software programs, such as those described above for determining the QC crystal structure and QC/QC substrate complex crystal structure.
[0065] The inhibitor includes but is not limited to imidazole-derived inhibitors, such as 1-vinylimidazole, 1-benzylimidazole, N-ω-acetylhistamine. For example, an electron-rich nucleophile having a good ability to ligate to the zinc ion of human QC, and combined with bulky hydrophobic substitutents may also be the structural basis of a potent QC inhibitor. As shown in FIGS. 5B through to 5 D, binding of the inhibitors results in the removal of six water molecules within the active-site pocket, including the zinc-coordinated one which is replaced by an imidazole nitrogen of the inhibitors.
[0066] The QC structure coordinates or the three-dimensional graphical representation generated from the coordinates may be used in conjunction with a computer for a variety of purposes, including identifying a inhibitor of QC. Various computational methods may also be used to determine whether a molecule or an active site thereof is “structurally equivalent” in terms of its three-dimensional structure to all or part of QC or its active site. One of ordinary skill in the art would understand that such methods may be carried out using software applications currently available.
[0067] E. Method of Making Crystal of Glutaminyl Cyclase
[0068] The present invention provides a method of making the crystal of human QC.
[0069] In one embodiment, the method of making the crystal of human QC comprises: (a) expressing the QC protein; (b) purifying the QC protein; and (c) crystallizing the QC protein to form the crystal of human QC. Preferably, the QC protein is crystallized by a hanging-drop vapor diffusion method.
[0070] F. Screening Drugs
[0071] Once a potential substrate is identified, it can be either selected from a library of chemicals as are commercially available from most large chemical companies. Alternatively, the potential substrate can be synthesized de novo.
[0072] When a suitable drug is identified, a supplemental crystal can be grown comprising a complex formed of the QC crystal and the drug. Preferably, the supplemental crystal effectively diffracts X-rays allowing the determination of the atomic coordinates of the QC/drug complex to a resolution of less than 3.0 Angstroms, and preferably less than 2.0 Angstroms.
[0073] The present invention contemplates methods for treating certain diseases in a mammal, preferably, human, by using the substrates, and preferably the inhibitors, as described herein.
[0074] The invention will now be described in further detail with reference to the following specific, non-limiting examples.
EXAMPLE 1
Expression and Purification of Human QC
[0075] The cDNA encoding human QC was amplified by PCR from a human bone marrow cDNA library (Clontech, Mountain View, Calif.); the mature enzyme (residues 33-361) was expressed in E. coli cells using a pET 32a expression vector (Novagen, Darmstadt, Germany) with several modifications as described previously in Taiwan Patent Application No. 094132349. SeMet-labeled protein was produced in E. coli using a non-auxotrophic protocol and purified in a manner similar to the native protein. In addition, the mutants of human QC were constructed using a “QuickChange site-directed mutagenesis kit” (Stratagene, La Jolla, Calif.) and were expressed and purified in the same manner as the wild-type human QC.
EXAMPLE 2
Crystallization of Human QC
[0076] Purified human QC was concentrated to 8-10 mg/ml and crystallized at 25° C. by the hanging drop vapor diffusion method. Rhombohedral crystals for wild-type, SeMet-labeled and mutant human QC were grown using equal volumes of the protein solution and the reservoir that contained 1.6-1.8 M (NH 4 ) 2 SO 4 , 4% dioxane and 10 mM MES, pH 6.5. In the condition of pH 8.0, the MES buffer in the reservoir was replaced by Tris-HCl.
[0077] In the case of substrate-bound form, the crystals of the mutant E201Q (grown at pH 7.0) were soaked for 1.5 hours into a solution consisting of 75% mother liquor, 25% glycerol and 1.1 M glutamine t-butyl ester. X-ray diffraction experiments were performed at various synchrotron beamlines as listed in Table 1. Prior to mounting on the X-ray machine, crystals were briefly soaked in mother liquor containing 20-25% glycerol (v/v) as cryoprotectants. All diffraction data were processed and scaled using the HKL package (Otwinowski et al., Methods Enzymol. 276: 307-326 (1997)). The space group of these crystals is R32, with typical unit cells of a=b=119 Å, c=333 Å, in which an asymmetric unit comprises two human QC molecules.
TABLE 1 MAD phasing statistics SeMet-QC Data set* SeMet-QC λ1 SeMet-QC λ2 λ3 Wavelength (Å) 0.9792 0.9794 0.9750 Space group R32 Resolution (Å) 50-1.8 (1.86-1.80) † Total observations 497057 497051 497136 Unique reflections 84184 84209 84238 Redundancy 5.9 (5.6) Completeness (%) 100.0 (100.0) I/σ(I) 21.1 (4.7) 25.2 (4.9) 27.4 (4.9) R merge (%) 7.8 (36.0) 6.4 (34.1) 6.2 (33.2) Figure of merit and Z-score (SOLVE)0.65, 112.2 (at resolution range of 15-2.0 Å) *X-ray diffraction experiment was performed at the beamline 5, KEK Photon Factory (Tsukuba, Japan). † Values in parentheses correspond to highest resolution shell.
EXAMPLE 3
Structure Determination and Refinement of Crystal of Human QC
[0078] The human QC structure at pH 6.5 was solved by the Multiwavelength anomalous diffraction (MAD) phasing method using the program SOLVE (Terwilliger et al., Methods Enzymol. 374: 22-37 (2003)). Having the MAD data at 20 to 2.0 Å resolution range collected at the wavelengths of 0.9792 Å (peak), 0.9794 Å (edge) and 0.9750 Å (high-energy remote) (see Table 1), all 14 Se atom sites were successfully located in the asymmetric unit. Subsequently, the program RESOLVE (Terwilliger et al., Methods Enzymol. 374: 22-37 (2003)) was performed where the initial electron density was modified by solvent flattening, and up to 83% of the protein model was automatically built using the entire MAD data of 50 to 1.8 Å resolution. Manual building of the remaining model and further refinement were carried out using the program 0 (Jones et al., Acta Crystallogr. A 47: 110-119 (1991)) against a 1.66 Å resolution data set of the wild-type crystal. The isomorphous structures of the mutants, different pH values and the substrate-bound and inhibitor-bound forms were phased using the refined model. For each structure, iterative cycles of model building with the program O and computational refinement with crystallography NMR system (CNS) (Brunger et al., Acta Crystallogr. D 54: 905-921 (1998)) were performed. R free values were calculated using 5% reflections. The stereochemical quality of the refined structures was checked using the program PROCHECK (Laskowski et al., J. Appl. Crystallogr. 26: 283-291 (1993)). Each of the final refined structures included 323 out of the 329 total residues in a human QC molecule, with a small disordered region of residues 183 to 188. Well-ordered water molecules were located and included in the models. The molecular figures were produced using the programs such as MOLSCRIPT (Kraulis et al., J. appl. crystallogr. 24: 946-950 (1991)), Raster3D (Merrit & Bacon et al., Methods Enzymol. 277: 505-524 (1997)) and GRASP (Nicholls et al., Proteins 11: 281-296 (1991)).
EXAMPLE 4
Structure of the Active Site of Human QC
[0079] The active site is mainly created by six loops between α3-α4, β3-α5, β4-7, β5-α8, α8-α9 and β6-α10 ( FIG. 3B ). The catalytic pocket is near the C-terminal edge of the central parallel strands β3, β4 and β5 ( FIG. 3A ). It is relatively narrow but accessible to the bulk solvent via a solvent channel. The single zinc ion of human QC lies at the bottom of the active-site pocket and is tetrahedrally coordinated to O delta (δ) 2 of Aspartic acid residue (D) 159 (D159 Oδ2), O epsilon (ε) 1 of Glutamic acid (E) 202 (E202 Oε1), N epsilon (ε) 2 of Histidine (H) 330 (H330 Nε2), and a water molecule. In addition, several other completely conserved residues, including E201, W207, D248, D305, F325, and W329, abut the zinc environment (see FIG. 3C ), suggesting some roles in catalysis. Mutations of those amino acids decreased enzyme activity significantly as evident in Table 2. The acidic residues E201, D248 and D305 are pointing to each other at both pH 6.5 and 8.0, likely forming hydrogen bonds between them. The peptide bond between the zinc-coordinated D159 and the following S160 adopts a cis-configuration, stabilized by a network of hydrogen bonds, including D159 Oδ1-H140 Nε2 (2.70 Å), S160 Oγ-D248 Oδ1 (2.66 Å), D159 O-water (2.65 Å), and S160 N-water (2.80 Å).
TABLE 2 Kinetic parameters of wild-type and mutant human QC K m (mM) k cat (s −1 ) k cat /K m (mM −1 s −1 ) Wild pH 7.0 0.79 ± 0.13* 7.30 ± 0.01 9.459 ± 1.544 pH 7.5 0.90 ± 0.09 9.76 ± 1.47 11.104 ± 2.716 pH 8.0 0.63 ± 0.01 8.63 ± 0.48 13.663 ± 0.497 pH 8.5 0.90 ± 0.05 9.93 ± 0.30 11.044 ± 0.331 pH 8.8 2.06 ± 0.62 8.56 ± 1.55 4.319 ± 0.544 Mutant † R54W 0.76 ± 0.04 7.35 ± 0.26 9.704 ± 0.824 K144A 1.47 ± 0.02 11.67 ± 0.34 7.944 ± 0.368 F146A 0.82 ± 0.16 7.91 ± 2.14 9.536 ± 0.769 E201D 12.62 ± 2.98 0.87 ± 0.28 0.068 ± 0.007 E201Q ‡ ND W207L 1.77 ± 0.07 0.43 ± 0.01 0.243 ± 0.002 W207F 0.59 ± 0.05 2.32 ± 0.07 3.943 ± 0.189 D248A ‡ ND Q304L 1.16 ± 0.09 9.39 ± 1.18 8.028 ± 0.386 D305L ‡ ND F325A 4.67 ± 0.24 12.91 ± 0.06 2.772 ± 0.132 W329A 29.53 ± 2.29 1.35 ± 0.07 0.046 ± 0.001 *Values are represented as mean ±S.D. (n = 2 or 3). † The assays for mutants were carried out under pH 8.0. ‡ E201Q, D248A and D305L were shown to possess the ≈0.001%, ≈0.1% and ≈0.03% activity of the wild-type enzyme, respectively. ND: Not detectable.
[0080] The hydrophobic active-site pocket is lined by residues K 144 , F146, F154, L249, I303, I321, F325, and W329, having approximate dimensions of 13×11×7 Å 3 . There are six water molecules located inside the pocket, including the water coordinated to the zinc ion. In addition, a sulfate ion is located near the opening of the pocket, hydrogen-bonded to K 144 Nζ, H206 Nδ1, W207 N, H330 Nδ1, and several water molecules ( FIG. 3C ). The active-site residues are shown and labeled. Possible hydrogen and coordination bonds are represented with dotted lines colored cyan and yellow, respectively. The green dotted lines depict the possibly unusual hydrogen bonds between D305 and E201 and between D305 and D248 of SEQ ID NO: 1
EXAMPLE 5
The Structure of Enzyme-Inhibitor Complexes
[0081] In the preparation of the inhibitor-bound crystal forms, a 1.5 μl protein solution containing human QC was mixed with 0.5 μl inhibitor solution (100 mM) in a 2 μl reservoir. The crystals formed as a result were subjected to X-ray diffraction and process as described in example 2. The crystal forms were determined and refined as described in example 3. As shown in FIGS. 5B through 5D , binding of the inhibitors results in the removal of six water molecules within the active-site pocket, including the zinc-coordinated one which is replaced by an imidazole nitrogen of the inhibitors. The inhibitors adopt different orientations, due to their different modifications on the imidazole ring. The small vinyl moiety of 1-vinylimidazole shows no interaction with the active site of human QC, leaving a large space in the catalytic pocket after its binding ( FIG. 5B ). However the bulky hydrophobic phenyl ring on 1-benzylimidazole is closely surrounded and stabilized by the phenyl and indole groups of F325 and W329, respectively ( FIG. 5C ). In contrast, the substitutent of N-ω-acetylhistamine is oriented almost parallel to the backbone of segment G301-Q304, stabilized mainly by three additional hydrogen bonds to D248 Oδ2, Q304 N and Q304 O of the enzyme ( FIG. 5D ). The detailed three-dimensional structures of human QC/1-vinylimidazole complex, human QC/1-benzylimidazole complex and human QC/N-ω-acetylhistamine complex are characterized by the atomic structure coordinates deposited as PDB ID codes 2AFZ, 2AFX and 2AFW, respectively in the protein data bank (www.pdb.org).
[0082] It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
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The invention relates to a crystalline structure of glutaminyl cyclase (QC). The invention also relates to the methods of preparing the crystalline structure of QC and the methods for identifying candidate inhibitors of QC. This invention further provides a structural basis for the rational design or identification of new inhibitors that may be used to treat QC-associated disorders.
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RELATED APPLICATIONS
The present invention was first described in Disclosure Document No. 595,156 filed on Feb. 16, 2006.
FIELD OF THE INVENTION
This invention relates to tree stands and, more particularly, to a combined tree supporting and watering stand for maintaining a tree at a vertical position while supplying a predetermined quantity of water to the tree.
BACKGROUND OF THE INVENTION
The holiday season is a time of great fun and happiness for everyone. A great deal of the holiday cheer comes from the yearly traditions that are passed from generation to generation. Perhaps the most well known of all traditions is that of the Christmas tree. The act of putting it up and decorating it in one's home is a process that can be enjoyed by all members of the family. However, the physical size of most Christmas trees causes a number of aggravations. First, it is difficult to get the tree to be straight and plumb in the stand. Second, the tree stand takes an inordinate amount of space that takes away from space for presents and/or other holiday decorations. Third, it is difficult to clean or vacuum around. Finally, one must kneel down or bend over to water the tree, which is difficult to do on a daily basis. Accordingly, there is a need for a means by which Christmas trees can be supported in a manner that reduces or eliminates the aggravations as described above. The development of the present invention fulfills this need.
Several attempts have been made in the past to develop a combined tree supporting and watering stand for maintaining a tree at a vertical position while supplying a predetermined quantity of water to the tree. U.S. Pat. No. 5,575,110 in the name of Couture discloses a self-watering tree stand having an external reservoir for holding a supply of water and a tube leading from the reservoir to a compartment in the tree stand. The compartment has a float valve for controlling the amount of water which is allowed to flow from the reservoir to the tree stand, and also, has a screen, the upper portion is made from a solid material and the lower portion is made from a screen type mesh which prevents debris and tree pitch from entering the compartment and interfering with the float valve. Unfortunately, this prior art example does not allow for supporting a tree from the middle section, thereby freeing up a quantity of space below the tree.
U.S. Pat. No. 5,522,179 in the name of Hollis discloses an automatic water level control system, for use in conjunction with a Christmas tree stand of the type having a watering basin with an outer rim and a tree clamping mechanism for holding the Christmas tree in an upright manner with the base portion of the tree disposed within the watering basin. The water level control system includes a water supply container, a flexible conduit, an attachment mechanism, and a valve mechanism. The water supply container serves as a holding tank for water which is supplied to the watering basin of the Christmas tree stand via the flexible conduit. The water level in the watering basin is regulated by the valve mechanism attached to the Christmas tree stand. The attachment mechanism has a main body and is attachable to the outer rim of the watering basin in a manner to functionally secure the main body to the Christmas tree stand. The valve mechanism includes a watering port, a valve, and a float member. The watering port is in fluid communication with the second end of the flexible conduit member such that water flowing from the water supply container through the flexible conduit ultimately exits the watering port into the watering basin. Unfortunately, this prior art example does not provide a means of suspending a water supply container in conjunction with the tree stand.
U.S. Pat. No. 5,791,083 in the name of Giangrossi describes a device for monitoring and maintaining the water level in the reservoir of a Christmas tree stand having a filler portion communicating with a flexible filler conduit. A water level indicator, includes an indicator float which is slidably engaged within the indicator float housing and which travels freely along a substantially vertical axis within the indicator float housing, a flexible indicator stem is attached to the indicator float and extends up through a flexible conduit for indicating, by means of the relative extension of the flexible indicator stem, the water level in the tree stand reservoir. The indicator float housing is formed having a number of holes through its outer wall for the free passage of water in and out of the indicator float housing from the reservoir for buoyantly raising or lowering the indicator float, consistent with the level of water in the reservoir. Unfortunately, this prior art example requires a separate tree stand be used in conjunction with the device, as opposed to incorporating the watering means with the tree stand.
U.S. Pat. No. 5,446,993 in the name of Cullen discloses a watering system which permits the convenient watering of potted plants and trees, in particular, evergreen trees, i.e. Christmas trees, in tree stands. The watering system is a tubular device having one end enlarged to form a funnel-like receptacle to receive the water or other liquid which is delivered via the tubular device to the pot or stand through an exit port at the opposite end. The base of the watering system is upheld upright by a band hooked about a projection on the watering system which supports the system against the base of a plant or tree. Between the two ends of the watering system, there is a bend which causes the funnel-like receptacle to extend beyond or into the foliage providing easy access for watering. Decorating elements may be added to camouflage or add ornamentation as desired. The watering system may be divided into several segments for convenience of storage and/or manufacturer. Unfortunately, this system does not incorporate a tree stand with the watering means, and also does not provide a water supply container.
None of the prior art particularly describes a combined tree supporting and watering stand for maintaining a tree at a vertical position while supplying a predetermined quantity of water to the tree. Accordingly, there is a need for a system which provides such features while overcoming the above-noted shortcomings.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the prior art, it has been observed that there is need for a combined tree supporting and watering stand for maintaining a tree at a vertical position while supplying a predetermined quantity of water to the tree.
The system includes a base removably positioned on a ground surface, a vertical member directly coupled to the base, without the use of intervening elements, and extending upwards therefrom, and a support member directly connected to the vertical member, without the use of intervening elements, and extending perpendicularly away therefrom. The support member is telescopically slidable along an extension member of the vertical member, which is important such that the support member is biased along a lateral direction. Of course, such members can be produced in a variety of sizes, as is obvious to a person of ordinary skill in the art.
The assembly further includes a power strip removably attached to the vertical member, which is essential for providing an electric power source to a plurality of decorative lights positioned on the tree.
The system further includes a mechanism for automatically watering a stalk of the tree during an extended period of time. Such an automatic watering mechanism is directly anchored to the support member, without the use of intervening elements. Such an automatic watering mechanism includes a water reservoir attached to the support member and suspended at an elevated height above the ground surface. A water receptacle is removably attached to the stalk of the tree and is in fluid communication with the reservoir. Of course, such a reservoir and receptacle can be produced in a variety of shapes and sizes, as is obvious to a person of ordinary skill in the art. A flexible tube has opposed ends directly mated to the reservoir and the receptacle, without the use of intervening elements, which is critical such that the tube selectively delivers water from the reservoir to the receptacle, which is advantageously located downstream of the reservoir. Of course, such a tube can be formed from a variety of suitable materials, as is obvious to a person of ordinary skill in the art.
The reservoir includes an unobstructive lid removably and snuggly fitted directly against an upper surface of the reservoir, without the use of intervening elements, which is essential for allowing necessary pressure equalization. The water receptacle is located subjacent to the water reservoir, which is critical for providing positive water pressure to the reservoir and thereby advantageously preventing the water from flowing upstream from the receptacle towards the reservoir.
The automatic watering system further includes a float valve operably attached to a distal end of the tube. Such a float valve has a float operably coupled thereto, which is crucial such that the float rises when a water level increases within the receptacle, and falls when the water level decreases within the receptacle. Such a float cooperates with the float valve in such a manner that the float valve advantageously opens and closes when the water level falls below and rises above a predetermined threshold respectively. Of course, such a float valve can be produced in a variety of shapes and sizes, as is obvious to a person of ordinary skill in the art.
The system further includes an extended arm that has opposed ends directly coupled to the float valve and the float respectively, without the use of intervening elements. Such an extended arm withholds a weight of the float and thereby advantageously absorbs a force due to buoyancy from the float for causing the extended arm to pitch. Upward movement of the float causes the extended arm to pitch upwardly, which is vital to close the float valve and to stop water, while downward movement of the float causes the extended arm to pitch downwardly, which is important to open the float valve and thereby permit water to flow into the receptacle.
The system further includes a mechanism for supporting the tree at an elevated vertical position above the ground surface. Such a tree supporting mechanism is advantageously anchored to the support member. The tree supporting mechanism includes a clamping mechanism monolithically formed with the support member. Such a clamping mechanism is adjustably and perpendicularly mounted to the vertical member via an extension member of the vertical member. Such a clamping mechanism is “U”-shaped and has a plurality of threaded bores formed therein.
A plurality of fasteners is threadably affixed with the bores respectively. Of course, such fasteners can be produced in a variety of shapes and sizes, as is obvious to a person of ordinary skill in the art. The clamp mechanism further includes a plurality of arcuate members adjustably coupled to the fasteners and directly abutted against the stalk of the tree, without the use of intervening elements. Each of such arcuate members includes a shaft rotatably connected directly to a corresponding one of the shafts, without the use of intervening elements. The fasteners define a plurality of sleeves, which is crucial for allowing the shafts to advantageously rotate about a lateral axis while the arcuate members remain disposed at a predetermined vertical height from the ground surface respectively.
The combination of a watering apparatus and a support mechanism in one system provides the unexpected benefit of allowing a user to both water and support a tree using only one associated group of elements within the one system, thereby overcoming prior art shortcomings.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is a side view of a self-watering vertically adjustable tree stand 10 securing a Christmas tree 100 , according to the preferred embodiment of the present invention;
FIG. 2 is a perspective view of a base member 20 with a vertical member 30 embedded thereon having a ground fault circuit interrupter (GFCI) power strip 40 removably attached thereon, according to the preferred embodiment of the present invention;
FIG. 3 is a top view of the base member 20 with the vertical member 30 removably attached thereon having the ground fault circuit interrupter (GFCI) power strip 40 removably attached thereon, according to the preferred embodiment of the present invention;
FIG. 4 is a perspective view of the base member 20 and the vertical member 30 with an adjustable clamping mechanism 96 and a pictorial representation of the placement of a water receptacle 120 , according to the preferred embodiment of the present invention;
FIG. 5 is a perspective view of the self-watering vertically adjustable tree stand 10 , according to the preferred embodiment of the present invention;
FIG. 6 is a side view of the self-watering vertically adjustable tree stand 10 with a transparent view of the water reservoir 130 , channeling tube 136 , and water receptacle 120 , according to the preferred embodiment of the present invention;
FIG. 7 a is a transparent side view of the water receptacle 120 and a float valve 150 having a float 125 with no water 140 residing in said water receptacle 120 , according to the preferred embodiment of the present invention;
FIG. 7 b is a transparent side view of the water receptacle 120 and a float valve 150 having a float 125 with water 140 residing in said water receptacle 120 , according to the preferred embodiment of the present invention;
FIG. 8 is a top close-up view of the clamping mechanism 96 securing cross-section of a tree stalk 105 thereof, according to the preferred embodiment of the present invention; and,
FIG. 9 is a side view of a rubber-coated member 115 and the insertion thereinto a winged screw 110 , according to the preferred embodiment of the present invention.
DESCRIPTIVE KEY
10
self-watering vertically adjustable tree stand
20
base
25
rubber feet
30
vertical member
40
ground fault circuit interrupter power strip
45
female adapter
46
cord
47
plug
48
plug prongs
55
extension member
56
pin aperture
57
receiving aperture
90
projection pin
95
support member
96
clamping mechanism
98
washer
99
shaft
100
Christmas tree
103
bore
105
tree stalk
110
winged screw
115
rubber-coated member
120
water receptacle
125
float
126
screw
130
water reservoir
135
lid
136
tube
137
protrusion
138
chain
140
water
145
extended arm
150
float valve
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 9 . However, the invention is not limited to the described embodiment and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention, and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
The present invention describes an apparatus and method that incorporates a self-watering, vertically adjustable tree stand. The self-watering vertically adjustable tree stand (herein described as the “apparatus”) 10 comprises a base 20 , a vertical member 30 , a water receptacle 120 , a clamping mechanism 96 , a water reservoir 130 , a ground fault circuit interrupter (GFCI) power strip 40 , and a means for attachment of said components.
Referring now to FIGS. 1 through 3 , pictorial representations of the apparatus 10 and a portion of the components according to the preferred embodiment of the present invention, is disclosed. A base member 20 of circular design is envisioned to support the apparatus 10 before, during, and after securing a Christmas tree 100 . The base 20 comprises a circular framework having an overall diameter sizable to accommodate the weight of the apparatus 10 and the tree 100 . The base 20 comprises a rectangular cross-section in a coplanar format with a reasonably dense thickness for optimum stability and strength capabilities. The bottom of the base 20 is envisioned to comprise a plurality of removably attachable rubber feet 25 for the minimization of damage done to rugs, hardwood floors, ceramic floors, or other floors. The feet 25 are envisioned to be fabricated of a hard rubber and may be attached thereto the bottom surface of the base 20 to protect the floor from scraping, scratching, rubbing, and the like against the desired floor surface while preventing sliding of the apparatus 10 .
The base member 20 comprises a vertical member 30 removably attached thereto, envisioned to comprise a circular cross-sectional tubing, projecting vertically upwards at a designated distance. The vertical member 30 can be welded, bolted, or otherwise permanently fixed transversally thereto the axial plane of the base 20 ; however, it is preferred if the vertical member 30 to be temporally affixed thereto the base 20 . The vertical member 30 comprises an upper end and a lower end thereof such that the lower end is detachably affixed thereto the base 20 thereof. The lower end is centrally positioned thereon the base 20 having the diameter preferably the same as the base 20 thickness for optimal stabilization. The upper end comprises an extension member 55 having a support aperture 57 receiving and accepting a support member 95 having a clamping mechanism 96 described in more detail subsequently.
A ground fault circuit interrupter (GFCI) power strip 40 is removably attached thereto the upper portion of the vertical member 30 to provide an electric power source to electrically power decorative lights and/or other ornamentation. The GFCI power strip 40 has a rectangular face comprising two (2) to four (4) openings or female adapters 45 embedded on the face in electrical communication with a power supply. The female adapter 45 is adapted to except and retain prongs 48 of an electric plug 47 , from decorative lights for example, and maintain electrical continuity. The GFCI power strip 40 comprises a cord 46 with a plug 47 electrically connected at the distal end thereof. The GFCI power strip 40 operates from an AC or DC input voltage power source preferably having remote reset capability to provide protection for the power supply and against user injury. The cord 46 extends downwardly and may be affixed to the vertical member 30 via ties, binding, string, or other suitable means such to prevent entanglement of the cord 46 .
Referring now to FIGS. 4 through 6 , pictorial representations of the apparatus 10 and a portion of the components according to the preferred embodiment of the present invention, is disclosed. A water receptacle 120 is removably attached thereto a stalk 105 of a desired Christmas tree 100 . The water receptacle 120 , envisioned to be fabricated brass coupling, which is dense, corrosion resistant, inexpensive, and readily available, has a diameter considerably larger than that of a conventional tree 100 such to encircle the stalk 105 of said tree 100 while leaving sufficient space to contain water 140 and to allow a user put in additives such as vitamins, preservatives, and the like. The water receptacle 120 comprises a screw 126 or nail welded thereon the base surface of the receptacle 120 . The receptacle 120 is designed as a one-piece component being leak-proof while keeping the minimum system water level 140 above the tree stalk 105 cut, insuring the tree stalk 105 is always in the water 140 . The water level 140 will typically be approximately one (1) to three (3) inches from the base of the stalk 105 such that it will remain immersed for adequate consumption for a live tree 100 . The removability features of the water receptacle 120 permit the occasional discarding of water 140 which may become dirty and somewhat stagnant.
The reservoir 130 is envisioned to be designed in a cylindrical format capable of holding a sufficient amount of water 140 to supply the water receptacle 120 with the necessary water 140 . The reservoir 130 is designed to be leak-proof while being unobstructive having a lid 135 to fit snuggly thereon the upper surface without having a seal, allowing the necessary pressure equalization to occur. The lid 135 protects from outside substances (i.e. pine needles) undesirably from traveling within the reservoir 130 while preventing spillage of water 140 residing therewithin. The lid 135 could be screwed threaded or could be simply a friction fit on the reservoir 130 .
The reservoir 130 will have a height sufficient to contain a water level 140 high enough to permit the flow of water 140 to the receptacle 120 . The size of the reservoir 130 will vary depending on the size of the tree 100 to be withheld. The reservoir 130 is capable of containing a sufficient amount of water 140 while still delivering a certain amount of water 140 to the receptacle 120 until the receptacle 120 is containing a sufficient amount of water 140 . The reservoir 130 is at a higher elevation therefrom the receptacle 120 thereby providing positive water 140 pressure thereto said reservoir 130 without the opportunity of the “old” water 140 in the receptacle 120 to flow backwardly and upwardly towards the reservoir 130 thereby providing clean water 140 therewithin. The receptacle 120 and/ reservoir 130 may be of plastic or glass such to contain transparent or translucent qualities so the amount of water 140 left residing therewithin may be easily discernible.
The base of the reservoir 130 comprises a fluid dispersing aperture (not pictured) to which the water 140 exits therethrough to a tube 136 . A flexible tube 136 of certain diameter, preferably, but not essentially, one-fourth (¼) of an inch, delivers the water 140 from the reservoir 130 to the receptacle 120 . The tube 136 comprises a fluid dispersing end which is in fluid communication with the receptacle 120 and a fluid receiving end which is in fluid communication with the fluid dispersing aperture of the reservoir 130 . Both ends of the tubing 136 , the fluid receiving end and the fluid dispersing end is connected and sealed to the fluid receiving aperture of the receptacle 120 and the fluid dispersing aperture of the reservoir 130 . The tube 136 allows a continuously inter-connection of the reservoir 130 and receptacle 120 water-sealed thereby preventing leakage. The tube 136 may be transparent or translucent such to permit a user to observe that the reservoir 130 and the receptacle 120 are continuously inter-connected. The tube 136 is long enough to span across the reservoir 130 thereto the receptacle 120 with ample excess remaining should additional tubing 136 be needed.
The reservoir 130 is secured thereon a support member 95 via a strapping mechanism preferably a chain 138 having links, as depicted in the figures. The strapping mechanism may be any other device suitable to secure and withstand the weight of the reservoir 130 and the water 140 residing therewithin. Protruding members 137 allow the points of connection of the chain 138 . The chain 138 is attached on two (2) sides of the outer diameter of the reservoir 130 preferably 180° apart thereof. The upward tension on the chain 138 , exerted by the weight of the reservoir 130 and water 140 stabilizes the chain 138 tightly against the support member 95 which allows the chain 138 to support the weight of the reservoir 130 and water 140 . The reservoir 130 may comprise a handle (not pictured) thereupon the surface so it can be easily moved and/or refilled.
Referring now to FIGS. 7 a and 7 b , transparent side views of the water receptacle 120 and a float valve 150 having a float 125 according to the preferred embodiment of the present invention, is disclosed. The receptacle 120 comprises a float valve 150 utilized as a mechanical electrical which operates having a float 125 to raise when the water level 140 goes up, as depicted in FIG. 7 b , and drop when the water level 140 goes down, as depicted in FIG. 7 a , with respect to a specified level. The float valve 150 is a mechanical feedback mechanism in fluid communication with the fluid receiving aperture of the tube 136 to regulate the water level 140 therewithin the receptacle 120 via a float 125 to drive an inlet valve such that a higher water level 140 will force the valve 150 closed whilst a lower water level 140 will force the valve 150 open. Thus, the float valve 150 will allow a predetermined level of water 140 to enter the receptacle 120 , thereby shutting off the water supply 140 , the water reservoir 130 . The float 125 , fabricated of a buoyant material, is free to move up and down according to the level of water 140 and is mounted thereupon an extended shaft arm 145 at the distant end.
The extended arm 145 withholds the weight of the float 125 thereby absorbing the force due to buoyancy from the float 125 and causing the extended arm 145 to pitch. Upward movement of the float 125 causes the extended arm 145 to pitch upwardly to close the float valve 150 and to stop the flow of water 140 , while downward movement of the float 125 causes the extended arm 145 to pitch downwardly to open the float valve 150 and to permit the flow of water 140 therein.
It will be appreciated to those skilled in the art that other float valve 150 designs may also be used in accordance with the invention to permit the automatic control of water flow 140 without intervening with the scope of the invention.
Referring now to FIG. 8 , a top close-up view of the clamping mechanism 96 securing a tree stalk 105 thereof according to the preferred embodiment of the present invention, is disclosed. A support member 95 is adjustably and perpendicularly mounted to the vertical member 30 via an extension member 55 permanently and perpendicularly integrated thereon the uppermost portion of said vertical member 30 . The vertical member 30 may bend perpendicularly such to provide the extension member 55 or the extension member 55 may be later installed thereupon the vertical member 30 at the uppermost edge.
The support member 95 is provided to provide support for the Christmas tree 100 and help maintain the upright position of the tree 100 . The extension member 55 is envisioned to have an opened end 57 such to slidably receive the support member 95 . The extension member 55 and the support member 95 are envisioned to comprise a circular cross-section, preferably tubular having the extension member 55 with a larger diameter than the support member 95 such that the inner diameter of said extension member 55 is similar or slightly larger than the outer diameter of said support member 95 .
The support member 95 has a first and second end comprising a circular cross-section, preferably tubular shaped to correspondingly be inserted therewithin the extension member 55 such that the inside walls of the extension member 55 uniformly abuts against the outside walls of the support member 95 . The support member 95 is sized to slidably move in a lateral direction within the extension member 55 . The extension 55 and support 95 members each have a contact surface having a plurality of apertures 56 equally spaced therethrough said surface. The apertures 56 are drilled therethrough the extension member 55 for selectively receiving a projection pin 90 to secure the relative position of the support member 95 . The apertures 56 are selectively alignable with the projection pen, and then fastenable with said projection pin 90 .
Referring now to FIG. 9 , a side view of the rubber-coated member 115 and the insertion thereinto a winged screw 110 according to the preferred embodiment of the present invention, is disclosed. The support member 95 comprises a clamping mechanism 96 for the proper secure the placement of the stalk 105 of a tree 100 in an upright position perpendicularly with respect to the ground or other horizontal surface. The clamping mechanism 96 is envisioned to be “U” shaped with a plurality of bores 103 with threads incorporated therewithin each to operably engage and receive a threaded screw 110 .
The two (2) threaded winged screws 110 are utilized to secure the stalk 105 of the tree 100 within said clamping mechanism 96 . The threaded screws 110 comprise a rubber-coated member 115 incorporated at the distal end shaped much like a “U”. The rubber-coated member 115 is slightly contoured and rounded to abut thereagainst the stalk 105 of the tree 100 . The rubber-coated member 115 is envisioned to comprise a shaft 99 to be operably received therewithin a bore or the like (not pictured) centered in the winged screws 110 with a washer 98 abutting thereagainst the rubber member 115 .
The winged screw 110 acts like a sleeve or the like to allow rotatable motion of the rubber-coated member 115 and/or shaft 99 about the lateral axis I-I, without the longitudinal movement of said rubber-coated member 115 and shaft 99 , as depicted in FIG. 9 . The rubber-coated members 115 are designed specifically to completely or partially encircle the stalk 105 of the tree 100 above the central point of the base 20 thereby securing the tree 100 with a center of gravity on or in close proximity to the center of the base 20 thereby providing optimum stability. The rubber-coated members 115 have an adjustable opening for receiving and securing the stalk 105 of the tree 100 . Said opening may be expanded by the utilization of the two (2) winged screws 110 mirrored equidistantly therefrom the axis of the support member 95 . The winged screws 110 bring the rubber-coated members 115 closer together for trees 100 whose stalks 105 comprise a relatively small diameter. On the contrary, the opposite applies for those stalks 105 which comprise a relatively large diameter, to which case, the screws 110 may bring the rubber-coated members 115 outwardly further apart thereby providing a wide range of opening space for larger and/or unsymmetrical stalks 105 .
The threaded screws 110 are inserted therewithin the clamping mechanism 96 comprising two (2) apertures defining bores for rotatably accepting said screws 110 so that the rubber coated member 115 may be abutting thereagainst the stalk 105 of the tree 100 in order for securely holding said tree 100 . The rubber-coated members 115 are envisioned to conform thereto the outer periphery of the stalk 105 of the tree 100 without puncturing said stalk 105 . The rubber material provides a frictional force against the stalk 105 for optimum holding stability capabilities. Further, the rubber-coated member 115 is envisioned to be rotatable and/or pivotable along the lateral axis, I, of the threaded screws 110 , as depicted in FIG. 9 , to provide adjustments as needed. The rotatable and/or pivotable rubber-coated member 115 allows said member 115 to adjust accordingly thereby providing a wide range of securing features for trees 100 comprising symmetrical or unsymmetrical stalks 105 . Alternate fastening mechanisms may be used.
An alternate embodiment of the present invention 10 may disclose alternate fixing means for the support member 95 to be adjustably slidably received therewithin the extension member 55 . The extension 55 and support 95 members may each have a contact surface having a plurality of matching and transverse apertures 56 equally spaced therethrough two (2) surfaces spaced 180 therefrom each other such to receive a through pin 90 . The transverse apertures of the support member 95 correspondingly match with the matching apertures 56 of the extension member 55 which may be selectively aligned and secured with the through pin to fix the relative position of the support member 95 . The through pin will be inserted therethrough the matching aperture 56 on the upper surface of the extension member 55 , therethrough the transverse aperture on the upper surface of the support member 95 , therethrough the transverse aperture on the lower surface of the support member 95 , and therethrough the matching aperture on the lower surface of the extension member 55 . Yet further, the present invention 10 may disclose a supporting member 95 that comprises a pivot point with a position pin inserted through one of the pivot position holes. Thus the support arm 95 may pivot sideways, downwardly, and/or upwardly.
Another alternate embodiment of the present invention 10 may disclose an adjustable vertical member 30 of telescoping construction so that the apparatus 10 may be adjusted in height. The vertical member 30 may be designed in sections such that each section is slightly smaller than the next such that the sections may be slid within one another so that the overall height of the apparatus 10 may be varied. Alternately, the vertical member 30 may contain apertures 56 for receiving a projection pin 90 or a through pin similar to the method used for the adjustable attachment of the extension member 55 and support member assembly 95 aforementioned.
Yet another alternate embodiment of the present invention 10 may disclose a decorative design with the colors symbolizing the time of the season with or without decorative motifs thereupon.
Still yet another alternate embodiment of the present invention 10 may disclose a support arm or the like integrally connected thereto the water receptacle 120 for further stabilization of the tree 100 . Said support arm may comprise adjustment means such that it may adjustably and slidably move upwardly and downwardly along the vertical member 30 and releasably secured in a desired position thereon said vertical member 30 utilizing a clamping mechanism or the like.
Yet still another alternate embodiment of the present invention 10 may utilize a float switch having a float 125 connected to an extended shaft of a determined weight. Once the water level 140 reaches a certain height, the float 125 and the extended shaft closes a circuit which either closes a valve. This may be done with a ball valve with an electromechanical actuator to effect a positive shut-off when the water 140 reaches a certain height; however, other valves or a solenoid may be utilized. The float switch would sense the level of water 140 within the receptacle 120 to activate a valve producing discrete outputs as the water 140 reaches many different levels within the receptacle 120 and actuates a micro-switch designed to be actuated by the physical motion of a mechanical device.
The preferred embodiment of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the self-watering, vertically adjustable tree stand 10 , it would be configured as indicated in FIGS. 1 through 9 .
The method of utilizing the device may be achieved by performing the following steps: securing the rubber feet 25 thereon the underside surface of the circular base 20 via screws, bolts, nuts, or other fastening means; securing the vertical member 30 perpendicularly thereon the base 20 with an extension member 55 protruding in a parallel arrangement therewith the floor; filling the water reservoir 130 therewith water 140 with or without additives therein; closing the lid 135 thereon the water reservoir 130 ; slidably attaching the support member 95 therein the extension member 55 until a designated position is achieved and locked via a projection pin 90 therethrough an aperture 56 ; attaching the reservoir 130 thereto the support member 95 via a chain 138 or other attachment means; fluidly attaching the float valve 150 and float 125 thereto the fluid receiving end of the receptacle 120 ; rotatably screwing the water receptacle 120 thereon the stalk 105 via a welded screw 126 positioned at the base of said receptacle 120 ; inserting the tree stalk 105 therein the clamping mechanism 96 ; securing said tree stalk 105 via rotatably screwing the screws 110 until the contoured rubber-coated members 115 are abutted thereagainst said tree stalk 105 ; fluidly attaching the tube 136 thereto the water reservoir 130 and/or water receptacle 120 , if needed; and, utilizing the GFCI power strip 40 to power the holiday decor.
The apparatus 10 is envisioned to come in a variety of sizes and utilized to securely hold a Christmas tree 100 at various specified distances from the floor later to be determined to allow a storage area for gifts and/or decorations under the tree 100 . The components of the apparatus 10 provide minimum storage space with the support member 95 , vertical member 30 , water receptacle 120 , and the water reservoir 130 being unattachably secured. The apparatus 10 or portions of the apparatus 10 may be decorative to resemble the holidays. The apparatus 10 may further disclose the securement and watering of other trees 100 not prone to the holidays. The apparatus 10 may be used to water other plants and/or animals. Because the water receptacle 120 and water reservoir 130 are envisioned to fabricated of plastic, they can be colorful and decorative being transparent, translucent, or opaque. The water receptacle 120 receives water 140 therefrom a water reservoir 130 . The water level 140 can likewise be checked either by lifting the lid 135 of the reservoir 130 , if not of transparent or translucent qualities, observing the water flow 140 therethrough the tube 136 , and/or observing the water receptacle 120 , if needed. The water level 140 is specifically maintained via a horizontal float valve 150 .
The reservoir 130 is located at an easily accessible point away from the tree 100 . The vertical member 30 is positioned at a reasonable distance away from the tree 100 such to prevent obstruction to the tree 100 and/or the decorations laid upon the tree 100 .
The water 140 flows from the reservoir 130 into the receptacle 120 via a tube 136 . As the water level 140 in the receptacle 120 rises, the buoyancy causes the float 125 to rise. The buoyancy exerted by the float 125 is reflected upon the extended arm 145 to which closes and seals the float valve 150 . As the water level 140 lowers in the receptacle 120 due to evaporation and absorption, the float 125 lowers accordingly eventually resulting in a buoyancy force no longer acting upon the float 125 and the extended arm 145 respectfully. The valve 150 is then opened to allow water 140 to flow from the reservoir 130 to the receptacle 120 . This cycle is repeated continuously and automatically until the apparatus 10 is not longer of use for the holidays.
As a result of evaporation and the absorption of water by the tree 100 , the water level 140 in the water receptacle 120 lowers. Float 125 lowers accordingly. With the force due to buoyancy of float 125 no longer acting upon the extended arm 145 , the float valve 150 opens. Water 140 again flows from the water reservoir 130 , through the tube 130 , and into the water receptacle 120 , and the cycle is repeated.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention and method of use to the precise forms disclosed. Obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application, and to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions or substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.
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The invention as presently conceived discloses a unique system and method that incorporates a self-watering tree stand that is an improvement on a conventional floor-standing holiday tree stand and watering system. The design of this novel tree stand is that it supports the tree from the tree's midsection that allows gravity to self-level the tree held within the stand. The stand comprises a large circular base for stability as well as adjustable height watering cup that can be brought up to the bottom of the tree and is fed from a water reservoir located on the vertical section of the stand at the outside perimeter of the tree. Also integral to the system and apparatus is a power receptacle fed from a power cord located near the top of the stand in order to power decorative lights or other electric tree decorations.
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BACKGROUND OF THE INVENTION
[0001] This invention generally relates to medical devices, and particularly to intracorporeal devices for therapeutic or diagnostic uses such as balloon catheters, and vascular grafts.
[0002] In percutaneous transluminal coronary angioplasty (PTCA) procedures, a guiding catheter is advanced until the distal tip of the guiding catheter is seated in the ostium of a desired coronary artery. A guidewire, positioned within an inner lumen of a dilatation catheter, is first advanced out of the distal end of the guiding catheter into the patient's coronary artery until the distal end of the guidewire crosses a lesion to be dilated. Then the dilatation catheter having an inflatable balloon on the distal portion thereof is advanced into the patient's coronary anatomy, over the previously introduced guidewire, until the balloon of the dilatation catheter is properly positioned across the lesion. Once properly positioned, the dilatation balloon is inflated with fluid one or more times to a predetermined size at relatively high pressures (e.g. greater than 8 atmospheres) so that the stenosis is compressed against the arterial wall and the wall expanded to open up the passageway. Generally, the inflated diameter of the balloon is approximately the same diameter as the native diameter of the body lumen being dilated so as to complete the dilatation but not overexpand the artery wall. Substantial, uncontrolled expansion of the balloon against the vessel wall can cause trauma to the vessel wall. After the balloon is finally deflated, blood flow resumes through the dilated artery and the dilatation catheter can be removed therefrom.
[0003] In such angioplasty procedures, there may be restenosis of the artery, i.e. reformation of the arterial blockage, which necessitates either another angioplasty procedure, or some other method of repairing or strengthening the dilated area. To reduce the restenosis rate and to strengthen the dilated area, physicians frequently implant a stent inside the artery at the site of the lesion. Stents may also be used to repair vessels having an intimal flap or dissection or to generally strengthen a weakened section of a vessel. Stents are usually delivered to a desired location within a coronary artery in a contracted condition on a balloon of a catheter which is similar in many respects to a balloon angioplasty catheter, and expanded to a larger diameter by expansion of the balloon. The balloon is deflated to remove the catheter and the stent left in place within the artery at the site of the dilated lesion. Stent covers on an inner or an outer surface of the stent have been used in, for example, the treatment of pseudo-aneurysms and perforated arteries, and to prevent prolapse of plaque. Similarly, vascular grafts comprising cylindrical tubes made from tissue or synthetic materials such as polyester, expanded polytetrafluoroethylene, and DACRON may be implanted in vessels to strengthen or repair the vessel, or used in an anastomosis procedure to connect vessels segments together.
[0004] To facilitate placement of the catheter at the desired location in the patient's vasculature, X-ray opaque (i.e., radiopaque) material is generally provided on conventional angioplasty catheters so that the physician can view the catheter under fluoroscopy. The radiopaque material is typically a metal marker band on the catheter shaft. For example, two marker bands on the inner tubular member of the shaft are typically provided, to indicate the proximal end and distal end of the working length of the balloon. Blending radiopaque material into the polymer matrix of the catheter components has been suggested as an alternative to radiopaque marker bands on the catheter shaft. Additionally, catheters visible to magnetic resonance imaging (MRI), also known as nuclear magnetic resonance (NMR) imaging systems have been suggested for use during MRI scans of a patient. MRI scans are used provide two-dimensional sectional images of a patient's internal body structures without exposing the patient to harmful radiation.
[0005] It would be a significant advance to provide catheter balloon or other medical device or component thereof with improved visibility within the patient.
SUMMARY OF THE INVENTION
[0006] This invention is directed to medical devices or components thereof, and particularly intracorporeal devices for therapeutic or diagnostic uses, which are formed at least in part of a polymeric material and a ferromagnetic or paramagnetic material, so that the medical device or component thereof is visible on magnetic resonance imaging (MRI) scans. In one embodiment, the medical device is a balloon catheter having an MRI visible balloon. While discussed below primarily in terms of a catheter balloon, it should be understood that the invention includes additional MRI visible medical devices or components thereof, and particularly expandable or inflatable members.
[0007] In a presently preferred embodiment, the MRI visible material is a ferromagnetic material, and a presently preferred ferromagnetic material is iron oxide, due to the ease of compounding iron oxide in the polymeric balloon material, the relative ease of dispersing in many types of balloon materials, and the lack of a magnetic field orientation effect in which the MRI image varies depending on the orientation of the medical device or component thereof. Preferably, a background is provided by a contrast solution within and/or around the balloon, such as the MRI visible bright/white background of a Gadolinium solution, to facilitate viewing the ferromagnetic containing balloon. A balloon with iron oxide present in the balloon wall in a concentration of about 5% is readily visible as a dark image in a bright background of a 1:10 Gadolinium contrast solution. A variety of suitable ferromagnetic materials can be used including iron, nickel and cobalt, and compounds thereof such as iron oxide, typically in the form of a fine powder. In one embodiment, the preferred MRI visible materials have hydrating power (i.e., they are present in a hydrated state), which facilitates MRI visibility. For example, in one embodiment, a proton donating fluid at the device or component is not required in order to produce the MRI image. In an alternative embodiment, the MRI visible material may be a paramagnetic material, preferably provided that magnetic field orientation effects are minimal or nonexistent. In one embodiment, the paramagnetic material is selected from the group consisting of dysprosium, gadolinium, chromium, copper, manganese, and vanadium, and compounds thereof such as dysprosium oxide.
[0008] The MRI visible materials suitable for use in the invention may be radiopaque in addition to being MRI visible. However, in a presently preferred embodiment, there is an insufficient amount of the ferromagnetic or paramagnetic material in or on the balloon wall to make the balloon radiopaque. The ferromagnetic or paramagnetic material does not have a disadvantageous effect on the strength and compliance of the balloon, unlike prior art catheter balloons in which it was proposed to make the balloon radiopaque by forming the balloon of a blend of polymeric and radiopaque materials. Specifically, such prior art catheter balloons would require a relatively large amount of radiopaque material to make the balloon radiopaque, which would consequently reduce the strength and effect the compliance of the balloon. Thus, the balloon of the invention, unlike prior art balloons, has an amount of ferromagnetic or paramagnetic material which is sufficient to make the balloon MRI visible but insufficient to make the balloon radiopaque, and does not have a radiopaque material (either the ferromagnetic or paramagnetic material, or a separate radiopaque material) in sufficient amounts to make the balloon radiopaque. Consequently, the balloon is MRI visible and is not radiopaque in use, and the balloon has excellent performance characteristics such as a relatively high rupture pressure.
[0009] The MRI visible ferromagnetic or paramagnetic material is a solid, typically with a particle size of about 0.01 to about 50 μm. In one embodiment of the invention, the ferromagnetic or paramagnetic material is dispersed in the polymeric material, preferably by compounding the polymeric material with the ferromagnetic or paramagnetic material. The term compounding should be understood to refer to a process in which a high concentration of ingredient(s) is mixed with a specific polymer to form a master batch. This master batch is then added to resin during extrusion to obtain a uniform dispersion of a desired concentration. As a result, the ferromagnetic material is typically located uniformly throughout the polymeric wall of the balloon as discrete particles of material. Alternatively, in another embodiment, the ferromagnetic or paramagnetic material is a coating on a surface of the polymeric wall of the balloon. The balloon may be a single layered balloon, or alternatively, may comprise multiple layers, at least one of which has the ferromagnetic or paramagnetic material therein or thereon. The multiple layers are preferably coextruded, although they may alternatively be separately extruded and then placed together. In one embodiment, the balloon has a first polymeric layer, and a second polymeric layer coextruded with the first layer and containing the ferromagnetic or paramagnetic material therein. In one embodiment, the second layer is an inner layer, to minimize any microbiological or other effects of the ferromagnetic or paramagnetic material on the patient.
[0010] The balloon may be detectable when viewed by magnetic resonance imaging as a dark image or alternatively as a bright image, depending on the nature of the MRI visible material forming the balloon. In a presently preferred embodiment, the MRI visible layer extends the entire length of the balloon. However, the ferromagnetic or paramagnetic material may be present in sections of the balloon covering less than the entire area of the balloon, including sections spaced apart along the length or around the circumference of the balloon.
[0011] In a presently preferred embodiment, the MRI visible medical device or component thereof is configured to be expandable or inflatable. It is particularly important to avoid disadvantageous effects on the strength of expandable or inflatable members, such as catheter balloons and vascular grafts, because the members are required to not tear or burst during expansion thereof. Thus, the relatively low loading of ferromagnetic or paramagnetic material, in accordance with the invention, is particularly advantageous in expandable or inflatable members.
[0012] The medical device or component thereof may comprise a variety of devices, including a vascular graft, a stent cover, and an intravascular catheter component, for a variety of clinical applications including coronary, peripheral, and neurological applications. Stent covers and vascular grafts of the invention generally comprise a tubular body formed at least in part of polymeric material and the ferromagnetic or paramagnetic material. The terminology vascular graft as used herein should be understood to include grafts and endoluminal prostheses which are surgically attached to vessels in procedures such as vascular bypass or anastomosis, or which are implanted within vessels, as for example in aneurysm repair or at the site of a balloon angioplasty or stent deployment. A balloon catheter of the invention, such as an angioplasty dilatation catheter or a stent delivery catheter, generally comprises an elongated shaft with at least one lumen and balloon on a distal shaft section with an interior in fluid communication with the at least one lumen. A wall of the catheter balloon, or a separate sheath member on an outer surface of the balloon, may be MRI visible in accordance with the invention.
[0013] The balloon, or other medical device or component thereof, of the invention has improved MRI visibility due to the ferromagnetic or paramagnetic material, without a disadvantageous effect on strength or compliance of the balloon. Additionally, radiopaque marker bands are not required on the balloon catheter of the invention for visualization of the balloon location in the patient. As a result, the distal section of the balloon catheter is more flexible and has a smaller profile for improved tracking compared to conventional balloon catheters. These and other advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying exemplary drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an elevational view, partially in section, of a stent delivery balloon catheter having a covered stent on the catheter balloon, which embodies features of the invention.
[0015] FIG. 2 is a transverse cross-section of the catheter shown in FIG. 1 taken at line 2 - 2 .
[0016] FIG. 3 is a transverse cross-section of the catheter shown in FIG. 1 taken at line 3 - 3 , showing the covered stent disposed over the inflatable balloon.
[0017] FIG. 4 is an elevational view, partially in section, of a vascular graft or stent cover which embodies features of the invention.
[0018] FIG. 5 is a transverse cross-section of the graft or cover shown in FIG. 4 , taken along lines 5 - 5 .
DETAILED DESCRIPTION OF THE INVENTION
[0019] FIGS. 1-3 illustrate an over-the-wire type stent delivery balloon catheter 10 embodying features of the invention. Catheter 10 generally comprises an elongated catheter shaft 12 having an outer tubular member 14 and an inner tubular member 16 . Inner tubular member 16 defines a guidewire lumen 18 adapted to slidingly receive a guidewire 20 , and the coaxial relationship between outer tubular member 14 and inner tubular member 16 defines annular inflation lumen 22 (see FIGS. 2 and 3 , illustrating transverse cross sections of the catheter 10 of FIG. 1 , taken along lines 2 - 2 and 3 - 3 respectively). An inflatable balloon 24 is disposed on a distal section of catheter shaft 12 . Balloon 24 has a proximal shaft section sealingly secured to the distal end of outer tubular member 14 and a distal shaft section sealingly secured to the distal end of inner tubular member 16 , so that its interior is in fluid communication with inflation lumen 22 . An adapter 26 at the proximal end of catheter shaft 12 is configured to provide access to guidewire lumen 18 , and to direct inflation fluid through arm 28 into inflation lumen 22 . Balloon 24 has an inflatable working length located between tapered sections of the balloon. An expandable stent 30 is mounted on the balloon working length, with a stent cover 40 on an outer surface of the stent 30 . FIG. 1 illustrates the balloon 24 in an uninflated configuration prior to deployment of the stent 30 . The distal end of the catheter may be advanced in a conventional manner to a desired region of a patient's vessel 32 defining a body lumen, and balloon 24 inflated to expand stent 30 , thereby implanting the stent in the body lumen.
[0020] The balloon 24 is formed of a polymeric material and an amount of ferromagnetic or paramagnetic material which is sufficient to make the balloon MRI visible and insufficient to make the balloon radiopaque within the patient. The ferromagnetic or paramagnetic material is preferably dispersed in the polymeric material forming the balloon wall, and in a presently preferred embodiment, the dispersed material is a ferromagnetic material. In the embodiment illustrated in FIG. 1 , the balloon comprises an outer layer 33 and an inner layer 34 , at least one of which is formed of the polymeric material/ferromagnetic or paramagnetic dispersion. The outer and inner layers 33 / 34 may be formed of the same polymeric material or different polymeric materials. A variety of suitable polymeric materials may be used to form the balloon, conventional in medical device balloon construction, including polyamides such as nylon 11 or nylon 12, copolyamides such as polyether block amide (PEBAX), copolyesters such as HYTREL or ARNITEL.
[0021] In a presently preferred embodiment, the amount of ferromagnetic or paramagnetic material is about 1% to about 30%, preferably about 5% to about 20%, by weight of the polymeric material/ferromagnetic or paramagnetic material dispersion, depending on the magnetic field strength, gradient field strength, and pulse sequences of the MRI system being used, as well as the clinical application of the catheter. The preferred percentages are for a multilayered balloon with a first layer formed of the MRI visible material dispersed in a polymer (i.e., the MRI visible layer), and a second layer free of the ferromagnetic or paramagnetic material. In an alternative embodiment in which the balloon is a single layered balloon (not shown) formed of the MRI visible material dispersed in a polymer, the concentration of ferromagnetic or paramagnetic material is typically lower, as for example about 50% lower than the above values for a single layered balloon having a wall thickness about 50% greater than the wall thickness of the MRI visible layer of the multilayered balloon. Applied as a coating, the ferromagnetic or paramagnetic material is preferably about 10% to about 20% or more by weight of the balloon.
[0022] The balloon 24 has a rupture pressure of about 200 to about 390 psi, preferably about 270 to about 330 psi. The rupture pressure is preferably the same as the rupture pressure of a balloon otherwise identical to the balloon but without the ferromagnetic or paramagnetic material.
[0023] The balloon catheter 10 can be used, for example in a balloon angioplasty procedure or stent deployment to treat a stenosed region of the patient's vasculature. The catheter 10 is introduced into the vessel 32 defining the body lumen, and advanced therein. The balloon is visualized under MRI to position the balloon at the desired location in the body lumen. The balloon is then inflated by introduction of inflation fluid into the balloon interior via the inflation lumen. A contrast solution is typically introduced into the balloon which doubles as the inflation fluid, and around the balloon through the guiding catheter, to enhance visibility of the balloon. A presently preferred contrast solution for a ferromagnetic containing balloon is a paramagnetic containing contrast solution. Because the wall of the balloon can be visualized during inflation thereof, the balloon 24 can be inflated at the site of a lesion in the body lumen to determine information about the lesion as part of a MRI diagnostic procedure. Specifically, for example, the compliance of the lesion to the inflated balloon can be determine by observing the balloon inflate against the lesion. Following the procedure, the balloon is deflated, and the catheter repositioned or removed from the patient.
[0024] Co-extruded balloon tubing, formed of a 20 wt % dispersion of iron oxide in a PEBAX 72D or Nylon 12 polymeric material as the inner layer of the multilayered balloon with a PEBAX 72D outer layer, was blow molded to form a balloon. The iron oxide particles had a particle size of about 0.01 μm. The balloon had a dual wall thickness of about 40 μm, and a burst pressure of about 250 psi to about 300 psi. The balloon was inflated at an inflation pressure of about 116 psi to about 150 psi to an inflated diameter of 3 mm, and MRI images of the inflated balloon were obtained at a field strength of 1.5 Tesla. A 1% to 10% Gadolinium solution in water is preferably used as a contrast solution within and/or around the balloon to enhance the visibility of the iron oxide containing balloon.
[0025] To the extent not discussed herein, the various catheter components can be formed conventionally of materials commonly used in catheter construction. The balloon 24 is typically secured to the catheter shaft as is conventionally known by adhesive or fusion bonding.
[0026] The dimensions of catheter 10 are determined largely by the size of the guidewires to be employed and the size of the artery or other body lumen through which the catheter must pass or the size of the stent being delivered. The outer tubular member 14 typically has an inner diameter of about 0.015 to about 0.035 inch (0.038 to 0.089 cm), usually about 0.03 inch (0.076 cm). The inner tubular member 16 typically has an outer diameter of about 0.012 to about 0.016 inch (0.030 to 0.041 cm), usually about 0.014 inch (0.036 cm). The overall working length of the catheter 10 may range from about 100 to about 150 cm, and is typically about 135 cm. Preferably, balloon 24 has a length about 0.5 cm to about 6 cm and typically about 2 cm, and an inflated working diameter of about 1 to about 8 mm, typically about 3 mm.
[0027] FIGS. 4 and 5 illustrate another embodiment of the invention, in which the expandable MRI visible medical device is a vascular graft 50 . The vascular graft 50 generally comprises a tubular body 51 formed at least in part of a polymeric material and a ferromagnetic or paramagnetic material in accordance with the invention, having a lumen 52 therein and ports 53 , 54 at either end of the graft 50 . The graft 50 is configured for being implanted in the patient, and it may be expanded into place within a vessel, or surgically attached to a vessel such as to a free end or a side wall of a vessel. The graft 50 length is generally about 4 to about 80 mm, and more specifically about 10 to about 50 mm, depending on the application, and single wall thickness is typically about 40 μm to about 2000 μm, preferably about 100 μm to about 1000 μm. The diameter is generally about 1 to about 35 mm, preferably about 3 to about 12 mm, depending on the application. Stent cover 40 is similar to vascular graft 50 , except it is on a stent as illustrated in FIG. 1 .
[0028] While the present invention is described herein in terms of certain preferred embodiments, those skilled in the art will recognize that various modifications and improvements may be made to the invention without departing from the scope thereof. For example, in the embodiment illustrated in FIG. 1 , the catheter is over-the-wire stent delivery catheter. However, one of skill in the art will readily recognize that other types of intravascular catheters may be used, such as rapid exchange balloon catheters having a distal guidewire port and a proximal guidewire port and a short guidewire lumen extending between the proximal and distal guidewire ports in a distal section of the catheter. Additionally, although the balloon catheter illustrated in FIG. 1 is a stent deploying catheter, a variety of balloon catheters may be used including dilatation balloon catheters. Moreover, although individual features of one embodiment of the invention may be discussed herein or shown in the drawings of the one embodiment and not in other embodiments, it should be apparent that individual features of one embodiment may be combined with one or more features of another embodiment or features from a plurality of embodiments.
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Medical devices or components thereof, and particularly intracorporeal devices for therapeutic or diagnostic uses, which are formed at least in part of a polymeric material and a ferromagnetic or paramagnetic material, so that the medical device or component thereof is visible on magnetic resonance imaging (MRI) scans. In one embodiment, the medical device is a balloon catheter having an MRI visible balloon. In a presently preferred embodiment, there is an insufficient amount of the ferromagnetic or paramagnetic material within a wall of the balloon or coated onto a wall of the balloon to make the balloon radiopaque.
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FIELD OF THE INVENTION
This invention relates to structures for railcars such as may be applicable, for example, to the reinforcement of hopper cars. One particular use for the invention is the reinforcement of hopper car roofs.
BACKGROUND OF THE INVENTION
The design of railway hopper cars is governed by three main requirements. First, the fully loaded weight of a 125 ton car must not exceed 315,000 lbs. Thus to maximize useful, load car designers try to minimize car weight. At present an empty grain hopper steel car may typically weigh about 63,000 lbs., such that lading in excess of 50,000 lbs. is permissible. Second, the car must withstand a draft load of 630,000 lbs. Third, the car must not buckle under buff loads of 650,000 to 1,000,000 lbs. when slowing or stopping. Under the first, dead weight, loading condition the car may be modelled as a simply supported hollow beam carrying a distributed vertical load in excess of 50,000 lbs., with a corresponding bending moment distribution. Under the second, tensile draft, and third, compressive buff, loading conditions the car is like a column, taking tensile and compressive loads.
The general structure of contemporary curved-sided hopper cars can be idealized as a load bearing monocoque in the form of a hollow, downwardly opening, generally C-shaped, thin walled, column. At each column end, the load is transferred through a transition structure from the shell into a stub sill and coupler by which the railcar is connected to the next rail car. The challenge in designing the structure for a hopper car, in general, is to reduce the mass of the thin shell, and any supporting structure, to a minimum while still maintaining the structural integrity required to withstand the given loads, and to transfer those loads between the couplers and the body shell. When the shell is made too thin it fails in compression due either to global buckling of the structure, or to the local buckling phenomenon of wrinkling. In such a hollow shell structure, the ability to resist the compressive buff load, without buckling, requires that the principle longitudinal structural components of the car, those being the roof and side walls, work together as a single integrated structure.
One way to reduce the weight of the car is to reduce the thickness of the roof. The thickness of the roof of a typical hopper car is commonly less than 3/16". Given a railcar length of roughly 60 feet and width of roughly 10 feet, the roof may be considered a thin shell structure. Under vertical loading conditions of the car, this thin shell structure is exposed to a compressive load, with a consequent tendency toward buckling or wrinkling. This tendency is increased when a compressive longitudinal load is also applied to the car.
In the past, hopper car roofs have been given an outwardly bulging curved panel form to resist buckling, and have been supported by internal bulkheads or partition sheets, such as disclosed in U.S. Pat. No. 4,275,662 of Adler, issued Jun. 30, 1981. For example, a three hopper rail car generally has two end walls and two intermediate partitions leaving three roof spans each having a length of 15 to 20 feet. The roof is supported along its outboard edges by top chord members frequently in the form of a closed hollow section as depicted, for example, in FIG. 2 of U.S. Pat. No. 4,275,662.
In U.S. Pat. No. 4,377,058 of Hallam et al., issued Mar. 22, 1983 partial, reinforced internal stiffeners, shown as web assemblies 34 and 36, extend internally across the full width of the car and maintain the curvature of the roof In general, internal fittings, and particularly internal welds, tend to be avoided if possible. First, internal welding tends to be more difficult. Second, each additional fitting creates one or more niches in which foodstuffs may collect and rot. Third, it is generally better to leave the inside of the hopper free of obstructions. Where stiffeners are used a common goal is to obtain adequate strength without adding unnecessary weight.
The unsupported spans of hopper car roofs between end walls and bulkheads have a tendency to deflect. In particular, rapid unloading of grain hoper cars is known to cause a partial vacuum inside the car which tends to draw the roof inward. This is more pronounced in grain hopper cars having a continuous, central, longitudinally extending, trough opening. It tends to cause the arcuate shape of the roof section to flatten. This problem worsens as the thickness of the roof material decreases. The central trough may be bordered by a coaming, and the deflection of the roof may tend not only to cause the coaming to deflect, but may also tend to twist the coaming and reduce its ability to strengthen the structure. Consequently as roof thickness is reduced to lower the weight of the car it is desirable to reinforce the roof so that it provides resistance to buckling and to deflection under internal vacuum comparable to a thicker un-reinforced roof It is also advantageous to provide stiffening to maintain a natural frequency comparable to previous roofs, as vibration remains a significant factor in railcar design generally.
In general, it would be advantageous to have, and there has been a long felt need for, an improved hopper car shell structure. To that end, it would be advantageous to have improved reinforcement of a hopper car roof.
SUMMARY OF THE INVENTION
The present invention provides, in one aspect, a reinforcement for an unsupported span of an hopper car roof structure subject to compressive forces applied in a longitudinal direction relative to the hopper car, the span having a desired cross-sectional profile, the reinforcement chosen from the set of reinforcement consisting of (a) a longitudinal beam for forming a border along an unsupported edge of the span, the beam having a first leg rooted to the edge and extending away from the span, said first leg having a distal portion distant from the edge, and a depending leg joined to the distal portion and extending therefrom back toward said span; and (b) an outwardly standing web attachable to the unsupported span, the web having a footprint for mating with at least a portion of the profile of the unsupported span.
In a further feature of that aspect of the invention, the reinforcement is the longitudinal beam extending along the unsupported edge of the span. The beam has a first leg rooted to the edge and extending away from the span. The first leg has a distal portion distant from the edge, and a depending leg joined to the distal portion and extending therefrom back toward the span. The first and second legs are parts of a continuous roll formed section.
In yet a further feature, the longitudinal beam is a roof coaming formed integrally with the roof span. The first leg is an upstanding leg folded upwardly from the span. A rounded coaming is lip formed at the uppermost end of the upstanding leg, and the depending leg is folded downwardly from the lip.
In a second aspect of the invention there is a hopper car roof assembly having a desired roof profile, and having at least one unsupported roof span and a reinforcement attached to the span, the reinforcement having a web upstanding from the span and a footprint attached to at least a portion of the span for maintaining the profile over at least a portion said span.
In an additional feature of that aspect of the invention, the reinforcement has a toe for location adjacent to a longitudinal roof stiffening section, and a heel for location in a position to receive support from a top chord of the hopper car. The footprint is of a length for reinforcing the span between the beam and the section and of a pattern to mate with the roof profile in an orientation chosen from the set of orientations consisting of (i) perpendicularly to the beam; and (ii) at an oblique angle to the beam.
In an alternative feature of that aspect of the invention, the assembly comprises at least two webs attached to the roof in spaced relationship from each other. The webs, in plan view, are oriented transversely to the longitudinal direction in an orientation chosen from the set of orientations consisting of a) parallel to each other and perpendicular to the longitudinal direction; b) parallel to each other and angled obliquely to the longitudinal direction; c) one perpendicular to the longitudinal direction, and the other angled obliquely thereto; and d) one angled obliquely to the longitudinal direction at one angle, and the other angled obliquely at another angle.
In a further aspect of the invention there is a hopper car roof assembly wherein the roof assembly has a pair of opposed outboard edges. The roof is reinforced at each outboard edge by a top chord beam, and has a central trough bounded by a coaming. The roof assembly includes at least two of the reinforcements oriented, in plan view, to extend inwardly of one of the outboard edges toward the coaming in a manner chosen from the set of orientations consisting of (a) perpendicularly to the outboard edge in parallel spaced relationship to each other; (b) obliquely to the outboard edge in offset parallel relationship to each other; (c) one extending perpendicularly to the outboard edge and the other lying obliquely thereto; and (d) one lying obliquely at a first angle to the outboard edge and the other lying obliquely at a second angle to the outboard edge, the webs being surmounted by horizontally extending flanges; and running boards mounted to the flanges.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention and to show more clearly how it may be carried into effect, reference is made by way of example to the accompanying drawings, which show an apparatus according to the preferred embodiment of the present invention and in which:
FIG. 1 is a general arrangement view of hopper car incorporating the present invention;
FIG. 2 is a longitudinal centre-line cross-section of the hopper car of FIG. 1 taken section `2--2`;
FIG. 3 is a plan section of the hopper of FIG. 1 taken on section `3--3`;
FIG. 4 is a lateral cross section of the hopper of FIG. 1 taken on section `4--4`;
FIG. 5 shows a sectional view of a roof of the hopper car of FIG. 1;
FIG. 6a shows a developed view of a carline for the roof of FIG. 5;
FIG. 6b shows a profile view of the carline of FIG. 6a;
FIG. 6c shows an end view of the carline of FIG. 6a;
FIG. 7a shows an alternative carline to that shown in FIG. 6b;
FIG. 7b shows an alternative carline to that shown in FIG. 6b;
FIG. 7c shows an alternative carline to that shown in FIG. 6b;
FIG. 7d shows an alternative carline to that shown in FIG. 6b;
FIG. 7e shows an alternative carline to that shown in FIG. 6b;
FIG. 8a shows a plan view of the roof of the hopper car of FIG. 1;
FIG. 8b shows a plan view of an alternative roof for the hopper car of FIG. 1;
FIG. 8c shows a plan view of an alternative roof for the hopper car of FIG. 1;
FIG. 9a enlarged detail of a coaming section for the roof of FIG. 5;
FIG. 9b shows an alternative embodiment of the coaming section of FIG. 9a.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The description of the invention is best understood by commencing with reference to FIG. 1, in which some proportions have been exaggerated for the purposes of conceptual illustration.
Referring to the preferred embodiment of FIGS. 1, 2, 3 and 4, a hopper car of all steel construction is shown generally as 20. It has trucks 22 in the customary manner, upon which a railcar body 24 rests. The body has end structures 26 and 28 supported on trucks 20. Three hoppers 30, 32 and 34 are defined by a combination of left and right main side walls 36 and 38, respectively; left and right hand, foremost, middle and rearmost inwardly downwardly sloping side sheets, 40, 42, 44, 46, 48, and 50, respectively; end walls 52 and 54; internal bulkhead partitions 56 and 58; and foremost and rearmost sloped sheets 60, 62, 64, 66, 68, and 70, tied together and reinforced by left and right hand side sills 72 and 74 and top chords beams 76 and 78 all of which are attached to end structures 26 and 28 and covered by a roof assembly 80.
In general terms, roof assembly 80 and sidewalls 36 and 38 form a three sided, downwardly opening, thin shelled structure, similar to a monocoque. This thin shell is, in effect, wrapped around endwalls 52 and 54 and bulkhead partitions 56 and 58 and extends downwardly to the level of side sills 72 and 74. End walls 52 and sloped sheet 60, endwall 54 and slope sheet 70, and bulkhead partitions 56 and 58 act in general terms as frames, or formers, forming a skeleton to which the monocoque-like structure is attached like a skin. The individual members of the structure are relatively thin and flexible alone, but when assembled work together mutually to stiffen each other and the entire structure. The ability of such a structure to bear service loads generally depends on the ability of the unsupported spans between the formers to maintain their desired shape. The formers shown are all upstanding, but need not be vertically upstanding, and need not be parallel to give a desired stiffening effect when the skins are welded in place.
In the embodiment shown the distance between each adjacent pair of formers defines the fore-and-aft length of one of hoppers 30, 32, or 34. Generally speaking sidewalls 36 and 38 extend along the formers between the discharge assemblies of the hopper car and the superstructure which is typically a roof assembly.
Butt welded roof assembly 80 has predominantly longitudinally extending left and right hand roof panels 222 and 224, and predominantly laterally extending end region panels 226 and 228. Left and right hand roof panels 222 and 224 extend inwardly from top chord beams 76 and 78, nominally following the curve of the arcuate upper edges 230 and 232 of bulkhead partitions 56 and 58 to terminate at upstanding left and right hand, rounded-lip coamings 236 and 238. U-shaped end coaming styles 240 and 242 are let into end region panels 58 and 60 to mate with the coamings 62 and 64 to form a continuous periphery, the gap bounded thereby defining a trough 244 through which grain may be introduced to hoppers 30, 32 and 34.
Since coamings 236 and 238 are formed integrally with roof panels 224 and 226 respectively in a roll forming process, they are made from the same thickness of material, i.e. 0.125 inch thick steel. The relatively deep, folded over sections of coamings 236 and 238, act like inboard longitudinal beams running along the otherwise unsupported inner edge of panel 224 or 226, and extend to reach across the longitudinal gap between partitions 56 and 58. To obtain a thicker coaming section, as illustrated in FIG. 9a, one may fold over a double thickness of sheet, and then pass it through rolls to form the coaming profile. Coaming 236 has a main leg 245 rooted to, and bent upwardly and outwardly away from, panel 222, a bulbous lip 246, curled back upon itself, and a depending leg 248 which extends approximately two thirds of the distance down the outside face of main leg 245 back toward panel 222. This unequal, double-leg design permits a stiffer coaming to be formed without additional welding.
Typical unsupported span 252 of roof panel 222 is bounded by end wall 52, bulkhead partition 56 and top chord beam 76. Typical unsupported span 254 is bounded by bulkhead partitions 56 and 58 and top chord beam 76. Typical unsupported span 254 is bounded by bulkhead partition 58, end wall 54, and top chord beam 76. Right and left hand carlines 260 and 262 surmount roof assembly 80, and provide a convenient support upon which to mount running boards 264 and 266. They replace the rung-like, 3/8 inch thick bent bar running board support brackets previously used for this purpose.
Carline 260, shown FIGS. 4 and 5, and in greater detail in FIGS. 6a, 6b, and 6c, has a web 268 oriented to stand upright, and to extend across roof panel 222 perpendicular to the longitudinal axis centreline 110 of hopper car 20 generally. Web 268 has a heel 272 welded to roof panel 222 near the juncture of roof panel 222, top chord beam 76, and main side wall 36. The web 268 has a gusset-like toe 274 having a first edge welded to the more or less horizontal arcuate portion of roof panel 222 and a web portion 276 extending roughly halfway up the height of, and welded to, leg 248 of the coaming 236. Further, the web 268 has a footprint 278 which a desired arcuate profile for mating with roof panel 222 and a number of reliefs 280, 282, 284, 286 and 288 therein. Web 268 also has a mid-web lightening hole 290, and a folded over flange 292, forming a stiffened spine for web 268. Running board 264 is attached to the web 268 by for example, a threaded fasteners as in the embodiment illustrated. The running boards also serve to stabilize neighbouring carlines 260 by maintaining them in fixed mutually parallel relationship to each other.
As shown, each carline 260 provides a stiff section between top chord beam 76 and coaming 236 and tends to reduce sagging at that section, not merely by virtue of its own stiffness but by tending to extend the range of influence of the torsional stiffness of the hollow section of top chord beam 76 further out into roof panel 222. Further, carline 260 also tends to maintain the orientation of coaming 242, that is it reduces the tendency of coaming 242 to twist. Further still, it tends to maintain the desired sectional profile of roof panel 222 and hence tends to maintain its resistance to buckling. The stiffness of carline 260 is such that, as illustrated in FIG. 8a, unsupported span 252 in the illustrated embodiment, roughly fifteen feet in length between bulkhead partitions 56 and 58, tends to have vibration properties similar to shorter panels 294, 296, 298 and 300.
In the preferred embodiment described above, roof panel 222 is 0.125 inches thick, as opposed to the 0.177 inch thickness butt welded roof panels currently used. Carlines 260 and 262 are made from 0.177 inch thick steel.
Other embodiments of hopper roof reinforcement carline are shown in FIGS. 7a, 7b, 7c, and 7d. In FIG. 7a, a carline 320 has a continuous arc 322 without reliefs for fillet welding to roof panel 222. The carline 320 also has two lightening holes 324 and 326 bridged by a brace 328, and a toe 330 which does not extend fully to coaming 236.
In FIG. 7b, a carline 340 has a heel 342 extending outboard over top chord 76, and a flange 344 running along the back of heel 342. A finger 346 extends for welding to the outside face of top chord beam 76.
In FIG. 7c, a carline 350 is shown having a foot print 352 which extends over only a partial arc of roof panel 222, but maintains the sectional profile of roof panel 222 over that arc.
In FIG. 7d, a further alternative carline 354 is shown having a footprint 356 for mating with a roof panel 358 having corrugations 360. These corrugations are shown as having the section of shallow, taper sided channels or ribs, but could be rectangular, triangular, or sinusoidal sections, or of some other chosen readily manufactured profile. The corrugations may have more or less ribs, of greater or lesser depth. In each case, the carline serves not only to stiffen roof assembly 80 but also supports running board 64.
An alternative internal brace is shown in FIG. 7e as 362, having a web 364, lightening holes 366, 368 and 370, a web flange 372, and a heel 374 welded to main side wall 36 in a position next to the top chord beam 76. Internal fittings are less favoured by the inventors, for the reasons noted above, and also because brace 362 does not also serve the second function of supporting running board 64, which must still be carried on a running board support 348.
While the illustrated, preferred, embodiment of FIG. 6c shows carline 260 having a web 268, which extends perpendicularly away from the roof panel 222, web 268 may extend away at an oblique upstanding angle. FIG. 8a shows a plan view of the preferred embodiment in which carlines 260 extend in parallel spaced relationship from each other perpendicularly to, and between, top chord beam 76 and coaming 236. FIG. 8b shows carlines 376 and 378 located at the diagonal at the corners of hopper car 20. FIG. 8c shows carlines 380 deployed in a diagonal pattern about roof assembly 372 leaving roughly triangular panels 374, 376, 378, 380.
Similarly, although the preferred embodiment employs specific arcuate footprint on a constant 130 inch radius of curvature, a different curvature, an arbitrary curve, a corrugated section, or a flat profile may be chosen to mate with the specific roof profile desired. Further still, although web 262 has been shown in a linear form it may, as seen from above, have a dog-leg, zig-zag, single arc, corrugated, or other chosen sectional profile. Flange 288 need not be folded over, but can alternatively be formed by, for example, welded fabrication. Similarly, while an all-welded car roof structure has been described other forms of fabrication could also be used including threaded fasteners, rivets, or bonding techniques.
FIG. 9b illustrates an alternative form of longitudinal roof coaming reinforcement. Rather than the integrally formed, bulbous-lipped folded embodiment shown in FIG. 9a, a curved coaming liner 302 is welded inside the folded curve of coaming 304. Liner 302 has an outer lip 306 which extends past the end of coaming lip 308 such that they may be fillet welded together more easily. Liner 302 also has a shank 310 extending down and stitch welded to the face of coaming 304. It will be appreciated that liner 302 can be mounted within the curve of coaming 304, or on the back side of coaming 304. Similarly in the embodiment of FIG. 9a, the material could be folded back on itself to give a depending shank lying on the hopper trough opening side of main leg 244.
Notably, while reinforcements in the nature of flutes have been described primarily in the context of main side walls 36 and 38, and reinforcements in the nature of transversely extending carlines have been described in the context of roof panels, while maintaining the overall envelope of the car, transverse stiffeners may be used to reinforce unsupported side wall panels, and longitudinal flutes may be used to stiffen the roof unsupported roof panels.
While a longitudinal reinforcement in the nature of longitudinally extending coamings is provided along the free edge of the otherwise unsupported spans of roof panels it would also be possible to deform the sections of those panels to provide longitudinal flutes or corrugations at intermediate locations relative to the arc between the respective side sills and coamings.
A particular preferred embodiment of the invention, and a number of alternative embodiments, have been described herein and illustrated in the figures. Those embodiments are described by way of illustration, and not of limitation, of the invention. The principles of the present invention are not limited to those specific embodiments, but are defined by the claims which follow, and equivalents thereof.
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A hopper car is described that is a thin shelled integrated structure having a roof and a pair of sidewalls. This structure is subject to longitudinal tensile and compressive loads, and to a partial internal vacuum during unloading. Local buckling phenomena and collapse due to the partial vacuum need to be resisted. The roof assembly has lateral stiffeners to maintain its profile, and a reinforced, roll formed longituding coaming.
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BACKGROUND OF INVENTION
1. Field of the invention
The invention described here relates to an apparatus and a method of alpha numeric data entry into small electronic devices equipped with word processing capability, such as portable computers, potable data processors, and mobile phones.
2. Description of the Prior Art
Electronic devices with word processing capability require miniaturization, space efficiency, and a relatively large display. Therefore, decreasing keypad area is necessary.
Since miniaturization of keypads is reaching its limit, there have been various approaches to decrease the quantity of keys.
A conventional telephone keypad has been proposed for inputting alpha numeric information into a device by means of numerical keyboard.
U.S. Pat. No. 4,658,417 proposed to locate the desired letters on the telephone keypad and to press the corresponding key either once, twice, or three times, followed by pressing an additional symbol key, for example, pressing key 7 three times will give letter “S”.
U.S. Pat. No. 5,339,358 proposed a method and apparatus for conversion of a standard ten-key keypad into a data entry by prearranged alphabetical letters with adjacent key pairs to be defined for each alphabetic letter.
There were other inventions which proposed a lower key count than a ten-key keypad.
U.S. Pat. No. 4,360,892 proposed five manually operated finger keys on a keyboard surface, four finger keys and at least one thumb key, being provided a methods of encoding alphabetic characters with pictographic relationship among each key combination.
Japanese laid-open Patent Application No.H6-274257 and
U.S. Pat. No. 4,791,408 also proposed a five-key entry system on a keyboard surface, or top and bottom surfaces, providing a method of encoding alphabetic characters with plural entry positions on each key.
U.S. Pat. No. 5,281,966 proposed a five-key entry system on a keyboard surface providing a method of encoding alphabetic characters by assigning characters by alphabetical order using vowels as root chords for following consonants.
These previous inventions of five-key keypads were designed for the keyboard device itself. There were none where consideration had to be given to space for a display.
These previous inventions of five-key keypads is worked from a mnemonic stand point, but very little consideration was given to on entry speed, which must be determined by relating key assignment to human finger movement and usage frequency.
SUMMARY OF THE INVENTION
a) Objectives
The general objective of the present invention is to provide compact electronic devices which have word processing capability with a means of entering data with at least five keys, overcoming the difficulties above and affording other features and advantages heretofore not available.
A specific objective of the present invention is to allow a relatively large display on a keyboard equipped with alpha numerical data entry keys.
Another specific objective of the present invention is to provide a method of operating five keys that enables the user to enter data at high speeds.
Yet another specific objective of the present invention is to allow one-handed data entry, and enable tactile data entry.
A further specific objective of the present invention is to provide a key-entry mouse unit.
A further more specific objective of the present invention is to provide a multi-service data processing, such as data handling and phone assistance, with a five-key keypad.
b) Summary of the Invention
The present invention of one-hand alpha numerical data entry comprises the following components:
The five keys for alpha numerical data entry are located on the sides of a portable electronic device with word processing capability. A display is on the front face of the device. The positioning of keys on the sides allows the display area to be made larger.
The five keys can also be located on the side of a mouse pad for a computer, so that operator does not need to use keyboard and mouse together, but only the mouse pad. The implementation of the present invention in a mouse pad frees up valuable desk space.
The five keys located on the sides of an electronic device are located at finger positions where operator naturally grips the device. The first key for the thumb is located on one side surface of the device. The other four keys for the four fingers are located on the other side surface.
A foldaway hook can be equipped on a portable device to help fixing the device in palm.
Each key has electrically-on status when it is pushed, and electrically-off status when it is released.
The five keys can theoretically generate thirty one combinations. Among thirty one combinations, twenty six are used for alphabetical assignment.
Alpha numerical characters are assigned to key combinations to obtain the highest entry speed. Therefore frequency of usage, finger movement, and mnemonic manner must be considered and examined. For instance, a more often used character is assigned to a key combination of easier and higher speed finger movement.
Other characters or commands can be assigned to the remaining key combinations, using hierarchy structure of assignment.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a plan view of the preferred embodiment of the present invention of a mobile phone,
FIG. 2 shows the mobile phone of FIG. 1 being held in a hand,
FIG. 3 is a schematic block diagram of the digital logic signal line connected to an associated programmable microprocessor,
FIG. 4 is a plan view of the preferred embodiment of the present invention in a mouse unit,
FIG. 5 is a plan view of the preferred embodiment of the present invention of a mobile phone with a foldaway hook, and
FIG. 6 shows the mobile phone of FIG. 5 being held in a hand.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a preferred embodiment in a mobile phone is illustrated. The mobile phone is equipped with word processing capability for e-mail or Internet.
Display 7 , microphone 9 , and speaker 10 are located on the front surface 11 . Key 1 is located onto the right side surface 13 , key 2 through 5 are located on the left side surface 15 , and an antenna 8 is located on the top side surface 12 .
As shown in FIG. 2, the thumb will be on key 1 , the forefinger on key 2 , the middle finger on key 3 , the third finger on key 4 , and the little finger on key 5 , when the phone is gripped with the right hand. A mirror image key arrangement is also possible for a left handed user. The key position and size are considered carefully to mach the hand and finger size of the average user. More keys, buttons or indicators can be put on the device for additional functions as desired.
Each key has electrically-on status when it is pushed and electrically-off status when it is released. The electrical signal goes to a microprocessor. FIG. 3 shows a schematic block diagram of the digital logic signal line connected to an associated programmable microprocessor, where the inputs are translated to alpha numeric characters or commands. The microprocessor is connected to RAM and EPROM through the bus line. It is possible to install a data processor between the keypad and the microprocessor to interpret a keypad status to a signal for the microprocessor.
The microprocessor takes input information, after a preset time has elapsed without any interruption of keypad status after the last key is electrically-on. The time count is reset whenever the keypad status changes, and another time count starts. In the present invention, there is also a second preset time which is longer than the first. When user continuously pushes keys until the second preset time, he can get a different character or command from the first. In the present invention, the user toggles between upper case and lower case by pushing keys until the second preset time has elapsed. It is very convenient to toggle between upper and lower case letters without going back to a special command for letter case size.
In the case of the scrolling function, scrolling on the display starts when the microprocessor takes an input after the first preset time elapsed without any interruption of keypad status after the last key is electrically on. When any key status changes, another time count starts.
It is very useful that the two kinds of preset time can be adjusted according to the users.
Key status is hereafter expressed with “0” for electrically-off, and “1” for electrically-on in order to compose a set of numbers, correspond to the key status from the first key to the fifth key. For example, combination code “10100” means key 1 is electrically-on, key 2 is electrically-off, key 3 is electrically-on, key 4 is electrically-off, and key 5 is electrically-off.
Detailed alpha numerical characters and commands with combination code in the present invention are explained as follows:
An operator can make sentences in text mode. In text mode, letters of the alphabet are assigned in the following manner;
1) Grouping
One of the major objectives of the invention is to provide a code system which is easily memorized. In general, a regular order system is easier to remember than an irregular or random order system. As explained below, however, simple alphabetical order can not be used, because the frequency of character usage must be taken into account. In the present invention, small groups of any relation are chosen from the prioritized list of usage frequency. On the other hand, groups of key combinations are created by considering finger dexterity mentioned below. In this present invention, prioritized groups of key combinations, and prioritized groups of letters are created first, then these groups are assigned along with the prioritized order, and finally, each letter is assigned to each combination code respectively within the assigned grouping.
2) Finger Dexterity
The most major objective of the invention is to provide an easy, high speed entry system. In general, all fingers do not have the same level of dexterity.
First, it has been found by experiment that the entry speed is very slow if a five finger combination includes a combination, in which middle finger presses for electrically-on status, third finger releases for electrically-off status, and little finger presses for electrically-on status. This combination should be used as seldom as possible. In the present invention, letter “Q”, “X” or “Z” is assigned to this specific key combination.
Second, it has been found by experiment that movement of the thumb does not significantly effect the other fingers, nor is the thumb by the movement of the other fingers.
Third, it has been found by experiment that single finger entry is overall the fastest.
Fourth, it has been found by experiment that an adjacent pair of fingers, excluding the thumb, demonstrates higher entry speed than any other combination of the four fingers overall.
Taking the above into consideration, key combinations are prioritized by lower quantity of electrically-on status as first, neighboring finger pairs second, and thumb status third.
As a result, the following groups of combination code, prioritized by entry speed, are created:
First group: “10000,01000,00100,00010,00001”
Second group: “01100,00110,00011”
Third group: “11000,10100,10010,10001”
Fourth group: “11100,10110,10011”
Fifth group: “01110,00111”
In each group, order of key combination is set by finger order. The thumb is most highly prioritized and the other fingers follow from the forefinger to the little finger. Then, 5 groups of 17 combination codes for high speed entry are chosen.
3) Usage Frequency
High entry speed is basically performed by assigning easy key combinations to frequently used letters. Vowels are used more than 50% of the time in Japanese and some other languages which consonants are normally followed by vowel. Vowels are used in English frequently, too. In the present invention, “A,E,I,O,U” is set on the first group.
In English, the most frequent usage as a sectional group of successive alphabetic order is the second group “R,S,T”. The next most frequent usage is third group “K,L,M,N”. The next most frequent usage is the fourth group “B,C,D”. The next most frequent usage is the fifth group “G,H”. Then, 5 groups of 17 letters are selected. Sentences consist mostly of the 17 most often used letters.
The alphabetical groups are assigned to the groups of combination code mentioned above in order.
Other letters are assigned with trying to be easier to remember relating the 17 letters. As a result, letters, “F,J,P,Q,V,W,X,Y,Z”, are assigned to the combination code, “01011,01001,01010,01101,11010,11001,11101,10111,11011”, respectively.
In the present invention, special commands are also assigned, in addition to the 26 combination codes of letters.
First, key combination “11111” is set aside for exchanging alphabet mode and edit(numbers) mode. In the edit(number) mode, 10 digits and any editing commands are obtained with hierarchy command structure, such as saving and loading files, erasing and moving text, copying and pasting text, scrolling and marking text, inputting special symbols or characters, etc.
Some symbols or letters which are used frequently are also included on the remaining key combination of text mode. The following ones are chosen and assigned: “10101” for undo, “11110” for comma, “01111” for space, “00101” for switching between English mode and other language mode. The last one might not be necessary in an English speaking country, and can be changed to another command or a letter. In other language mode, as one example, alphabetical input which is usually phonetic based is translated to the other language automatically in the display by a pre-installed program. The other example of other language mode is to change to native alphabet which characteristics are assigned to different combination codes.
The overall assignment of combination code is summarized in the following list:
10000 : a
(A)
11100 : b
(B)
10110 : c
(C)
10011 : d
(D)
00010 : e
(E)
01011 : f
(F)
01110 : g
(G)
00111 : h
(H)
01000 : i
(I)
01001 : j
(J)
11000 : k
(K)
10100 : l
(L)
10010 : m
(M)
10001 : n
(N)
00001 : o
(O)
01010 : p
(P)
01101 : q
(Q)
01100 : r
(R)
00110 : s
(S)
00011 : t
(T)
00100 : u
(U)
11010 : v
(V)
11001 : w
(W)
11101 : x
(X)
10111 : y
(Y)
11011 : z
(Z)
00101 : Exchange English/Other
10101 : Undo
11110 : Comma
(Period)
01111 : Space
11111 : Exchange Alphabet/Edit&Number
(Exchange Text mode/Phone
mode)
The commands or letters in the parenthesis are obtained when a key combination is held until the second preset time. In the Edit&Number mode, 10 digits are assigned to easy key combinations, and scrolling commands are also prioritized. And then, various editing commands are assigned among the remaining key combinations or further key combinations in hierarchy.
In the present invention, the 10 digits are assigned with consideration given to high speed entry and easy memorization, using the same manner as used for alphabet. The following key combination code are assigned; “10000” for digit 1 , “01000” for digit 2 , “00100” for digit 3 , “00010” for digit 4 , “00001” for digit 5 , “11000” for digit 6 , “01100” for digit 7 , “00110” for digit 8 , “00011” for digit 9 , and “10001” for digit 0 .
Scrolling commands are assigned as follows: “11110” for moving upward, “01111” for moving downward, “11100” for moving left, “00111” for moving right, and “01110” for confirmation at the current cursor position.
When the mobile phone is used to dial a number, phone mode is set as the normal mode. Other kinds of handheld electronic devices, such as palm-top personal computers, should be set to text mode for the normal mode.
Some of the major key operations of the phone in phone mode in the present invention are as follows:
An user can dial with “10000” for digit 1 , “01000” for digit 2 , “00100” for digit 3 , “00010” for digit 4 , “00001” for digit 5 , “11000” for digit 6 , “01100” for digit 7 , “00110” for digit 8 , “00011” for digit 9 , and “10001” for digit 0 . “10110” for calling, and “10111” for hang up. If the number to be dialed is already memorized in a built-in computer, the number can be chosen by scrolling in display using scrolling command; “11110” for moving upward, “01111” for moving downward, “11100” for moving left, “00111” for moving right, and “01110” for confirmation at the current cursor position. When an user wants to use text mode, “11111” is entered to switch from phone mode to text mode.
Other necessary functions such as recording a new number, sending e-mail, and so on, are also assigned on the remaining key combinations or further key combinations in hierarchy.
FIG. 4 shows five key pad application on mouse unit 21 with scrolling ball unit 22 on the bottom surface 24 . The key 1 is on the side surface 26 , and the other four keys are on the other side surface 25 . The side surfaces can be slanted or rounded for a more comfortable grip. The wire 23 connected to the computer can be replaced by a wireless connection such as infra-red, microwave, or laser transmission. The key board which is usually used along with mouse unit can be taken off the working desk, freeing up valuable desk space.
FIG. 5 . shows another preferred embodiment in a mobile phone. The mobile phone has the first key on the top surface 12 and a foldaway hook 16 on the side surface 15 . The foldaway hook 16 is normally stored in the mobile phone and opened to use supporting the apparatus during data entry by hooking on the root of thumb finger as illustrated in FIG. 6 . Single hand data entry becomes very smooth with well-fixed mobile phone in the palm.
In the present invention, only a five-key keypad is explained, however, other keys can be added for other additional functions.
Because many varying and different embodiments may be made within the scope of the inventive concept discussed here, and because many modifications may be made in the embodiments herein detailed, it is to be understood that the details discuss here are to be interpreted and not intended to limit the invention.
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A keypad system for a compact electronic machine featuring word processing capability has five keys located on the side walls of electronic machine in order to allow quick and easy entry of alpha numerical information with single hand. Alpha numeric characters are assigned to combinations of electrically-on status and electrically-off status of five keys suitably according to finger movement, usage frequency, and mnemonic manner in order to achieve fast entry speed. The unique location of keys also allows for a relatively large display or mouse ball on the front or bottom surface.
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BACKGROUND
The application relates to an actuator assembly suitable for use with a resistance welding gun. More specifically the application relates to a resistance welding gun actuator assembly that incorporates an external retract mechanism and an adaptable welding cylinder.
Retracting welding guns are well known in the industry and are commonly applied when the welding gun must reach over the workpiece or tooling to weld on a far side. An intermediate or retracted electrode position eliminates the time that might be wasted to fully open the electrodes at each spot to be welded on the workpiece. Retracting welding guns are also used when the space inside of the workpiece or tool is constrained and does not permit full opening of the electrodes.
It is common to provide a single retract position in such welding guns. To properly position the resistance welding electrodes relative to the workpiece, the stroke of the retract cylinder may have to be adapted from time to time to accommodate such things as the specific access condition or length of the welding gun arms. In the prior art designs of singular construction where the retract and welding cylinders are integrated, such adaptations can result in a large number of actuators within a particular manufacturing plant. These actuators are also large and expensive because of the high degree of customization.
What is needed is an actuator assembly that is compact, easily adaptable between various applications and less expensive.
SUMMARY
An actuator assembly for a welding gun is provided that has at least three positions in the example. The actuator assembly includes separate working and retract actuators. The working actuator includes a working rod movable between first and second positions. The retract actuator includes a retract rod independently movable relative to the working rod between third and fourth positions. The retract actuator is external to and non-concentrically arranged relative to the working actuator in the example shown. Actuation of the working and retract actuators is coordinated to provide at least three positions while enabling the actuators to be changed or modified independently from one another.
A latching device is configured to selectively interlock the working and retract actuators to one another automatically in response to movement the working rod from the first position to the second position. As a result, a separate actuation device is not required to lock the working and retract actuators relative to one another.
These and other features of the application can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a welding gun with an example actuator assembly.
FIG. 2 is a cross-sectional view of the actuator assembly in FIG. 1 taken along line 2 - 2 .
FIG. 3 is a cross-sectional view of the actuator assembly in FIG. 2 taken along line 3 - 3 .
FIG. 4 is an enlarged cross-sectional view of the actuator assembly shown in FIG. 2 in a return position.
FIG. 5 is cross-sectional view of the actuator assembly shown in FIG. 4 in a retract position.
FIG. 6 is cross-sectional view of the actuator assembly shown in FIG. 4 in an advance position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A welding gun 10 is shown in FIG. 1 , which is manipulated using an example actuator assembly 12 . It should be understood that, although the actuator assembly 12 is shown configured for use with a welding gun, the actuator assembly 12 also could be used with riveting tools, clinching and metalworking tools, and other applications.
The actuator assembly 12 is secured to a support 14 that includes a rotary bail 16 , which rotationally orients the welding gun 10 relative to a workpiece (not shown) to a desired position. Opposing arms 18 rotate relative to one another about a pivot 20 to close electrodes 22 about the workpiece in a desired manner, as is known. In the example, one of the arms 18 is fixed and the other of the arms 18 is movable relative to the fixed arm. A transformer 24 supplies current to the electrodes 22 to spot-weld the workpiece.
In one example configuration, the actuator assembly 12 includes a working actuator 28 and a retract actuator 30 that cooperate with one another to move the electrodes 22 between three or more positions (corresponding to L 1 -L 3 shown in FIGS. 4-6 ). While a push-type arrangement is shown, it should be understood that the actuator assembly 12 could be configured to a pull-type configuration and still fall within the scope of this application. According, the terms “return,” “retract” and “advance” are meant as relative positions and should be construed broadly. Furthermore, although the example working and retract actuators 28 , 30 are illustrated as pneumatic cylinders, pneumatic, hydraulic, air-over-oil, electric servo actuators or any combination thereof may also be used.
Referring to FIG. 2 , first and second fluid sources 32 , 34 selectively provide pressurized fluid to the working and retract actuators 28 , 30 in response to commands from a controller 36 . Of course, more or fewer fluid sources can be used in conjunction with control valves and vents may be employed to obtain desired movement of the working and retract actuators 28 , 30 , which is within the scope of one of ordinary skill in the art. The working and retract actuators 28 , 30 are manipulated independently from one another and can be optimized separately based upon the particular application without requiring an entirely new integrated actuator, as required by the prior art.
The working and retract actuators 28 , 30 respectively include working and retract rods 38 , 40 that cooperate to manipulate the electrodes 22 through various positions. The working and retract rods 38 , 40 are non-concentric and parallel in the example shown. An end of the working rod 38 is connected to the movable arm 18 . In the example, a retract actuator 30 is arranged on each of opposing sides of the working cylinder 28 . The number and size of the retract actuators 30 is selected based upon the particular application. The retract rods 40 are secured to the mounting plate 26 by blocks 42 . The working rod 38 extends through an aperture in the mounting plate 26 between the blocks 42 . Brackets 44 secure the retract actuators 30 to the working actuator 28 .
The working actuator 28 includes a front block 46 that supports the working rod 38 for axial movement. In the example, the working actuator 28 includes an adaptable cylinder 47 having multiple sections 48 , the number and size of which are selected based upon the desired force for the particular application. Each section 48 includes a cavity 50 having a piston 52 that is connected to the working rod 38 . The working rod 38 is moved axially in fore and aft directions in response to selective pressurization of the chambers on either side of the pistons 52 , as is known.
The retract actuator 30 includes a retract cylinder 54 that includes a piston 58 arranged in a cavity 56 . The piston 58 is connected to the retract rod 40 , which is moved axially in the fore and aft directions relative to the retract cylinder 54 in response to selective pressurization of the chambers on either side of the piston 58 , as is known.
Referring to FIGS. 2 and 3 , a latching device 59 is used to affix the front block 46 of the working actuator 28 relative to the mounting plate 26 once the retract actuators 30 have been moved from a return position ( FIGS. 2 and 4 ) to a retract position ( FIG. 5 ). The latching device 59 is shown unlatched in the retract position ( FIG. 5 ) and latched in an advance position ( FIG. 6 ). The retract actuators 30 are mechanically linked to the position of the working rod 38 through the latching device 59 , which latches automatically, to obtain a desired response time and to eliminate separate control elements of some prior art arrangements.
The latching device 59 includes opposing plungers 62 received in bores 64 in the front block 46 . The plungers 62 have inner ends that are in engagement with the outer surface of the working rod 38 . The plungers 62 are arrange normal to the working rod 38 and are received in detents 60 in the outer surface when the working rod 38 is positioned as shown in the return and retract positions ( FIGS. 4 and 5 , respectively).
The plungers 62 include latches 66 supported at ends opposite the detents 60 . The latches 66 are configured to engage recesses 68 in the blocks 42 when the plungers 62 are forced radially outward relative to the working rod 38 as the working rod moves axially to unseat the plungers 62 from the detents 60 , as shown in the advance position ( FIG. 6 ). Guide pins 74 are secured to each latch 66 and extend through holes 72 in a plate 70 that is secured to the front block 46 . Springs 76 cooperate with the guide pins 74 to bias the latches 66 toward the detents 60 .
Referring to FIGS. 4-6 , the example actuator assembly 12 works by using two retract actuators 30 mounted independently of the main working actuator 28 to provide retract motion ( FIG. 5 ) for the assembly, which provides an intermediate position for improved cycle times. FIG. 4 show the latches 66 in their retracted position with the ends of the plungers 62 resting in detents 60 in the working rod 38 . When the retract actuators 30 are advanced as in FIG. 5 , the latching device 59 is aligned so that the working rod 38 can be advanced and the latches 66 engaged. When the working rod 38 is advanced the detents 60 actuate the two plungers 62 that in turn cause the two latches 66 to lock the assembly into retract position. The working rod 38 then proceeds to advance the electrodes towards the workpiece as shown in FIG. 6 .
Example operation of the welding gun 10 with the example actuator assembly 12 is as follows:
Return Position
Compressed air or other suitable fluid is applied to the return port of the retract cylinders 54 causing the retract rods 40 to extend to a point where the piston 58 is pressing against the end of the cylinder 54 . In this position ( FIG. 4 ) the distance between the moveable mounting plate 26 and the latching device 59 are at the maximum separation. At the same time the working actuator 28 has air from another fluid power valve acting against its piston 52 , causing the working rod 38 to be fully returned (distance L 1 ). The combination of both of these cylinder positions results in the maximum amount of welding electrode opening.
Retract (Intermediate) Position
The return port is vented to atmosphere while compressed air is applied to the retract port of the retract cylinders 54 . This causes the retract rods 40 to retreat inside the retract cylinders 54 and to pull the mounting plate 26 relatively towards the latching device 59 ( FIG. 5 ) moving the working rod 38 to a distance L 2 relative to the mounting plate 26 . This causes the welding electrodes 22 to move towards each other. During this motion the return air is maintained on the welding cylinder return port(s).
Advanced (Welding) Position
When the retract position has been achieved, compressed air is applied to the working actuator 28 to advance the working rod 38 to an axial distance L 3 . This causes the latches 66 to advance to prevent the working actuator 28 from working against the retract actuators 30 . As the working rod 38 continues to advance, the welding electrodes 22 are brought into contact with the workpiece with sufficient force to conduct the resistance welding process.
Return Position Subsequent to Advanced Position
At the completion of the welding process, if the fully returned position of the electrodes 22 is desired, the retract and weld stroke ports are vented to atmosphere and air is applied to the return ports. Once the working rod 38 has started to return causing the latching device 59 to disengage, the retract cylinder return port can be pressurized, thereby fully returning the unit. If opening the welding gun only to the retracted position is desired, the air is retained on the retract advance port and the air is applied to the welding cylinder return port. This will retract the electrodes 22 sufficiently to allow moving to the next weld position.
Although an example embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims. For that reason, the following claims should be studied to determine their true scope and content.
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An actuator assembly for a welding gun is provided that has at least three positions in the example. The actuator assembly includes separate working and retract actuators. The working actuator includes a working rod movable between first and second positions. The retract actuator includes a retract rod independently movable relative to the working rod between third and fourth positions. The retract actuator is external to and non-concentrically arranged relative to the working actuator in the example shown. Actuation of the working and retract actuators is coordinated to provide at least three positions while enabling the actuators to be changed or modified independently from one another. A latching device is configured to selectively interlock the working and retract actuators to one another automatically in response to movement the working rod from the first position to the second position.
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CLAIM OF PRIORITY
This application claims the benefit of U.S. Provisional Patent Application 61/352,274, entitled “Methods and systems for resolving conflicting client/server data in a multi-tenant database environment,” by Movida et al, filed Jun. 7, 2010, the entire contents of which are incorporated herein by reference.
COPYRIGHT NOTICE
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
One or more implementations relate generally to data storage, and more particularly to data synchronization.
BACKGROUND
The subject matter discussed in the background section should not be assumed to be prior on merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions.
Conventional systems may desire to store one or more copies of data in a plurality of locations. For example, identical data records may be stored both at a client of a system as well as a server of the system, and may be periodically synchronized (e.g., for purposes of maintaining updated data, etc.). Unfortunately, traditional data synchronization techniques have been associated with various limitations.
Just by way of example, conflict may arise during the synchronization of data between locations. For example, alterations may have been made simultaneously to the same data elements at different locations. Accordingly, it is desirable to effectively manage and resolve such data conflicts.
BRIEF SUMMARY
In accordance with embodiments, there are provided mechanisms and methods for resolving a data conflict. These mechanisms and methods for resolving a data conflict can enable an improved user experience, increased efficiency, time savings, etc.
In an embodiment and by way of example, a method for resolving a data conflict is provided. In one embodiment, a synchronization error is detected within a system. Additionally, it is determined that the synchronization error includes a data conflict. Further, the data conflict is resolved.
While one or more implementations and techniques are described with reference to an embodiment in which resolving a data conflict is implemented in a system having an application server providing a front end for an on-demand database system capable of supporting multiple tenants, the one or more implementations and techniques are not limited to multi-tenant databases nor deployment on application servers. Embodiments may be practiced using other database architectures, i.e., ORACLE®, DB2® by IBM and the like without departing from the scope of the embodiments claimed.
Any of the above embodiments may be used alone or together with one another in any combination. The one or more implementations encompassed within this specification may also include embodiments that are only partially mentioned or alluded to or are not mentioned or alluded to at all in this brief summary or in the abstract. Although various embodiments may have been motivated by various deficiencies with the prior art, which may be discussed or alluded to in one or more places in the specification, the embodiments do not necessarily address any of these deficiencies. In other words, different embodiments may address different deficiencies that may be discussed in the specification. Some embodiments may only partially address some deficiencies or just one deficiency that may be discussed in the specification, and some embodiments may not address any of these deficiencies.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following drawings like reference numbers are used to refer to like elements. Although the following figures depict various examples, the one or more implementations are not limited to the examples depicted in the figures.
FIG. 1 illustrates a method for resolving a data conflict, in accordance with one embodiment;
FIG. 2 illustrates method for performing error detection, in accordance with another embodiment;
FIG. 3 illustrates an example of an icon on top of a synchronization button, in accordance with another embodiment;
FIG. 4 illustrates a conflict overview screen of a conflict resolution user interface, in accordance with another embodiment;
FIG. 5 illustrates a conflict error screen of a conflict resolution user interface, in accordance with another embodiment;
FIG. 6 illustrates a conflict summary screen of a conflict resolution user int rface, accordance with another embodiment;
FIG. 7 illustrates a block diagram of an example of an environment wherein an on-demand database system might be used; and
FIG. 8 illustrates a block diagram of an embodiment of elements of FIG. 7 and various possible interconnections between these elements.
DETAILED DESCRIPTION
General Overview
Systems and methods are provided for resolving a data conflict.
As used herein, the term multi-tenant database system refers to those systems in which various elements of hardware and software of the database system may be shared by one or more customers. For example, a given application server may simultaneously process requests for a great number of customers, and a given database table may store rows for a potentially much greater number of customers.
Next, mechanisms and methods for resolving a data conflict will be described with reference to example embodiments.
FIG. 1 illustrates a method 100 for resolving a data conflict, in accordance with one embodiment. As shown in operation 102 , a synchronization error is detected within a system. In one embodiment, the system may include one or more clients. For example, the system may include a desktop computer, a laptop computer, a handheld device (e.g., a cell phone, personal digital assistant (PDA), etc.), or any other device capable of performing computation. In another embodiment, the system may include one or more servers. For example, the system may include one or more server computers, a cloud computing environment, a multi-tenant on-demand database system, etc. In yet another embodiment, the one or more clients and the one or more servers of the system may communicate utilizing a network.
Additionally, in one embodiment, the synchronization may include the exchange of data between a client of the system and a server of the system. For example, a copy of the same data may be stored at both the client and the server of the system, and both copies may be periodically synchronized. In this way, it may be ensured that the stored data is accurate and current. In another embodiment, the synchronization may be performed utilizing one or more application programming interface (API) calls. In yet another embodiment, the synchronization may be performed in response to data being saved within the system (e.g., at the client, at the server, etc.).
Further, in one embodiment, the synchronization error may include any error that is encountered during synchronization. For example, the synchronization error may include one or more failed API calls. In another embodiment, a message may accompany the synchronization error. For example, an error message may be received in response to a failed synchronization between a client and server within the system.
Further still, it should be noted that, as described above, such multi-tenant on-demand database system may include any service that relies on a database system that is accessible over a network, in which various elements of hardware and software of the database system may be shared by one or more customers (e.g. tenants). For instance, a given application server may simultaneously process requests for a great number of customers, and a given database table may store rows for a potentially much greater number of customers. Various examples of such a multi-tenant on-demand database system will be set forth in the context of different embodiments that will be described during reference to subsequent figures.
Also, as shown in operation 104 , it is determined that the synchronization error includes a data conflict. In one embodiment, it may be determined that the synchronization error includes a data conflict by identifying an error message. For example, an error message (e.g., an error code, a message string, etc.) received in response to the synchronization error may indicate that such synchronization error is the result of a data conflict. Of course, however, the synchronization error may be determined to include a data conflict in any manner. In another embodiment, the determining may be performed by a fault handler of the system.
Additionally, in one embodiment, the data conflict may include a conflict of data between a server of the system and a client of the system. For example, identical copies of data may be stored at both the client and the server of the system, and after a first synchronization is performed, the data copy stored on the client may be altered (e.g., by a user editing the data, deleting the data, etc.). Additionally, after the first synchronization is performed, the data copy stored on the server may also be altered in a different manner than the data copy stored on the client. In another example, the data copy stored on the server may be altered before the alteration of the data copy on the client, after the alteration of the data copy on the client, at the same time as the alteration of the data copy on the client, etc.
Further, in one embodiment, during a second synchronization of the data with the server after the first synchronization, it may be determined that both the copy of the data on the client and the copy of the data on the server have been separately altered since the last synchronization of the data between the server and the client.
Further still, a shown in operation 106 , the data conflict is resolved. In one embodiment, resolving the data conflict may include determining which of two conflicting copies of data is to be stored within the system. For example, if identical copies of data stored on both a client and server of a system are both independently altered before a synchronization is performed, resolving the data conflict may include determining whether the data copy stored on the client or the data copy stored on the server is to be saved in the system, whether both data copies are to be saved in the system, etc.
Also, in one embodiment, the data conflict may be resolved utilizing a user interface (UI). For example, the data conflict may be presented to, and manually resolved by, a user of the system utilizing a conflict resolution UI. In another embodiment, the may list a plurality of data conflicts, and the user may choose which data conflicts to manually address. In yet another embodiment, the user may select from one or more possible resolutions for the data conflict from within the UI. In still another embodiment, the user may perform one or more additional operations associated with resolving the data conflict utilizing the UI. For example, the user may send a message to another entity within the system regarding the conflict. In another example, the user may save a copy of the chosen resolution of the data conflict within the system. In this way, the user interface may assist the user in manually resolving the data conflict.
In addition, in one embodiment, the data conflict may be resolved automatically. For example one or more programs may be created utilizing a toolkit as part of an application programming interface (API) to address the data conflict. In another embodiment, the one or more programs may automatically resolve the data conflict based on one or more criteria. For example, the one or more programs may resolve the data conflict based on a time and date of data modification, entity priority within the system, the type of data in conflict, an organization associated with the data, etc. In this way, the data conflict may be included within a large volume of data conflicts which may be automatically resolved by the one or more programs and may not have to be manually addressed by a user of the system.
FIG. 2 illustrates a method 200 for performing error detection, in accordance with another embodiment. As an option, the method 200 may be carried out in the context of the functionality of FIG. 1 . Of course, however, the method 200 may be carried out in any desired environment. The aforementioned definitions may apply during the present description.
As shown in operation 202 , a data management service (DMS) receives an error message in response to a system web service call. In one embodiment, the system web service call may include a request to synchronize data between a client and server of the system. In another embodiment, the error message may be received after the request to synchronize the data has failed. In yet another embodiment, the error message may be received in response to replaying an uncommitted queue during an online commit, where a data service adapter may invoke a web service API calls.
Additionally, as shown in operation 204 , the database management service calls a system data service adapter with the error message. Further, as shown in operation 206 , the data service adapter asks a fault handler to handle the error, based on the web service call. Further still, as shown in operation 208 , the fault handler conditionally retrieves the original item associated with the web service call from the server to determine the nature of the fault. In one embodiment, the decision may be based on a type of the web service call involved, the error message (e.g., an error code within the error message, etc.), etc. In this way, unnecessary operations may be avoided (e.g., attempting to access an item from the server that the error code notes has been deleted from the server, etc.).
Also, as shown in operation 210 , the fault is determined to be a conflict. For example, it may be determined that identical copies of a file stored at both a client and a server of the system have each been modified independently of each other after a synchronization including those files has been performed. In another example, it may be determined that data that is attempted to be modified has been modified on the server since the last synchronization. In one embodiment, the determination may be made by retrieving the data associated from the web service call from a client and server of the system, comparing the data, and determining that such data is different at the server and client.
In addition, as shown in decision 212 , it is determined whether a fault handler is registered. In one embodiment, the fault handler may be user-defined. For example, a user of the system may utilize one or more of a template, user interface, a system toolkit, and an application programming interface (API) to create a fault handler to resolve conflicts within the system. In another embodiment, the fault handler may include code that makes decisions regarding conflicting data within the system without having to prompt a user.
Furthermore, if it is determined in decision 212 that a fault handler is registered, then in operation 214 , the conflict is passed to the fault handler. In one embodiment, a conflict or error context may be passed to the fault handler. In another embodiment, one or more fields associated with the conflict may be identified to the fault handler. For example, fields associated with an item that include conflicting data may be identified to the fault handler. In this way, specific information associated with the conflict may be provided to the fault handler. In yet another embodiment, one or more algorithms created by a developer of the system may determine which data is to be saved among the conflicting data.
For example, the fault handler may apply an algorithm that compares an item at the client to the conflicting item at the server and selects one of the items to be saved to both the client and the server. In one embodiment, the algorithm may default to the data stored at the client or the server. In another embodiment, the algorithm may select the data that has been saved at the latest date. In still another embodiment, the algorithm may select the data based on a type of the data, an organization in which the data is stored, or any other criteria. In this way, the conflict may be programmatically resolved without manual decision-making. In yet another embodiment, the fault handler may revert to the operation that produced the fault, handle the fault in an application (e.g., by displaying an error message on the screen, etc.), put the fault in a conflict queue to be later handled manually, etc.
Further still, if it is determined in decision 212 that a fault handler is not registered, then in operation 216 the conflict is placed in a conflict queue. Additionally, as shown in operation 218 , the fault is retrieved from the conflict queue and is manually resolved utilizing a conflict resolution user interface (UI). In one embodiment, the conflict resolution UI (CRUI) may allow users to visually resolve conflicts and/or errors which happened during the sync process. For example, when conflicts and/or errors are detected, a status bar at the bottom of an application may display a colored icon on top of a button used to synchronize data. FIG. 3 illustrates an example of an icon 302 on top of a synchronization button 304 . In another example, pressing this button may show the CRUI. In another embodiment, the CRUI may show all the items in the conflict queue and users may have a chance to take action to resolve these conflicts.
Also, in one embodiment, users may not be forced to resolve conflicts. For example, having unresolved conflicts and/or errors may not preclude users from continuing to work with one or more software applications on a client. In another embodiment, users may continue modifying, creating, and/or deleting items, so long as they are not trying to save an item in conflict.
FIG. 4 illustrates a conflict overview screen 400 of a conflict resolution user interface, in accordance with another embodiment. As an option, the screen 400 may be carried out in the context of the functionality of FIGS. 1-3 . Of course, however, the screen 400 may be carried out in any desired environment. The aforementioned definitions may apply during the present description.
As shown, the conflict overview screen 400 allows users to see an overview of all unresolved synchronization conflicts that have occurred by comparing a server value 402 of an object with a client value 404 of the object. In one embodiment, a user may select the “select most recent” icon 406 of the screen 400 , which may select conflicting values that have occurred most recently. In another embodiment, the user may select the “select all server” icon 408 or the “select all client” 410 icon of the screen 400 , which may select conflicting values stored at the server or the client, respectively. In this way, user may resolve conflict globally. In yet another embodiment, users may resolve conflicts by creating blended records (e.g., a mixture of server and client values, etc.).
FIG. 5 illustrates a conflict error screen 500 of a conflict resolution user interface, in accordance with another embodiment. As an option, the screen 500 may be carried out in the context of the functionality of FIGS. 1-4 . Of course, however, the screen 500 may be carried out in any desired environment. The aforementioned definitions may apply during the present description.
As shown, the conflict error screen 500 includes an error column 502 . In one embodiment, the error column 502 may provide a detailed view into specific errors and related error messages. Additionally, the conflict error screen 500 includes a client value column 504 . In another embodiment, a user may resolve conflict errors by entering a new/correct value for conflict fields on records within the client value column 504 .
FIG. 6 illustrates a conflict summary screen 600 of a conflict resolution user interface, in accordance with another embodiment. As an option, the screen 600 may be carried out in the context of the functionality of FIGS. 1-5 . Of course, however, the screen 600 may be carried out in any desired environment The aforementioned definitions may apply during the present description.
As shown, the conflict summary screen 600 includes a summary column 602 which may include a summary of how a user resolved one or more conflicts. In one embodiment, a user may go back to a previous screen to change selections by selecting the “change selections” icon 604 of the screen 600 . In another embodiment, a user may commit their conflict resolution selections for re-synchronization by selecting the “finish” icon 606 of the screen 600 . In this way, a user may manually resolve data conflicts between a client and server.
In this way, the system may discriminate between data conflicts and errors, and may provide for resolution through either programmatic or GUYI wizard means. In another embodiment, conflicts and errors discovered by the server may be received, exception information may be correlated to the original records, and the records may be routed to the appropriate handlers. In yet another embodiment, a full GUI wizard may be provided that may guide users through the process of identifying and resolving client/server data conflicts. The wizard may separate the records by type, and then may identify each conflicted field and/or manage conflicts on dependent picklists, etc. The user may be able to select the appropriate client or server value to resolve the conflict. Another path may allow platform developers to specify their own resolution mechanisms. The information relevant to each conflict may be passed to their callback methods through a standardized API and they may be responsible for programmatically indicating how they would like the conflict to be resolved.
System Overview
FIG. 7 illustrates a block diagram of an environment 710 wherein an on-demand database system might be used. Environment 710 may include user systems 712 , network 714 , system 716 , processor system 717 , application platform 718 , network interface 720 , tenant data storage 722 , system data storage 724 , program code 726 , and process space 728 . In other embodiments, environment 710 may not have all of the components listed and/or may have other elements instead of, or in addition to, those listed above.
Environment 710 is an environment in which an on-demand database system exists. User system 712 may be any machine or system that is used by a user to access a database user system. For example, any of user systems 712 can be a handheld computing device, a mobile phone, a laptop computer, a work station, and/or a network of computing devices. As illustrated in FIG. 7 (and in more detail in FIG. 8 ) user systems 712 might interact via a network 714 with an on-demand database system, which is system 716 .
An on-demand database system, such as system 716 , is a database system that is made available to outside users that do not need to necessarily be concerned with building and/or maintaining the database system, hut instead may be available for their use when the users need the database system (e.g., on the demand of the users). Some on-demand database systems may store information from one or more tenants stored into tables of a common database image to form a multi-tenant database system (MTS). Accordingly, “on-demand database system 716 ” and “system 716 ” will be used interchangeably herein. A database image may include one or more database objects. A relational database management system (RDMS) or the equivalent may execute storage and retrieval of information against the database object(s). Application platform 718 may be a framework that allows the applications of system 716 to run, such as the hardware and/or software, e.g., the operating system. In an embodiment, on-demand database system 716 may include an application platform 718 that enables creation, managing and executing one or more applications developed by the provider of the on-demand database system, users accessing the on-demand database system via user systems 712 , or third party application developers accessing the on-demand database system via user systems 712 .
The users of user systems 712 may differ in their respective capacities, and the capacity of a particular user system 712 might be entirely determined by permissions (permission levels) for the current user. For example, where a salesperson is using a particular user system 712 to interact with system 716 , that user system has the capacities allotted to that salesperson. However, while an administrator is using that user system to interact with system 716 , that user system has the capacities allotted to that administrator. In systems with a hierarchical role model, users at one permission level may have access to applications, data, and database information accessible by a lower permission level user, but may not have access to certain applications, database information, and data accessible by a user at a higher permission level. Thus, different users will have different capabilities with regard to accessing and modifying application and database information, depending on a user's security or permission level.
Network 714 is any network or combination of networks of devices that communicate with one another. For example, network 714 can be any one or any combination of a LAN (local area network), WAN (wide area network), telephone network, wireless network, point-to-point network, star network, token ring network, hub network, or other appropriate configuration. As the most common type of computer network in current use is a TCP/IP (Transfer Control Protocol and Internet Protocol) network, such as the global internetwork of networks often referred to as the “Internet” with a capital “I,” that network will be used in many of the examples herein. However, it should be understood that the networks that the one or more implementations might use are not so limited, although TCP/IP is a frequently implemented protocol.
User systems 712 might communicate with system 716 using TCP/IP and, at a higher network level, use other common Internet protocols to communicate, such as HTTP, FTP, AFS. WAP, etc. In an example where HTTP is used, user system 712 might include an HTTP client commonly referred to as a “browser” for sending and receiving HTTP messages to and from an HTTP server at system 716 . Such an HTTP server might be implemented as the sole network interface between system 716 and network 714 , but other techniques might be used as well or instead. In some implementations, the interface between system 716 and network 714 includes load sharing functionality, such as round-robin HTTP request distributors to balance loads and distribute incoming HTTP requests evenly over a plurality of servers. At least as for the users that are accessing that server, each of the plurality of servers has access to the MTS' data however, other alternative configurations may be used instead.
In one embodiment, system 716 , shown in FIG. 7 , implements a web-based customer relationship management (CRM) system. For example, in one embodiment, system 716 includes application servers configured to implement and execute CRM software applications as well as provide related data, code, forms, webpages and other information to and from user systems 712 and to store to, and retrieve from, a database system related data, objects, and Webpage content. With a multi-tenant system, data for multiple tenants may be stored in the same physical database object, however, tenant data typically is arranged so that data of one tenant is kept logically separate from that of other tenants so that one tenant does not have access to another tenant's data, unless such data is expressly shared. In certain embodiments, system 716 implements applications other than, or in addition to, a CRM application. For example, system 716 may provide tenant access to multiple hosted (standard and custom) applications, including a CRM application. User (or third party developer) applications, which may or may not include CRM, may be supported by the application platform 718 , which manages creation, storage of the applications into one or more database objects and executing of the applications in a virtual machine in the process space of the system 716 .
One arrangement for elements of system 716 is shown in FIG. 7 , including a network interface 720 , application platform 718 , tenant data storage 722 for tenant data 723 , system data storage 724 for system data 725 accessible to system 716 and possibly multiple tenants, program code 726 for implementing various functions of system 716 , and a process space 728 for executing MTS system processes and tenant-specific processes, such as running applications as part of an application hosting service. Additional processes that may execute on system 716 include database indexing processes.
Several elements in the system shown in FIG. 7 include conventional, well-known elements that are explained only briefly here. For example, each user system 712 could include a desktop personal computer, workstation, laptop, PDA, cell phone, or any wireless access protocol (WAP) enabled device or any other computing device capable of interfacing directly or indirectly to the Internet or other network connection. User system 712 typically runs an HTTP client, e.g., a browsing program, such as Microsoft's Internet Explorer browser, Netscape's Navigator browser, Opera's browser, or a WAP-enabled browser in the case of a cell phone, PDA or other wireless device, or the like, allowing a user (e.g., subscriber of the multi-tenant database system) of user system 712 to access, process and view information, pages and applications available to it from system 716 over network 714 . Each user system 712 also typically includes one or more user interface devices, such as a keyboard, a mouse, trackball, touch pad, touch screen, pen or the like, for interacting with a graphical user interface (GUI) provided by the browser on a display (e.g., a monitor screen, LCD display, etc.) in conjunction with pages, forms, applications and other information provided by system 716 or other systems or servers. For example, the user interface device can be used to access data and applications hosted by system 716 , and to perform searches on stored data, and otherwise allow a user to interact with various GUI pages that may be presented to a user. As discussed above, embodiments are suitable for use with the Internet, which refers to a specific global internetwork of networks. However, it should be understood that other networks can be used instead of the Internet, such as an intranet, an extranet, a virtual private network (VPN), a non-TCP/IP based network, any LAN or WAN or the like.
According to one embodiment, each user system 712 and all of its components are operator configurable using applications, such as a browser, including computer code run using a central processing unit such as an Intel Pentium® processor or the like. Similarly, system 716 (and additional instances of an MTS, where more than one is present) and all of their components might be operator configurable using application(s) including computer code to run using a central processing unit such as processor system 717 , which may include an Intel Pentium® processor or the like, and/or multiple processor units. A computer program product embodiment includes a machine-readable storage medium (media) having instructions stored thereon/in which can be used to program a computer to perform any of the processes of the embodiments described herein. Computer code for operating and configuring system 716 to intercommunicate and to process webpages, applications and other data and media content as described herein are preferably downloaded and stored on a hard disk, hut the entire program code, or portions thereof, may also be stored in any other volatile or non-volatile memory medium or device as is well known, such as a ROM or RAM, or provided on any media capable of storing program code, such as any type of rotating media including floppy disks, optical discs, digital versatile disk (DVD), compact disk (CD), microdrive, and magneto-optical disks, and magnetic or optical cards, nanosystems (including molecular memory ICs), or any type of media or device suitable for storing instructions and/or data. Additionally, the entire program code, or portions thereof, may be transmitted and downloaded from a software source over a transmission medium, e.g., over the Internet, or from another server, as is well known, or transmitted over any other conventional network connection as is well known (e.g., extranet, VPN, LAN, etc.) using any communication medium and protocols (e.g., TCP/IP, HTTP, HTTPS, Ethernet, etc.) as are well known. It will also be appreciated that computer code for implementing embodiments can be implemented in any programming language that can be executed on a client system and/or server or server system such as, for example, C, C++, HTML, any other markup language, Java™, JavaScript, ActiveX, any other scripting language, such as VBScript, and many other programming languages as are well known may be used. (Java™ is a trademark of Sun Microsystems, Inc.).
According to one embodiment, each system 716 is configured to provide webpages, forms, applications, data and media content to user (client) systems 712 to support the access by user systems 712 as tenants of system 716 . As such, system 716 provides security mechanisms to keep each tenant's data separate unless the data is shared. If more than one MTS is used, they may be located in close proximity to one another (e.g., in a server farm located in a single building or campus), or they may be distributed at locations remote from one another (e.g., one or more servers located in city A and one or more servers located in city B). As used herein, each MTS could include one or more logically and/or physically connected servers distributed locally or across one or more geographic locations. Additionally, the term “server” is meant to include a computer system, including processing hardware and process space(s), and an associated storage system and database application (e.g., OODBMS or RDBMS) as is well known in the art. It should also be understood that “server system” and “server” are often used interchangeably herein. Similarly, the database object described herein can be implemented as single databases, a distributed database, a collection of distributed databases, a database with redundant online or offline backups or other redundancies, etc., and might include a distributed database or storage network and associated processing intelligence.
FIG. 8 also illustrates environment 710 . However, in FIG. 8 elements of system 716 and various interconnections in an embodiment are further illustrated. FIG. 8 shows that user system 712 may include processor system 712 A, memory system 71213 , input system 712 C, and output system 712 D. FIG. 8 shows network 714 and system 716 . FIG. 8 also shows that system 716 may include tenant data storage 722 , tenant data 723 , system data storage 724 , system data 725 , User interface (UI) 830 , Application Program interface (API) 832 , PL/SOQL 834 , save routines 836 , application setup mechanism 838 , applications servers 800 1 - 800 N , system process space 802 , tenant process spaces 804 , tenant management process space 810 , tenant storage area 812 , user storage 814 , and application metadata 816 . In other embodiments, environment 710 may not have the same elements as those listed above and/or may have other elements instead of, or in addition to, those listed above.
User system 712 , network 714 , system 716 , tenant data storage 722 , and system data storage 724 were discussed above in FIG. 7 . Regarding user system 712 , processor system 712 A may be any combination of one or more processors. Memory system 712 B may be any combination of one or more memory devices, short term, and/or long term memory. Input system 712 C may be any combination of input devices, such as one or more keyboards, mice, trackballs, scanners, cameras, and/or interfaces to networks. Output system 712 D may be any combination of output devices, such as one or more monitors, printers, and/or interfaces to networks. As shown by FIG. 8 , system 716 may include a network interface 720 (of FIG. 7 ) implemented as a set of HTTP application servers 800 , an application platform 718 , tenant data storage 722 , and system data storage 724 . Also shown is system process space 802 , including individual tenant process spaces 804 and a tenant management process space 810 . Each application server 800 may be configured to tenant data storage 722 and the tenant data 723 therein, and system data storage 724 and the system data 725 therein to serve requests of user systems 712 . The tenant data 723 might be divided into individual tenant storage areas 812 , which can be either a physical arrangement and/or a logical arrangement of data. Within each tenant storage area 812 , user storage 814 and application metadata 816 might be similarly allocated for each user. For example, a copy of a user's most recently used (MRU) items might be stored to user storage 814 . Similarly, a copy of MRU items for an entire organization that is a tenant might be stored to tenant storage area 812 . A UI 830 provides a user interface and an API 832 provides an application programmer interface to system 716 resident processes to users and/or developers at user systems 712 . The tenant data and the system data may be stored in various databases, such as one or more Oracle™ databases.
Application platform 718 includes an application setup mechanism 838 that supports application developers' creation and management of applications, which may be saved as metadata into tenant data storage 722 by save routines 836 for execution by subscribers as one or more tenant process spaces 804 managed by tenant management process 810 for example. Invocations to such applications may be coded using PL/SOQL 834 that provides a programming language style interface extension to API 832 . A detailed description of some PL/SOQL language embodiments is discussed in commonly owned co-pending U.S. Provisional Patent Application 60/828,192 entitled, PROGRAMMING LANGUAGE METHOD AND SYSTEM FOR EXTENDING APIS TO EXECUTE IN CONJUNCTION WITH DATABASE APIS, by Craig Weissman, filed Oct. 4, 2006, which is incorporated in its entirety herein for all purposes. Invocations to applications may be detected by one or more system processes, which manages retrieving application metadata 816 for the subscriber making the invocation and executing the metadata as an application in a virtual machine.
Each application server 800 may be communicably coupled to database systems, e.g., having access to system data 725 and tenant data 723 , via a different network connection. For example, one application server 800 1 might be coupled via the network 714 (e.g., the Internet), another application server 800 N-1 might be coupled via a direct network link, and another application server 800 N might be coupled by yet a different network connection. Transfer Control Protocol and Internet Protocol (TCP/IP) are typical protocols for communicating between application servers 800 and the database system. However, it will be apparent to one skilled in the art that other transport protocols may be used to optimize the system depending on the network interconnect used.
In certain embodiments, each application server 800 is configured to handle requests for any user associated with any organization that is a tenant. Because it is desirable to be able to add and remove application servers from the server pool at any time for any reason, there is preferably no server affinity for a user and/or organization to a specific application server 800 . In one embodiment, therefore, an interface system implementing a load balancing function (e.g., an F5 Big-IP load balancer) is communicably coupled between the application servers 800 and the user systems 712 to distribute requests to the application servers 800 . In one embodiment, the load balancer uses a least connections algorithm to route user requests to the application servers 800 . Other examples of load balancing algorithms, such as round robin and observed response time, also can be used. For example, in certain embodiments, three consecutive requests from the same user could hit three different application servers 800 , and three requests from different users could hit the same application server 800 . In this manner, system 716 is multi-tenant, wherein system 716 handles storage of, and access to, different objects, data and applications across disparate users and organizations.
As an example of storage, one tenant might be a company that employs a sales force where each salesperson uses system 716 to manage their sales process. Thus, a user might maintain contact data, leads data, customer follow-up data, performance data, goals and progress data, etc., all applicable to that user's personal sales process (e.g., in tenant data storage 722 ). In an example of a MTS arrangement, since all of the data and the applications to access, view, modify, report, transmit, calculate, etc., can be maintained and accessed by a user system having nothing more than network access, the user can manage his or her sales efforts and cycles from any of many different user systems. For example, if a salesperson is visiting a customer and the customer has Internet access in their lobby, the salesperson can obtain critical updates as to that customer while waiting for the customer to arrive in the lobby.
While each user's data might be separate from other users' data regardless of the employers of each user, some data might be organization-wide data shared or accessible by a plurality of users or all of the users for a given organization that is a tenant. Thus, there might be some data structures managed by system 716 that are allocated at the tenant level while other data structures might be managed at the user level. Because an MTS might support multiple tenants including possible competitors, the MTS should have security protocols that keep data, applications, and application use separate. Also, because many tenants may opt for access to an MTS rather than maintain their own system, redundancy, up-time, and backup are additional functions that may be implemented in the MTS. In addition to user-specific data and tenant specific data, system 716 might also maintain system level data usable by multiple tenants or other data. Such system level data might include industry reports, news, postings, and the like that are sharable among tenants.
In certain embodiments, user systems 712 (which may be client systems) communicate with application servers 800 to request and update system-level and tenant-level data from system 716 that may require sending one or more queries to tenant data storage 722 and/or system data storage 724 . System 716 (e.g., an application server 800 in system 716 ) automatically generates one or more SQL statements (e.g., one or more SQL queries) that are designed to access the desired information. System data storage 724 may generate query plans to access the requested data from the database.
Each database can generally be viewed as a collection of objects, such as a set of logical tables, containing data fitted into predefined categories. A “table” is one representation of a data object, and may be used herein to simplify the conceptual description of objects and custom objects. It should be understood that “table” and “object” may be used interchangeably herein. Each table generally contains one or more data categories logically arranged as columns or fields in a viewable schema. Each row or record of a table contains an instance of data for each category defined by the fields. For example, a CRM database may include a table that describes a customer with fields for basic contact information such as name, address, phone number, fax number, etc. Another table might describe a purchase order, including fields for information such as customer, product, sale price, date, etc. In some multi-tenant database systems, standard entity tables might be provided for use by all tenants. For CRM database applications, such standard entities might include tables for Account, Contact, Lead, and Opportunity data, each containing pre-defined fields. It should be understood that the word “entity” may also be used interchangeably herein with “object” and “table”.
In some multi-tenant database systems, tenants may be allowed to create and store custom objects, or they may be allowed to customize standard entities or objects, for example by creating custom fields for standard objects, including custom index fields. U.S. patent application Ser. No. 10/817,161, filed Apr. 2, 2004, entitled “Custom Entities and Fields in a Multi-Tenant Database System”, and which is hereby incorporated herein by reference, teaches systems and methods for creating custom objects as well as customizing standard objects in a multi-tenant database system. In certain embodiments, for example, all custom entity data rows are stored in a single multi-tenant physical table, which may contain multiple logical tables per organization. It is transparent to customers that their multiple “tables” are in fact stored in one large table or that their data may be stored in the same table as the data of other customers.
While one or more implementations have been described by way of example and in terms of the specific embodiments, it is to be understood that one or more implementations are not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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In accordance with embodiments, there are provided mechanisms and methods for resolving a data conflict. These mechanisms and methods for resolving a data conflict can enable an improved user experience, increased efficiency, time savings, etc.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to household items, and in particular, to a hamper that can be collapsed to a compact configuration for convenient storage and transportation.
2. Description of the Prior Art
Space, storage, convenience and shipping are major concerns relating to the shipment and sale of household items. For example, the bulkiness and large sizes of many of these household items can not only increase the shipping costs of such items, but can also present space and storage problems to consumers who live in smaller homes and apartments.
An example of such household items is laundry hampers. Laundry hampers tend to be large in size to hold a reasonable amount of dirty clothing. However, transportation and storage of these hampers is quite troublesome, since their large sizes and bulkiness makes it more costly to ship them from the manufacturer to retailers. In addition, the consumer often needs sufficient space in their vehicles to take them home, and then needs sufficient floor space in the home to store these hampers when they are not in use.
Thus, there remains a need for a laundry hamper that can be conveniently shipped, transported, stored and deployed for use, and which takes up minimal space, thereby decreasing the shipping costs and increasing convenience to the consumer.
SUMMARY OF THE DISCLOSURE
In order to accomplish the objects of the present invention, there is provided a hamper assembly that has a plurality of separate sections, and a plurality of supports. Each section has a first side and a second side, and a connector provided on each side of each section. In addition, each support removably couples the connector on the first side of one section and the connector on the second side of an adjacent section.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a hamper assembly according to one embodiment of the present invention.
FIG. 2 is a sectional view of a pair of connectors of the assembly of FIG. 1 .
FIG. 3 is a top perspective view of a lid that can be used with the assembly of FIG. 1 .
FIG. 4 is a bottom perspective view of the lid of FIG. 3 .
FIG. 5 is a perspective view of the assembly of FIG. 1 with a laundry bag deployed therein.
FIG. 6 is a perspective view of a hamper assembly according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims. In certain instances, detailed descriptions of well-known devices, components, mechanisms and methods are omitted so as to not obscure the description of the present invention with unnecessary detail.
The present invention provides hamper assemblies that can be collapsed to reduce bulk and size for more convenient storage and transportation. The hamper assemblies according to the present invention have a plurality of sections that are coupled together to form a frame. These sections can be detached and then placed on top of each other to provide a smaller profile and less bulk for storage and transportation.
FIGS. 1-5 illustrate one embodiment of the hamper assembly 10 of the present invention. The assembly 10 has a plurality of sections 12 and 14 , and two pole supports 16 and 18 for connecting the sections 12 and 14 to form the assembly 10 . Each section 12 and 14 can be made from a solid material, such as rattan, wicker, metal, plastic or similar materials.
In the embodiment of FIGS. 1-5, each section 12 and 14 can be curved or generally semi-circular in configuration, although other configurations can be used (such as illustrated in FIG. 6 below). Each section 12 and 14 has two sides 20 , 22 and 24 , 26 , respectively. One or more aligning connectors can be provided in spaced-apart manner along each side 20 , 22 , 24 , 26 . For example, the side 20 of section 12 can have two connectors 30 and 32 , the side 22 of section 12 can have two connectors 34 and 36 , the side 24 of section 14 can have two connectors 38 and 40 , and the side 26 of section 12 can have two connectors (not shown). Each connector 30 , 32 , 34 , 36 , 38 , 40 can be a curved metal plate having an opening 42 provided in the center thereof, and with a shaft 44 connecting the curved metal plate to a side 20 , 22 , 24 or 26 . Each metal plate is preferably concave in that the curvature extends radially inwardly towards the center of the corresponding section 12 or 14 .
Each pole support 16 and 18 has a pole 50 and 52 , respectively. Each pole 50 and 52 has a lower end that is connected (e.g., by welding or by a screw 54 ) to a leg 56 and 58 , respectively. If a screw 54 is used to connect each leg 56 , 58 to its pole 50 , 52 , then a threaded opening 60 can be provided in the leg 56 , 58 and the lower end of each pole 50 and 52 can have a threaded bore (not shown), so that the screw 54 can be threaded through the opening 60 and secured inside the threaded bore.
The assembly 10 is shown in FIG. 1 with its components disassembled, and can be assembled in the following manner. The sections 12 and 14 can be positioned with the sides 20 and 24 adjacent to each other, and the sides 22 and 26 adjacent to each other. When so positioned, the connectors 30 and 38 on sides 20 and 24 , respectively, and the connectors 32 and 40 , will be positioned adjacent each other with their openings 42 aligned. Similarly, the connectors 34 and 36 on the side 22 will be aligned with the connectors on the side 26 . The pole 50 is then placed into the concave region defined by the pairs of aligned connectors 30 + 38 and 32 + 40 . FIG. 2 illustrates the alignment of connectors 30 and 38 , as viewed from the center of the internal space defined by the sections 12 and 14 . The pole 50 has two threaded openings 62 and 64 that are adapted to be aligned with the aligned connectors 30 + 38 and 32 + 40 , respectively. One screw 66 can then be inserted from the internal space through the aligned openings 42 (for connectors 30 and 38 ) and 62 , and another screw 68 can then be inserted from the internal space through the aligned openings 42 (for connectors 32 and 40 ) and 64 , to secure the sides 20 and 24 to the pole 50 . The other pole 52 can be secured to the other sides 22 and 26 in the same manner. Thus, the assembly 10 is complete and ready for use.
When the components of the assembly 10 are disassembled, the sections 12 and 14 can be placed one on top of the other, in a nested fashion, and the poles 50 , 52 placed in the concave region of the sections 12 , 14 . This provides a slim profile (i.e., two stacked sections 12 , 14 ) that will occupy less space for shipping, packing, storage and transportation.
Although FIG. 1 illustrates the use of two sets of connectors for each side of a section 12 , 14 , it is possible to provide any number of connectors for each side.
When the assembly 10 is assembled in the manner illustrated above, the assembly 10 can act as a frame for supporting a laundry bag. Referring to FIG. 5, any conventional fabric or plastic laundry bag 70 can be draped over the top edges 72 and 74 of the sections 12 and 14 , respectively, with its opening 76 exposed to the top of the assembly 10 . A separate lid 80 can be placed over the top of the assembly 10 to cover the laundry bag 70 . The lid 80 is illustrated in FIGS. 3 and 4, and can be a flat plate having a handle 82 secured to a top surface 84 , and a pair of bars 86 positioned on a bottom surface 88 . The bars 86 are positioned to be adjacent the sections 12 and 14 when the lid 80 is positioned over the assembly 10 , and functions to help the user align the lid 80 to the top of the assembly 10 . The lid 80 has a shape that preferably corresponds to the shape of the opening 76 . An optional pair of indents 90 can be provided on either end of the lid 80 to accomodate the poles 50 and 52 , if necessary.
Although FIG. 1 illustrates two curved sections 12 and 14 , it is also possible to provide the assembly 10 with any number of sections, and with each section being flat. For example, FIG. 6 illustrates another assembly 100 having four separate flat sections 102 , 104 , 106 , 108 that are connected to four separate poles 110 , 112 , 114 , 116 . Two poles 110 and 112 can be connected to one leg 118 , and the other two poles can be connected to another leg 120 . The sections 102 , 104 , 106 , 108 and poles 110 , 112 , 114 , 116 can be assembled in the same manner as illustrated above for the assembly 10 .
Those skilled in the art will appreciate that the embodiments and alternatives described above are non-limiting examples only, and that certain modifications can be made without departing from the spirit and scope thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention.
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A hamper assembly has a plurality of separate sections, and a plurality of supports. Each section has a first side and a second side, and a connector provided on each side of each section. In addition, each support removably couples the connector on the first side of one section and the connector on the second side of an adjacent section.
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This is a continuation of copending application(s) Ser. No. 07/913,000 filed on Jul. 14, 1992 now abandoned.
SUMMARY OF THE INVENTION
This invention concerns an improved drawbar connection for railroad cars. The drawbar connection reduces slack between cars and thereby improves train handling and reduces damage to lading.
A primary object of the invention is a drawbar connection which can be utilized on cars having a standard draft gear pocket. This permits cars originally equipped with conventional couplers and draft gears to be connected by drawbars without having to make extensive modifications to the car structure. Similarly, carbodies originally connected by drawbars can be readily divided into separate cars and equipped with individual couplers and draft gears.
Another object of the invention is a drawbar connection which reduces slack between connected railroad cars.
A further object of the invention is a drawbar connection which utilizes several conventional components, including the draft gear follower, coupler pin and yoke.
A further object of the invention is a drawbar connection which accommodates vertical angling of the drawbar.
These and other objects are realized by a drawbar connection which replaces the standard draft gear with a filling means which is relatively rigid compared to a standard draft gear. This eliminates draft gear travel, which is the largest single source of horizontal movement in a standard drawbar or coupler connection. The filling means is placed in the standard draft gear pocket utilizing a standard yoke. The yoke is connected to a drawbar in the same manner as it would be connected to a conventional coupler having a "F" shank.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the filling means used in the drawbar connection of the present invention.
FIG. 2 is a side elevation view of the filling means installed in a yoke and compressed prior to installation in a draft gear pocket.
FIG. 3 is a plan view of a railroad freight car draft sill and draft gear pocket, with the cover plate removed to show the rear draft lugs.
FIG. 4 is a plan view of the installed drawbar connection.
FIG. 5 is a side elevation view of the drawbar connection.
FIG. 6 is a side elevation of an alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 4 and 5 illustrate the drawbar connection 10 of the present invention. The drawbar connection 10 fits in a draft sill shown generally at 12. The draft sill is connected to the remainder of the railroad freight car in the conventional manner.
The draft sill 12 includes vertical side walls 14 and 16 which flare out at the open ends 18 and 20. The ends 18 and 20 are connected to J-shaped plates 22 and 24. Plates 22 and 24 are connected by upper and lower lateral braces 26 and 28. A channel 30 reinforces the brace 28. Horizontal flanges 32 and 34 connect to the bottom edges of the side walls 14 and 16, respectively. These flanges have a plurality of bolt holes 36 (FIG. 3). The top edges of the side walls are connected by a cover plate 38.
As best seen in FIG. 3, pairs of front and rear draft lugs define a draft gear pocket. The front draft lugs are shown at 40 and 41 while the rear draft lugs are shown at 42 and 43. The draft lugs are attached to the side walls 14 and 16. The space between the draft lugs is referred to as the draft gear pocket. The draft pocket is located longitudinally within the draft sill at a location such that a conventional coupler, yoke and draft gear appropriate for the particular car can be applied using the draft pocket. While the illustrations show a configuration suitable for a car with long end overhang, it will be appreciated that for a car with shorter overhang, the draft pocket would be located closer to the end of the draft sill. In cases where the overhang is short enough to permit the use of Type "E" couplers using cross keys for connection to the yoke, the front draft lugs 40 and 41 would incorporate longitudinal slots to permit application of the cross key when the drawbar is replaced by individual couplers.
In prior art coupler or drawbar connections utilizing a conventional draft gear pocket the draft gear pocket is filled with a draft gear. The present invention replaces the usual draft gear with a relatively rigid filling means shown generally at 44 in FIG. 1. It will be understood that the term relatively rigid is defined to mean the filling means has a travel which may range from essentially no travel to about a half inch or so. This amount of travel contrasts with the standard draft gear travel of about three and one quarter inches. Thus, the filling means of the present invention is relatively rigid compared to the standard draft gear. This reduced amount of travel is also controlled such that no travel occurs until a predetermined amount of coupler force is applied to the draft system. In the present embodiment of the invention, this predetermined coupler force is set at approximately 100,000 pounds, but it is apparent that this force level can be set to any desired value.
The filling means 44 is disposed in the draft gear pocket and extends from the front draft gear lugs 40, 41 to the rear lugs 42, 43. In this embodiment, the filling means includes a follower block 46 located at the front of the filling means. The follower block has a spherical depression 48 in its front face for receiving the rounded end of the drawbar and may be a standard Y46 follower. Next to the follower block is a mini-draft gear 50. The mini-draft gear provides controlled travel when subjected to compressive force and may consist of a series of rubber blocks 52 located between end plates 54 and compressed by bolts 56. The mini-draft gear may have a maximum travel on the order of one-half inch. That is, it may be compressed about a half an inch or so.
A spacer 58 is located adjacent the mini-draft gear 50. The spacer has a thickness, as required, to give the entire filling means 44 a length such that the wedge 60 is raised upward in the opening provided by the yoke 70. The overall length of the filling means is determined when it is assembled in the yoke and a preload of about 100,000 pounds is applied, as will be explained below.
A wedge 60 fits next to the spacer 58. Upon initial installation of the filling means parts, the wedge is located with its upper edge at or near the upper edge of the mini-draft gear. The wedge is designed to drop down under the force of gravity, as seen in FIG. 5, to compensate for wear in the filling means components. The wedge fits between the spacer 58 and a rigid filler block 62. In this embodiment the filler block is a casting having a front wall 64 with an inclined front surface 66. The angle of the surface 66 matches that of the wedge 60, as best seen in FIG. 2. The other end of the filler block 62 has a rear wall 68. The angle of the filler block 66 and the wedge 60 has been carefully selected so as to prevent inadvertent lifting of the wedge under impact but also to provide sufficient compensation for wear of the various components in the draft pocket as the wedge drops.
The drawbar connection also has a yoke 70. Preferably, this is a standard Y-45 yoke. It has top and bottom longitudinally-extending arms 72, 74 which are connected at the front by a head portion 76 and at the rear of the yoke by a heel 78. The head has an opening disposed on a horizontal axis for receiving the drawbar. The head also has a second opening 80 (FIG. 4) on a vertical axis for receiving the coupler pin.
The drawbar itself is shown at 82 in FIGS. 4 and 5. The drawbar has an opening 84 near its end aligned with the opening 80 of the yoke. A coupler pin 86 is disposed vertically in opening 80 of the yoke and opening 84 of the drawbar to connect the drawbar and the yoke together. The portion of the drawbar which contacts the drawbar connection has the same contour as that of a conventional Type "F" coupler shank.
Once the yoke and filling means are installed in the draft sill, they are held in place by carrier plates 88 which are bolted to flanges 32, 34 by bolts 90. The bolts extend through the bolt holes 36. The filling means 44 has been designed to allow for inspection of the wedge 60 without the need to remove the carrier plates 88. Similarly, the coupler pin 86 is held by a coupler pin carrier plate 92 which is bolted to flanges 32,34. The carrier plates complete the construction of the drawbar connection. Attention will now be turned to the preferred method of installing the above-described parts.
The first step in installing the connection is to measure the draft gear pocket length between the front and rear draft lugs. That is, the distance between the lugs 40, 42 and between lugs 41, 43 is measured. The greater of these two measurements is used as the draft gear pocket length.
Next, the filling means, minus the spacer 58, is assembled in the yoke and a preload of about 100,000 pounds is applied. This preload is applied by a hydraulic ram 98 which is temporarily located within the openings of the yoke head. The ram butts up against a halved coupler pin 100 which is also temporarily located in the yoke head for purposes of installing the filling means. After applying the preload, the overall length of the filling means' components (less spacer 58) is measured. The thickness of the spacer 58 is chosen to obtain a total filling means length equal to the measured draft gear pocket length with the wedge 60 raised a maximum amount within the yoke 70. Once this dimension is obtained, the pressure of the hydraulic ram is released and a spacer 58 of the desired thickness is inserted between the mini-draft gear 50 and the wedge 60. The hydraulic ram 98 is then reapplied and the pressure is increased to compress the assembly to a length of about 1/8 inch less than the draft gear pocket length.
With the filling means thus compressed, the yoke and filling means are inserted into the draft sill from the open underside, with the follower block 46 slipping in adjacent to the front draft lugs 40, 41 and the filler block 62 sliding in adjacent to the rear draft lugs 42, 43. Once the yoke and filling means are inserted into the draft gear pocket, the carrier plates 88 may be bolted in place to hold the yoke and filling means in place. At this point the pressure of the hydraulic ram 98 is released and it is removed from the yoke, along with the halved pin 100. The drawbar 82 can then be inserted into the head of the yoke, with the drawbar opening 84 aligned with the yoke vertical opening 80. The coupler pin 86 is installed, followed by the bolted pin carrier plate 92.
The end of the drawbar fits into the depression 48 of the follower block 46. Buff loads are transmitted by the drawbar through the follower block 46, mini-draft gear 50, spacer 58, wedge 60, and filler block 62 to the rear draft lugs 42, 43. Draft loads are transmitted by the coupler pin to the yoke head, arms and heel and, from there, through the filling means in the reverse order of that described above to the front draft lugs 40, 41.
The purpose of the mini-draft gear 50 is to accommodate vertical angling of the drawbar as is required when the car negotiates vertical curves in the track. The mini-draft gear may be configured with a preload so that application of a minimum amount of compressive force is required before the draft gear compresses. This preload may be set at any desired value, such as 100,000 pounds. The maximum travel of the mini-draft gear is set at a value, such as 1/2-inch, that is just sufficient to permit the portion of the drawbar behind the coupler pin 86 to angle in the vertical plane without becoming bound between the coupler pin 86 and the follower block 46.
The described drawbar connection reduces slack on three levels compared to a standard coupler connection. First, replacing couplers with a drawbar removes the contour slack in the coupler heads and knuckles. Second, replacing the usual draft gear with a relatively rigid filling means and wedge eliminates draft gear travel which is the largest single source of coupler or drawbar movement. Third, the mini-draft gear permits a minimal amount of movement, just enough to prevent binding of the coupler pin. The drawbar connection can be used to connect two or more carbodies to form a complete multi-unit car. The inventors have successfully connected as many as four carbodies with the described drawbar connection.
An alternate form of the drawbar connection is shown in FIG. 6. This embodiment uses many of the same parts as the previous embodiment. Description of those parts will not be repeated. In the embodiment of FIG. 6, the mini-draft gear 50 and short filler block are replaced by a single, longer filler block 102.
When the controlled travel of the mini-draft gear is eliminated, the limited amount of slack in the connection of the yoke, coupler pin, drawbar butt and follower block is relied upon to permit vertical angling of the drawbar.
While preferred and alternate forms of the invention have been shown and described, it will be realized that modifications may be made thereto without departing from the scope of the following claims.
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An improved drawbar connection for railroad cars reduces slack between cars and results in improved train handling. The drawbar connection fits in a standard draft gear pocket and utilizes a standard yoke, standard follower and standard coupler pin, thereby permitting the application of drawbars with minimal structural modification to cars originally equipped with conventional couplers. The usual draft gear is replaced by a filler which is relatively rigid. The filler includes a follower block, a wedge, a filler block and may include a mini-draft gear having a maximum travel of about one-half inch.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional of U.S. application Ser. No. 10/734,429 filed Dec. 12, 2003 by the same inventors, and claims priority therefrom. The original U.S. patent application Ser. No. 10/734,429 is hereby incorporated by reference in its entirety. This divisional application is being filed in response to a Restriction Requirement in that prior application.
BACKGROUND
[0002] Thin-film transistor array backplanes for applications such as flat-panel display systems and image sensors have become increasingly prevalent. However, the displays and image sensors using such backplanes remain quite complex and expensive. One of the reasons for the high expense is the use of conventional photolithographic and thin-film deposition processes are often used to fabricate the transistor array backplanes.
[0003] In order to lower the cost, alternative processes and materials have been explored. One area of research has been using organic and polymeric semiconductors to replace the traditional silicon-based transistors. However, carrier mobility in organic and polymeric semiconductors, especially solution processable semiconductors, is often lower than carrier mobility in amorphous and crystalline silicon structures. The lower carrier mobility results in slower switching speeds and lower drive currents compared to traditional silicon-based semiconductors. Thus the performance of organic and polymeric thin-film transistors are typically below that of thin-film transistors made from more traditional materials such as amorphous silicon.
[0004] Thus a structure or method of improving the performance of organic and polymeric semiconductor transistors is needed.
SUMMARY
[0005] A thin-film transistor array for use as an addressable electronic backplane is described. The array is formed from a repetitive arrangement of unit cells or pixels that includes a thin-film transistor used to drive an overlying media. The pixel includes at least two dimensions, a width and a length. The thin film transistor is shaped such that a transistor channel width exceeds the shorter of either the width or length of the pixel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 shows a typical display device coupled to drive electronics.
[0007] FIG. 2 shows a layered display structure including a transistor layer to drive pixels in a media layer
[0008] FIG. 3 shows a top view of a thin film ring transistor with a channel.
[0009] FIG. 4 shows a top view of four thin film ring transistor, each thin film transistor is coupled to a pixel.
[0010] FIG. 5 shows an alternative embodiment of a thin film transistor with an open circle design
[0011] FIG. 6 shows a corbino ring transistor geometry including interdigitated structures.
[0012] FIG. 7 shows a top view of a transistor utilizing a closed spiral channel.
[0013] FIG. 8 shows an alternate embodiment of a transistor including an open spiral channel.
DETAILED DESCRIPTION
[0014] An improved transistor array backplane is described. The transistor array backplane can be used to drive media for display applications or sensors for image sensing. FIG. 1 shows drive electronics coupled to a typical display device 104 . In the illustrated embodiment, drive electronics include a video driver card 108 in a computer 112 . Display device 104 receives signals from video driver card 108 and renders images on a screen for a viewer. Although a video driver card is shown, any circuit used to control a display may be used, including but not limited to a television, DVD player or other display controlling device.
[0015] FIG. 2 shows an expanded view of the active device array used in a display structure. The active devices are arranged in rows and columns that define a pixel. Typically buslines 204 and associated first electrodes 206 are formed on a substrate layer 208 . The buslines carry signals from the drive electronics and provide electrical voltages to first electrodes 206 . In one embodiment, the first electrode may be a gate electrode.
[0016] A thin film transistor heterostructure layer 212 is formed over substrate layer 208 . The thin film transistor hetrostructure layer (hereinafter TFT layer) includes several transistor components including a semiconductor layer, a dielectric layer, and a second and a third electrode. In one embodiment, the second and third electrodes may be source and drain electrodes. A channel region is disposed between the second and third electrodes. The channel may be of arbitrary shape, but is typically formed to overlap the position of the first electrode in substrate layer 208 .
[0017] An electric potential on the first electrode controls transistor switching. When an electric potential is applied to the first electrode, the electric field in the first electrode causes a change in transconductance of the semiconductor layer, forming a conductive channel, adjacent to the dielectric layer and first electrode. The conductive channel allows current to flow from the second electrode to the third electrode. When the electric potential is removed from first electrode, the channel is no longer conductive and the transistor is in an “off” state. In another embodiment, the channel layer does not extend the entire length between the second and third electrode. This embodiment is typical for high voltage thin-film transistors.
[0018] In the illustrated embodiment, buslines in a data line layer 216 are deposited over the TFT layer. Data lines carry an electrical signal from drive electronics to the transistor source electrodes in TFT layer 212 . An encapsulation layer is formed over the data line layer to isolate the TFT layer. A media layer 220 is deposited over the encapsulation layer. In one embodiment, patterned vias etched into the encapsulation layer connect the TFT layer with the media layer. The pixels switched by transistors in TFT layer 208 are defined by the boundaries of the buslines. The media may be made from liquid crystals, electrophorectic inks, amorphous Si, particle dispersed liquid crystals, light-emitting semiconductors, or other materials known in the art. In an array backplane for a display, a voltage output from a transistor determines the state of a pixel causing the pixel to convert to a state that either generates or improves the transmission or reflection of light. In an image sensing array, the transistor switches to determine the voltage input from the sensing media.
[0019] As used herein, the pixel is the smallest addressable unit in an array of elements. The shape and dimensions of a pixel may vary, however, in many arrays the spacing of the buslines, e.g. gate lines and the data lines, determines the pixel dimensions. Often, adjacently spaced gate lines and adjacently spaced data lines form the approximate borders of a pixel. However, it is not required that the data line and gate lines bound the pixel; pixel structures that overlap gate and data lines are available.
[0020] A detailed description of forming transistor and transistor arrays and using the arrays as addressable backplanes may be found in Technology and Applications of Amorphous Silicon (Editor: R. A. Street, Springer-Verlag, 1999), which is hereby incorporated by reference in its entirety. Although an example display has been described, it should be recognized that other methods and arrangements for forming thin film transistors to drive a display are available. For example, the gate lines may be formed over the TFT layer and the data lines under the TFT layers. The same techniques may also be used to form equivalent structures such as sensors where the pixels detect the incidence of photons rather than reflect or alter the transmission of light. Thus the invention should not be limited to the specific structure previously described.
[0021] FIG. 3 shows a thin film transistor 304 . A gate line 308 and a data line 312 addresses thin film transistor 304 . The thin film transistor includes a channel 316 having a length 332 and a width 336 . As used herein, channel region is broadly defined as the semiconductor region between two electrodes, control of the channel controls the flow of electrons between the two electrodes. In a field effect transistor, these two electrodes are a source and a drain. The length of the channel is defined as the direction of current flow between the electrodes, typically the direction of electron flow between a transistor source and a transistor drain. The channel width is defined as the channel dimension perpendicular to the direction of electron or current flow. In measuring the width of a curved transistor, some ambiguity exists because the measured width will be different depending on where in the channel the width is measured. For purposes of this invention, the width is measured in the center of the channel. Thus the width is measured by a line that bisects the length of the channel.
[0022] In transistor 304 , current flows from electrode 320 through channel 316 to electrode 324 . A voltage applied to electrode 328 controls the current flow. The operation of such transistors is described in Technology and Applications of Amorphous Silicon (Editor: R. A. Street, Springer-Verlag, 1999), which is hereby incorporated by reference.
[0023] In a display system, each transistor usually addresses a pixel. Pixel state depends on a voltage applied to the pixel. The media in the pixel, in a first state, either generates, transmits or reflects light. In a second state, the same media in pixel blocks or absorbs light.
[0024] In color systems, pixels often include a plurality of sub-pixels. For example, in order to generate color, a pixel may be divided into three sub-pixels. Each sub-pixel may correspond to a basic or primary color and may be individually addressed by a corresponding transistor. When a square pixel is desired each sub-pixel may be rectangular in shape with a three to one aspect ratio such that together, three sub-pixels form a square pixel. Monochromatic systems often do not utilize sub-pixels, instead using a single square pixel in which a width equals a length.
[0025] Although square pixels are more common, other sizes and shapes may be used. The actual dimensions and shape of a pixel may vary widely according to the size and resolution of the display, but as previously described, usually the dimensions of each pixel in a display is bounded or confined to the area between adjacent gate lines and adjacent data lines.
[0026] As previously described, transistors formed from low mobility semiconductors suffer from slower response times and higher voltages for switching. Increasing the width to length ratio of the channel partially compensates for the lower mobility. In one embodiment, transistors made from organic or polymeric semiconductor having electron mobilities below 0.5 cm 2 /Volt-second have low switching speeds and low drive current. The drive current of the device is improved by increasing the channel width to length ratios. FIGS. 4-8 show various geometry TFT channel structures that increase the ratio of width to length in a pixel by forming at least one bend or curve in the channel.
[0027] FIG. 4 shows a top view of a layout for four transistors 404 , 408 , 412 , 416 . Each transistor addresses a corresponding pixel, for example, transistor 408 may address pixel 420 . Voltages applied to gate lines 424 controls switching of transistor 404 . Pixel 420 has dimensions including a pixel width 444 and a pixel length 448 . Typically pixel widths and lengths range from 85 to 500 microns for displays. Typical sensor pixel dimensions can range down to 1 micron, although the provided dimensions are for reference only and other sizes may be fabricated as needed.
[0028] Each transistor such as transistor 404 includes a channel 452 separating electrode 450 and electrode 451 . In the illustrated embodiment, channel 452 is a closed structure that completely encircles electrode 451 . Closed structures that isolate the drain help minimize leakage currents. Channel 452 has a length 460 which is parallel to the direction of current flow and usually the shortest distance from the electrode 450 to the electrode 451 . Channel 452 also has a width 456 , a dimension perpendicular to the direction of current flow and illustrated by a line 453 running along the center of channel 452 and bisecting length 560 . As shown the width substantially exceeds the length. Bends, such as channel bend 464 , also help to enable the channel width to exceed linear dimensions (either pixel length or pixel width) of pixel 420 . Transistor 404 addresses pixel 420 .
[0029] FIG. 5 shows an alternative open “circle” design of the transistor for use in a display device. In an open design, the drain is not completely encircled by the channel. A pixel 508 addressed by transistor 504 lies between the adjacent gate lines 512 , 516 and adjacent data lines 520 , 524 . The transistor includes a channel 528 where the channel width shown as dotted line 532 exceeds a dimension of the pixel addressed by the transistor.
[0030] Additional increases in the width to length ratio may be achieved by adding bends or curve in the channel structure. Adding multiple bends enables channel width to length ratios in excess of 100 . FIG. 6 shows a top view of a geometry having interdigitated electrode-channel-electrode layout that offers higher width to length ratios. As used herein, interdigitated means that channel 604 includes at least two significant bends, such as bends 605 , 606 such that channel 604 surrounds on three sides a section 607 of electrode 624 or electrode 628 . Region 607 which is surrounded on three sides is referred to as the “digit”.
[0031] In FIG. 6 , each transistor such as transistor 600 switches a corresponding pixel 608 . In one embodiment, pixel 608 has dimensions of approximately 17×17 unit cells. The width of a channel 620 is typically between 100 and 1000 microns. In the embodiment shown, the approximate width to length may exceed 100, and is often around 120.
[0032] Larger area transistors may interfere with the pixel output, particularly in backlit displays, such as conventional twisted nematic liquid crystal displays. In such display designs, image quality can sometimes be improved by increasing the aperture size of the pixel. One way to increase aperture size is to use transparent conductor pixel pads that allow light to pass through parts of the transistor and the pixel pads. When opaque gate lines are used, minimizing gate line and source/drain overlap can also help to maximize light transmission through the transistor. Such transparent transistor structures are described in “Optimization of External Coupling and Light Emission in Organic Light-Emitting Devices: Modeling and Experiment”, J. Appl. Phys. Vol. 91, No. 2 pp. 595-604 by Lu and Sturm (2002) which is hereby incorporated by reference.
[0033] FIG. 7 shows an alternate transistor 700 that uses a spiral pattern for a channel. In FIG. 7 , a spiral channel 704 surrounds a spiral electrode 708 in a closed geometry. A first electrode typically controls the conductivity of spiral channel 704 . In one embodiment, the first electrode is also spiral shaped. A spiral source 712 provides a source of current to transistor 700 . The illustrated spiral patterns also enable width to length ratios in excess of 100.
[0034] Many variations are possible on the spiral pattern. For example, FIG. 8 shows an open geometry in which electrode 804 is not completely surrounded by a channel 808 .
[0035] Although a number of details have been provided in the specification, such details are provided as examples and to facilitate an understanding of the invention and should not be interpreted to limit the invention. Indeed, the details of the invention may be amended to encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein. Thus the scope of the invention should only be limited by the scope of the claims which follow and their equivalents.
[0036] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.
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An improved transistor array for a display or sensor device is described. The display or sensor device includes a plurality of pixels. Each pixel includes a width and a length. Each pixel is addressed by a transistor. The transistor addressing each pixel has a channel with a channel width. Each channel width is greater than the width or length of the pixel being addressed. By fabricating transistors with extremely long channel widths, lower mobility semiconductor materials can easily be used to fabricate the display device.
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BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The invention relates to novel polybenzoxazole and polybenzothiazole precursors and to resist solutions containing these precursors.
Throughout the specification and claims, the parenthetical expression (thio) is used as a convenient abbreviation to denote independently at each occurrence the alternative presence of oxygen or sulfur in hydroxyl, mercaptan, ether and thioether groups, as in poly[bis(phenolcarboxamide)-ether] and poly[bis(thiophenolcarboxamide)-thioether] precursors for polybenzoxazoles and polybenzothiazoles respectively.
In microelectronics, highly heat-resistant polymers are needed as protection and insulation layers. Such polymers can be employed as dielectric between two metal planes, for example in multi chip modules and memory and logic chips, or as buffer coat between the chip and its housing. Some of these polymers, for example precursors of aromatic polyimides (PIs) and polybenzoxazoles (PBOs), have good solubility in organic solvents and good film-forming properties and can be applied to the electronic components by inexpensive spin-coating methods. The precursors are then cyclized, i.e. converted into the corresponding polymer, by heat treatment, and thus obtain their final properties. ##STR2##
The cyclization is accompanied by disappearance of the polar, hydrophilic groups of the PBO precursor (OH, NH and CO), which would otherwise adversely affect the dielectric properties and water absorption. This is, for example, an essential advantage of polybenzoxazoles over polyimides and in particular over hydroxypolyimides. However, the cyclization is not important just for good dielectric properties and low water absorption of the end product, but also for its high heat stability.
The demands made of the cyclized final product are very high. For example, besides the lowest possible dielectric constant and high thermal stability, a particular requirement is for low moisture absorption. This is because absorbed moisture impairs not only the electrical properties, but can also promote corrosion of the metallic conductor tracks or result in bubble formation and flaking at high temperatures.
Polyimides and polybenzoxazoles have the following advantages over many other high-temperature-stable polymers:
In contrast to the cyclized end product, they can be applied to a substrate as a soluble precursor and then cyclized, during which the solubility and thus the sensitivity to solvents and other process chemicals decreases greatly. For this reason, the processing of, for example, precyclized polybenzoxazoles is difficult.
The addition of suitable photo-active components to the precursors allows the preparation of photo-sensitive compositions, enabling inexpensive, direct structuring of the dielectric. Polybenzoxazoles have the further advantage over polyimides of being structurable in positive mode and developable in aqueous-alkaline media (see EP 0 023 662 B1 corresponding to U.S. Pat. No. 4,395,482, EP 0 264 678 B1 and EP 0 291779 B1). To this end, the PBO precursors used must be soluble in alkaline developers, preferably ones which are free from metal ions.
Benzocyclobutene (BCB), which can be processed in a similar way and structured negatively, has a significantly lower heat stability than polyimide and polybenzoxazole.
A further, important requirement in connection with inexpensive production of microelectronic components is the planarization capacity of the dielectric. The reason for this is that, during the production of such components, level differences occur during application of various layers, making further processing, for example lithographic production of fine structures, more difficult. By contrast, a planarized substrate allows photo-lithographic processes to be carried out with better dimensional accuracy and greater process tolerances. The use of a dielectric which allows good planarization enables expensive polishing procedures (chemical mechanical polishing, CMP) to be avoided in the production of the components.
Alkali-soluble PBO precursors which are suitable for the preparation of photo-sensitive compositions are disclosed, for example, in EP 0 023 662 B1, EP 0 264 678 B1, EP 0 291 779 B1 and DE 37 16 629 C2; these precursors can be cyclized on the substrate (in this respect, see EP 0 291778 B1). However, the known polymers exhibit relatively high moisture absorption, for example 1.7% (see EP 0 291778 B1), after cyclization (conversion into the polybenzoxazole). There is no mention of the planarization capacity of the polymers prepared.
SUMMARY OF THE INVENTION
According to this invention, there are provided poly[bis(thio)phenolcarboxamide(thio)ether] polybenzoxazole and polybenzothiazole precursors which are readily soluble in both organic solvents and in aqueous-alkaline developers which are free from metal ions, are highly suitable for photosensitive compositions and can be processed by spin-coating methods. These precursors are easy to cyclize on substrates and, after cyclization, have, in particular, very low moisture absorption of 1% by weight or even less, and a high degree of planarization, in addition to high heat stability.
The poly[bis(thio)phenolcarboxamide-(thio)ether] polybenzoxazole and polybenzothiazole precursors of this invention contain the following partial structure: ##STR3## where: A 1 to A 6 are--independently of one another--H, F, CH 3 , CF 3 , OCH 3 , OCF 3 , CH 2 CH 3 , CF 2 CF 3 , OCH 2 CH 3 or OCF 2 CF 3 ;
T is O or S, and m is 0 or 1;
Z is one of the following carbocyclic or heterocyclic aromatic radicals: ##STR4## where Q=C--A or N, where A=H, F, (CH 2 ) p CH 3 , (CF 2 ) p CF 3 , O(CH 2 ) p CH 3 , O(CF 2 ) p CF 3 , CO(CH 2 ) p CH 3 , CO(CF 2 ) p CF 3 where p=0 to 8 (linear or branched chain), OC(CH 3 ) 3 , OC(CF 3 ) 3 , C 6 H 5 , C 6 F 5 , OC 6 H 5 , OC 6 F 5 , cyclopentyl, perfluorocyclopentyl, cyclohexyl or perfluorocyclohexyl,
where, in the isolated aromatic rings, a maximum of 3 N-atoms may be present per ring and only 2 N-atoms may be adjacent, and, in the fused ring systems, a maximum of 2 N-atoms may be present per ring,
M=a single bond, (CH 2 ) n , (CF 2 ) n , CH(CH 3 ), CH(CF 3 ), CF(CH 3 ), CF(CF 3 ), C(CH 3 ) 2 , C(CF 3 ) 2 , CH(C 6 H 5 ), CH(C 6 F 5 ), CF(C 6 H 5 ), CF(C 6 F 5 ), C(CH 3 ) (C 6 H 5 ), C{CH 3 ) {C 6 F 5 ) C(CF 3 ) (C 6 H 5 ) C{CF 3 ), (C 6 F 5 ), (C 6 H 5 ) 2 , C(C 6 F 5 ) 2 , CO, SO 2 , ##STR5## with the proviso that, when Z=phenylene (these are the first three of the radicals where Q=C--A which are listed above under Z) or m=0, at least one of the radicals A 1 to A 6 must be other than H, and when
Z= ##STR6## where Q is C--F and M is a single bond, the NH--CO groups of the polybenzoxazole precursor partial structure must be in the o- or p-position to the O bridge.
In the poly[bis(thio)phenolcarboxamide-(thio)ether] precursor for polybenzoxazoles and polybenzothiazoles according to the invention, the above partial structure is linked to the residue having one to thirty carbon atoms and up to three aromatic rings of at least one dicarboxylic acid. The precursor includes from 2 to 10.000 partial structures and dicarboxylic acid residues, a number within this range resulting in a weight average molecular weight ranging preferably from 5.000 to 100.000.
Poly[bis(thio)phenolcarboxamide-(thio)ether] polymer precursors of the structure indicated above are prepared by reacting one or more corresponding bis-o-aminophenols or bis-o-aminothiophenols with approximately stoichiometric quantities of one or more suitable dicarboxylic acids or dicarboxylic acid derivatives, in particular active esters and chlorides. The bis-o-aminophenol or bis-o-aminothiophenol and the dicarboxylic acid or dicarboxylic acid derivative are reacted in an organic solvent at a temperature of from -20 to 150° C., and the polymer is then precipitated by adding the reaction solution drop wise to a suitable precipitant. Depending on the relative proportions of bis-o-amino(thio)phenol and dicarboxylic acid reactants the resulting polymer is terminated with carboxyl groups, o-amino(thio)phenol groups, or some of each. The precipitated polymer is already ready for use after filtration and drying. Before the precipitation of the polymer, amino end groups when present can be masked, i.e. blocked, using a dicarboxylic anhydride.
The poly[bis(thio)phenolcarboxamide-(thio)ether] polymer precursors of the invention are readily soluble in many organic solvents, such as acetone, cyclohexanone, diethylene glycol monoethyl or diethyl ether, N-methylpyrrolidone, γ-butyrolactone, ethyl lactate, tetrahydrofuran and ethyl acetate, and in aqueous-alkaline developers which are free from metal ions, and can easily be processed by spin-coating methods. After cyclization on the substrate, the resultant polybenzoxazoles and polybenzothiazoles have very low moisture absorption, a high degree of planarization and high heat stability.
The poly[bis(thio)phenolcarboxamide-(thio)ether] precursors of the invention are compatible with diazoketones and are therefore advantageously suitable for photoresist solutions containing--dissolved in a solvent--a polybenzoxazole or polybenzothiazole precursor and a diazoketone-based photo-active component. Such photo-active compositions surprisingly exhibit high resolution and very good film quality. In the photo-resist solutions, the weight ratio between polybenzoxazole or polybenzothiazole precursor and diazoquinone is advantageously between 1:20 and 20:1, preferably between 1:10 and 10:1.
DESCRIPTION OF PREFERRED EMBODIMENTS
The bis-o-aminophenols and bis-o-aminothiophenols employed for the preparation of the poly[bis(thio)phenolcarboxamide-(thio) ether] polybenzoxazole and polybenzothiazole precursors of the invention have the following structure: ##STR7## in which A 1 through A 6 , T, Z, and m are as defined above.
These bis-o-aminophenols and bis-o-aminothiophenols are the subject-matter of the following simultaneously filed German patent applications:
No.197 42 195.4--"Bis-o-amino(thio)-phenols, and their preparation" (GR 97 P 3688);
No. 197 42 196.2--"Bis-o-amino(thio)-phenols, and their preparation" (GR 97 P 3684).
Furthermore, the characterizations " 1 A 1 -A 3 " and "A 4 -A 6 " in the structural formulae mean that the aminophenyl groups contain radicals A 1 , A 2 and A 3 , and A 4 , A 5 and A 6 respectively.
Preferred are such bis-o-aminophenols and bis-o-aminothiophenols and the resulting poly[bis(thio)phenolcarboxamide-(thio)ether] precursors for polybenzoxazoles and polybenzothiazoles in which, in the partial structure defined above, each Q is C--H or C--F.
Also preferred are such bis-o-aminophenols and bis-o-aminothiophenols and the resulting poly[bis(thio)phenolcarboxamide-(thio)ether] precursors for polybenzoxazoles and polybenzothiazoles in which, in the partial structure defined above, from zero to two Q are N.
Particularly preferred are such bis-o-aminophenols and the resulting poly[bis(phenolcarboxamide)-ether] precursors for polybenzoxazoles in which, in the partial structure defined above T=O and m=1, and especially such bis-o-aminophenols and resulting precursors for polybenzoxazoles in which Z is ##STR8## in which from zero to three Q are N not adjacent to one another and the remaining Q are C--H, C--F, or C--F 3 ,
in which Z is ##STR9## or in which Q is C--H or C--F and M is a single bond, C (CF 3 ) 2 or CO.
Examples of such bis-o-aminophenols are the following: ##STR10##
For the preparation of the poly[bis(thio)phenolcarboxamide-(thio)ether] precursors, aromatic and non-aromatic dicarboxylic acids, such as 4,4'-oxybisbenzoic acid, 2,2-bis-(4-carboxyphenyl)perfluoropropane, adipic acid, azelaic acid, perfluoroisophthalic acid, 1,3-bis(3-carboxypropyl)tetramethyldisiloxane and isophthalic acid, are particularly suitable. In principle, however, all dicarboxylic acids which have 1 to 30 carbon atoms linking the carboxyl groups and/or up to three aromatic rings can be used. If dicarboxylic acid chlorides are used in the polymerization, the use of a basic acid scavenger is advantageous. Preferred basic acid scavengers are pyridine, triethylamine, diazabicyclooctane and polyvinylpyridine. However, it is also possible to use other basic acid scavengers, particular preference being given to those which are readily soluble in the solvent used for the synthesis, for example N-methylpyrrolidone, and in water or water/alcohol mixtures (precipitant) and also those which are totally insoluble in the solvent, for example cross-linked polyvinylpyridine. In place of dicarboxylic acid chlorides in the polymerization there can be used active esters such as dicarboxylic acid phenyl esters, or free dicarboxylic acids in conjunction with a non-acidic water reactive condensing agent such as N,N'-dicyclohexylcarbodiimide or carbonyldiimidazole.
Particularly suitable solvents for the poly[bis(thio)phenolcarboxamide-(thio)ether] precursor synthesis are dimethylacetamide, γ-butyrolactone and N-methylpyrrolidone. In principle, however, any solvent in which the starting components are readily soluble can be used. Particularly suitable precipitants are water and mixtures of water with various alcohols, for example ethanol and isopropanol.
Cyclization of the poly[bis(thio)phenolcarboxamide-(thio)ether] polybenzoxazole and polybenzothiazole precursors of this invention to moisture- and high temperature stable polybenzoxazoles and polybenzothiazoles is effected by heat tempering the precursors at 300-400° C. for 10 minutes to 24 hours, preferably at 325-375° C. for 0.5 to 4 hours.
Photoresist solutions according to this invention are obtained by combining a solution of a poly[bis(thio)phenolcarboxamide-(thio)ether] polybenzoxazole or polybenzothiazole precursor of this invention in an organic solvent with a photo-active diazoketone component and optionally an adhesion promoter. Effective diazoquinones (o-benzoquinone and o-naphthoquinone diazides) are known and described, for example in U.S. Pat. Nos. 2,767,092, 2,772,972, 2,797,213, 3,046,118, 3,106,465, 3,148,983, 3,669,658 and 4,395,482. Particularly preferred are diazoquinones that are insoluble in aqueous alkalies, that is having strongly hydrophobic properties, and become very soluble after exposure to light in aqueous alkaline developer solution. Particularly preferred diazoquinones with these properties include for example N-dehydroabietyl-6-diazo-5(6)-oxo-1-naphthalenesulfonamide, 2,2-bis(4-hydroxyphenylpropane) diester of naphthoquinone [1.2] diazo-(2)-5-sulfonic acid, n-dehydroabietyl-3-diazo-4(3)-oxo-1-naphthalenesulfonamide, N-dehydroabietyl-[5.6.7.8]-tetrahydro-4-diazo-(3(4)-oxo-2-napthalenesulfonamide, and N-dextropimaryl-3-diazo-4-oxo[1.5]-cyclohexadiene-1-sulfonamide.
Effective diazoquinones that can be used also include the 1,2-diazonaphthoquinone-4-sulfonic acid and 1,2-diazonapththoquinone-5-sulfonic acid esters of various phenols described in Proc. SPIE 1466 (1991) pages 106-116, which disclosure is here incorporated by reference.
Suitable adhesion promoters include, for example, polyamidocarboxylic acids, such as condensation products of an aromatic tetracarboxylic acid dianhydride with a diaminosiloxane. Such an adhesion promoter condensation product can have the structure ##STR11##
Heat stable and moisture-resistant structures are obtained by coating a photo-resist solution according to this invention on a substrate, exposing to actinic light, electron beam or ion beam through a mask and extracting the solubilized portions resulting from the exposure. Preferred substrates include glass, metal, plastic, or semiconductor material, especially silicon wafers.
Further details of known techniques and materials for preparing resist structures are found in U.S. Pat. No. 4,395,482 at column 5 line 15 to column 6 line 57, which disclosure is here incorporated by reference.
The invention will be illustrated in greater detail below with reference to working examples.
EXAMPLE 1
Preparation of a bis-o-aminophenol: 4,4'-bis(4-amino-3-hydroxyphenoxy)octafluorobiphenyl
24.5 g of 5-hydroxy-2-nitrophenyl benzyl ether (0.1 mol) and 16.7 g of decafluorobiphenyl (0.05 mol) are dissolved in 270 ml of dry dimethyl sulfoxide in a three-neck flask fitted with reflux condenser, stirrer and nitrogen inlet. After 30 g of potassium carbonate (0,22 mol) have been added, the solution is heated at 100° C. for 4 hours in a temperature-controllable oil bath. The reaction solution is then allowed to cool to room temperature, and the residue is filtered off via a fluted filter. The solution is then added to 500 ml of water, and concentrated hydrochloric acid is added until the mixture is acidic. The yellow-beige reaction product which precipitates during this is filtered off via a Buchner funnel, washed three times with water and, then recrystallized from a mixture of methanol and methylene chloride (volume ratio 1:1). The reaction product is then dried for 48 hours under nitrogen at 40° C./10 mbar in a vacuum drying cabinet.
72 g of the 4,4'-bis(4-nitro-3-5 benzyloxyphenoxy)octafluorobiphenyl prepared in this way (0.09 mol) are dissolved in 600 ml of a mixture of tetrahydrofuran and ethyl acetate (volume ratio 1:1), and 7 g of Pd/C (palladium/carbon) are added to the solution. The mixture is then hydrogenated at room temperature in an autoclave with vigorous stirring using hydrogen at a pressure of 1 bar; after 7 days, the reaction is terminated. The yellow-beige solution is evaporated to half in a rotary evaporator and left to stand overnight at room temperature, during which the reaction product precipitates in crystalline form. The reaction product is then dried for 48 hours under nitrogen at 40° C./10 mbar in a vacuum drying cabinet.
EXAMPLE 2
Preparation of a PBO Precursor
54.4 g of 4,4'-bis{4-amino-3-hydroxyphenoxy)octafluorobiphenyl prepared as described in Example 1 (0.1 mol) are dissolved in 300 ml of distilled N-methylpyrrolidone. A solution of 29.5 g of oxybisbenzoyl chloride (0.1 mol) in 150 ml of γ-butyrolactone is added drop wise to this solution at 10° C. with stirring, and the reaction solution is stirred for 16 hours. A solution of 17.4 g of pyridine (0.22 mol) in 80 ml of γ-butyrolactone is then slowly added drop wise to the reaction solution at room temperature, and the resultant reaction solution is stirred at room temperature for 2 hours. The resultant polymer is precipitated by adding the reaction solution drop wise to a mixture of isopropanol and water (1:3), washed three times with fresh precipitant and dried for 72 hours at 50° C./10 mbar in a vacuum oven.
The PBO precursor prepared in this way is readily soluble in solvents such as N-methylpyrrolidone, γ-butyrolactone, acetone, tetrahydrofuran, cyclopentanone, diethylene glycol monoethyl ether, ethyl lactate and ethanol, and in commercially available aqueous-alkaline developers which are free from metal ions, such as NMD-W (Tokyo Ohka).
EXAMPLE 3
Determination of Moisture Absorption
4 g of the PBO precursor from Example 2 are dissolved in 12 g of distilled N-methylpyrrolidone. The solution is applied to a substrate in the form of a cleaned, dried and precisely weighed silicon wafer by means of a plastic syringe provided with a prefilter, and spun in a spin-coating apparatus (Convac ST 146). The film formed on the substrate is first predried at 120° C. on a hotplate and then--for the cyclization (on the substrate)--heated to 350° C. under nitrogen in a programmable laboratory oven ("Sirius Junior", LP-Thermtech AG) and held at this temperature for 1 hour, then cooled. The heating and cooling rates are each 5° C./min.
The coated substrate is placed in a tared microbalance (Mettler Toledo AT 261 Deltarange) with a sealed chamber containing phosphorus pentoxide as desiccant. The total weight determined after 24 hours is 11.50864 g, This gives a weight of 0.15432 g for the cyclized polymer (weight of the pure silicon wafer=11.35432 g). The phosphorous pentoxide is then replaced by a saturated sodium chloride solution, and a relative humidity (23° C.) of 76% is set in the chamber. After storage for a further 24 hours, the weight of the film increases to 0.15562 g. This gives a moisture absorption of 0.84%. An uncoated silicon wafer exhibits no moisture absorption under identical conditions.
EXAMPLE 4
Determination of the Degree of Planarization
The planarization capacity of polybenzoxazoles prepared from the precursors of the invention by cyclization on a substrate is determined on silicon wafers having aluminum structures 1.2 micron in height (planarization wafers) The degree of planarization is given for the repeating 5 micron structures (=line and space width; alternating). The degree of planarization is determined as described by D. S. Soane and Z. Martynenko: "Polymers in Microelectronics--Fundamentals and, Applications", Elsevier Science Publishers B.V., Amsterdam 1989, pages 189 to 191.
The PBO precursor of Example 2 is applied--as in Example 3--to a planarization wafer (substrate) and cyclized. The cyclized film has a thickness of 2.0 microns; the degree of planarization is 84%.
EXAMPLE 5
Heat Stability
Some of the cyclized polymer of Example 3 is removed from the substrate after the moisture measurement and analyzed thermogravimetrically (Polymer Laboratories STA 1500 instrument). This analysis shows that a weight loss of 1% is not achieved until a temperature of 480° C. By comparison, a weight loss of 1% is already achieved at a temperature of from 420 to 430° C. in known polybenzoxazoles (see SU 1 205 518 A).
EXAMPLE 6
Photostructuring
4 g of the PBO precursor of Example 2 together with 1 g of a diester of bisphenol A and diazonaphthoquinone-5-sulfonic acid (photo-active component) are dissolved in 15 g of N-methylpyrrolidone. This photo-resist solution is applied to a substrate in the form of a cleaned and dried silicon wafer by means of a plastic syringe provided with a prefilter, and is spun in spin-coating apparatus (Convac ST 146). The resist film formed on the substrate is firstly predried at 120° C. on a hotplate and then exposed through a mask in an exposure apparatus (Karl Suss 121). After development using an aqueous-alkaline developer (NMD-W, Tokyo Ohka, diluted 1:1 with water) and cyclization (on the substrate) at 350° C. as described in Example 3, high-temperature-stable resist structures having a resolution of 2 micron at a layer thickness of 1.7. micron are obtained.
EXAMPLE 7 (COMPARATIVE EXAMPLE)
A PBO precursor is prepared analogously to Example 2, using--under otherwise identical conditions--hexafluoro-2,2-bis(3-amino-4-hydroxyphenyl)propane (0.1 mol, i.e. 36.6 g) as described in EP 0 264 678 B1 as bis-o-aminophenol. For this precursor, a moisture absorption of 1.8% (see Example 3) and a degree of planarization of 68% (see Example 4) are determined.
EXAMPLE 8 (COMPARATIVE EXAMPLE)
A PBO precursor is prepared analogously to Example 2, using--under otherwise identical conditions--3, 3'-dihydroxybenzidine (0.1 mol, i.e. 21.6 g) as described in EP 0 023 662 B1 as bis-o-aminophenol. For this precursor, a moisture absorption of 2.1% (see Example 3) and a degree of planarization of 61% (see Example 4) are determined.
EXAMPLE 9
Preparation of a PBO Precursor and Determination of its Properties
A PBO precursor is prepared analogously to Example 2, using--under otherwise identical conditions--4,4'-bis(4-amino-3-hydroxyphenoxy)octafluorobenzophenone (0.1 mol, i.e. 57.2 g) as bis-o-aminophenol. The bis-o-aminophenol is prepared--analogously to Example 1--from 5-hydroxy-2-nitrophenyl benzyl ether and decafluorobenzophenone.
The PBO precursor obtained is readily soluble in the solvents listed in Example 2. For this precursor, a moisture absorption of 0.95% (see Example 3) and a degree of planarization of 87% (see Example 4) are determined. After the photo-structuring carried out as described in Example 6 and cyclization on the substrate, high-temperature-stable resist structures having a resolution of 2 micron at a layer thickness of 1.9 micron are obtained.
EXAMPLE 10
Preparation of a PBO Precursor and Determination of its Properties
A PBO precursor is prepared analogously to Example 2, using--under otherwise identical conditions--4, 6-bis(4-amino-3-hydroxy-2,5,6-trifluorophenoxy)pyrimidine (0.1 mol, i.e. 43.4 g) as bis-o-aminophenol and isophthaloyl dichloride (0.1 mol, i.e. 20.3 g) is employed as dicarboxylic acid dichloride.
The bis-o-aminophenol is prepared--analogously to Example 1--from 4,6-dihydroxypyrimidine and pentafluoronitrobenzene.
The PBO precursor obtained is readily soluble in the solvents listed in Example 2. For this precursor, a moisture absorption of 0.97% (see Example 3) and a degree of planarization of 86% (see Example 4) are determined. After the photo-structuring carried out as described in Example 6 and cyclization on the substrate, high-temperature-stable resist structures having a resolution of 2 micron at a layer thickness of 2 micron are obtained.
EXAMPLE 11
Preparation of a PBO Precursor and Determination of its Properties
A PBO precursor is prepared analogously to Example 2, using--under otherwise identical conditions--2, 2-bis[4-(4-amino-3-hydroxy-2,5,6-trifluorophenoxy)phenyl]hexafluoropropane (0.1 mol, i.e. 65.8 g) as bis-o-aminophenol and perfluoroisophthaloyl dichloride (0.1 mol, i.e. 27.5 g) is employed as dicarboxylic acid dichloride. The bis-o-aminophenol is prepared--analogously to Example 1--from 6F-bisphenol A and pentafluoronitrobenzene.
The PBO precursor obtained is readily soluble in the solvents listed in Example 2. For this precursor, a moisture absorption of 0.79% (see Example 3) and a degree of planarization of 84% (see Example 4) are determined. After the photo-structuring carried out as described in Example 6 and cyclization on the substrate, high-temperature-stable resist structures having a resolution of 2 micron at a layer thickness of 1.9 micron are obtained.
EXAMPLE 12
Preparation of a PBO Precursor and Determination of its Properties
A PBO precursor is prepared analogously to Example 2, using--under otherwise identical conditions --1,4-bis(4-amino-3-hydroxy-2,5,6-trifluorophenoxy)tetrafluorobenzene (0.1 mol, i.e. 50.4 g) as bis-o-aminophenol and adipic dichloride (0.1 mol, i.e.18 g) is employed as dicarboxylic acid dichloride. The bis-o-aminophenol is prepared--analogously to Example 1--from tetrafluorohydroquinone and pentafluoronitrobenzene.
The PBO precursor obtained is readily soluble in the solvents listed in Example 2. For this precursor, a moisture absorption of 0.96% (see Example 3) and a degree of planarization of 85% (see Example 4) are determined. After the photo-structuring carried out as described in Example 6 and cyclization on the substrate, high-temperature-stable resist structures having a resolution of 2 micron at a layer thickness of 2.2 micron are obtained.
EXAMPLE 13
Preparation of a PBO Precursor and Determination of its Properties
The PBO precursor described in Example 2 can also be prepared by a chloride-free method. To this end, 25.8 g o oxybisbenzoic acid (0.1 mol) are dissolved in 200 ml of N-methylpyrrolidone, and 34.1 g of carbonyldiimidazole (0.21 mol) are added in portions. When the evolution of gas (CO 2 ) has subsided, the mixture is stirred for a further 2 hours. The resultant suspension is then added to 54.4 g of 4,4'-bis(4-amino-3-hydroxyphenoxy)octafluorobiphenyl (0.1 mol) dissolved in 300 ml of N-methylpyrrolidone, and the mixture is stirred at room temperature for 40 hours; during this period, the reaction solution becomes clear again. The precipitation and drying of the PBO precursor are carried out as in Example 2.
The PBO precursor obtained is readily soluble in the solvents listed in Example 2. For this precursor, a moisture absorption of 0.86% (see Example 3) and a degree of planarization of 82% (see Example 4) are determined; the heat stability is 480° C. (see Example 5). After the photo-structuring carried out as described in Example 6 and cyclization on the substrate, high-temperature-stable resist structures having a resolution of 2 micron at a layer thickness of 2.2 micron are obtained.
EXAMPLE 14
Preparation of a PBO Precursor and Determination of its Properties
A PBO precursor is prepared analogously to Example 13, using--under otherwise identical conditions--4,4'-bis(4-amino-3-hydroxy-2,5,6-trifluorophenoxy)octafluorobiphenyl (0.1 mol, i.e. 65.2 g) as bis-o-aminophenol and 4,4'-bis(4-carboxyphenoxy)octafluorobiphenyl (0.1 mol, i.e. 57 g) is employed as dicarboxylic acid. The bis-o-aminophenol is prepared--analogously to Example 1--from 4,4'-octafluorobiphenol and pentafluoronitrobenzene.
The PBO precursor obtained is readily soluble in the solvents listed in Example 2. For this precursor, a moisture absorption of 0.72% (see Example 3) and a degree of planarization of 82% (see Example 4) are determined. After the photo-structuring carried out as described in Example 6 and cyclization on the substrate, high-temperature-stable resist structures having a resolution of 2 micron at a layer thickness of 1.8 micron are obtained.
EXAMPLE 15
Preparation of a PBO Precursor and Determination of its Properties
A PBO precursor is prepared analogously to Example 13, using--under otherwise identical conditions--2,4-bis(4-amino-3-hydroxyphenoxy)-3,5,6-trifluoro-pyridine (0.1 mol, i.e. 37.9 g) as bis-o-aminophenol and 4,4-bis(4-carboxyphenoxy)octafluorobiphenyl (0.1 mol, i.e. 57 g) is employed as dicarboxylic acid. The bis-o-aminophenol is prepared--analogously to Example 1--from 5-hydroxy-2-nitrophenyl benzyl ether and pentafluoropyridine.
The PBO precursor obtained is readily soluble in the solvents listed in Example 2. For this precursor, a moisture absorption of 0.96% (see Example 3) and a degree of planarization of 84%(see Example 4) are determined. After the photo-structuring carried out as described in Example 6 and cyclization on the substrate, high-temperature-stable resist structures having a resolution of 2 micron at a layer thickness of 2 micron are obtained.
EXAMPLE 16
Preparation of a PBO Precursor and Determination of its Properties
A PBO precursor is prepared analogously to Example 13, using--under otherwise identical conditions--2,4-bis(4-amino-3-hydroxyphenoxy)-1-trifluoromethyl-3,5,6-trifluorobenzene (0.1 mol, i.e. 44.6 g) as bis-o-aminophenol and isophthaloyl dichloride (0.1 mol, i.e. 20.3 g) is employed as dicarboxylic acid dichloride. The bis-o-aminophenol is prepared--analogously to Example 1--from 5-hydroxy-2-nitrophenyl benzyl ether and octafluorotoluene.
The PBO precursor obtained is readily soluble in the solvents listed in Example 2. For this precursor, a moisture absorption of 0.9% (see Example 3) and a degree of planarization of 83% (see Example 4) are determined. After the photo-structuring carried out as described in Example 6 and cyclization on the substrate, high-temperature-stable resist structures having a resolution of 2 micron at a layer thickness of 2 micron are obtained.
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The polybenzoxazole and polybenzothiazole precursors of the invention have the following partial structure: ##STR1## where: A 1 to A 6 are--independently of one another--H, F, CH 3 , CF 3 , OCH 3 , OCF 3 , CH 2 CH 3 , CF 2 CF 3 , OCH 2 CH 3 or OCF 3 CF 3 ;
T is O or S, and m is 1;
Z is a carbocyclic or heterocyclic aromatic radical.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a turbomachine combustion chamber shell ring.
The shell ring in question herein defines a flame tube, which is thus subject to considerable overheating on the inner face thereof, whereas the outer face thereof is crossed by a cool gas flow, originating from the turbomachine compressors and mixing with the combustion gases downstream from the shell ring before entering the turbines.
2. Description of the Related Art
Such a shell ring is traversed by a plurality of types of holes, including dilution holes having a relatively large diameter intended to allow the entry of a portion of the outer flow into the flame tube so as to improve the composition of the combustion mixture, and finer ventilation holes, which are more numerous and distributed on most of the surface area of the shell ring, to also enable the entry of air from the outer flow, but which have the effect of protecting the shell ring from overheating, by forming a flush flow in the downstream direction on the inner face of the shell ring and thus a boundary layer cooler than the combustion gases.
This boundary layer is reformed poorly downstream from the large diameter holes, interrupting the flush flow, and the corresponding portions of the shell ring, all or almost all subject to overheating, are subject to deformation and stress arising from differential expansions, which may give rise to cracks.
The document EP-A-1 703 207 describes a combustion chamber whereon the invention may be implanted. In addition, the above problems are mentioned in the French patent application registered under the number 11 53232 disclosing a modification of the conventional shell ring arrangement to reform the boundary layer immediately downstream from the large-diameter holes and thus relieve the shell ring. A further solution is however proposed with the present invention.
BRIEF SUMMARY OF THE INVENTION
In a general form, it relates to a turbomachine combustion chamber shell ring, comprising dilution holes and ventilation holes surrounding the dilution holes and finer and more numerous than said holes, characterised in that it comprises inserts extending over and around the dilution holes on an outer face of the shell ring, the shell ring is devoid of ventilation holes at portions situated above the inserts, the inserts each comprising an edge for attaching to the shell ring and an orifice extending over one of the respective dilution holes, and the inserts are traversed by holes directed towards said portions of the shell ring.
The essential effect obtained is that the high pressure present around the shell ring allows the entry of air via the holes of the insert, in streams striking the outer face of the shell ring and producing the sought cooling at this location, with a greater intensity than ventilation holes arranged through the shell ring, traversed very quickly by the air. Instead, the air sucked in below the insert flows on the outer face of the shell ring after reaching same, towards the dilution hole, and this flow time causes a greater elimination of heat. When the air enters the dilution hole, the relatively low speed driving same may make it possible for it to resume a tangent downstream direction relatively easily, which will help restore the boundary layer on the inner face of the shell ring and will enhance the ventilation further.
According to requirements, the inserts may be parallel with the shell ring or inclined relative thereto in an axial direction of the shell ring. The holes of the inserts are advantageously perpendicular to the shell ring, but they may also be positioned obliquely; all these adaptations are to be decided in each design.
Advantageously, the inserts extend more in the downstream direction of the shell ring than in other directions from the centres of the dilution holes, since the portions of the shell ring subject to intense overheating are specifically downstream from these holes. The inserts may however be subject to retraction in this downstream direction of the shell ring, since the boundary layer is reformed according to the same shape, bypassing the dilution holes.
A further favourable feature is obtained if the inserts each comprise an inner edge surrounding the respective orifice and extending towards the respective dilution passage, making it possible to channel both the air sucked in directly by the dilution holes via the insert orifice, and the air sucked in by the insert holes and blowing onto the shell ring, then flowing around this inner edge.
Satisfactory cohesion is obtained if the inner edge is enclosed between the attachment sectors situated in the respective dilution hole, flow sectors being defined in said respective dilution hole by the inner edge and between the attachment sectors. In order to help continue the flow on the downstream side of the dilution hole, more advantageously, the dilution holes and the inner edge have centres offset in an axial direction of the shell ring, such that the flow sectors have a main surface area downstream from the inner edge.
A further aspect of the invention is a turbomachine combustion chamber comprising such a shell ring.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The invention will now be described with reference to the following figures:
FIG. 1 is a general view of a turbomachine combustion chamber and the shell ring thereof; and
FIGS. 2 and 3 disclose the invention more specifically.
DETAILED DESCRIPTION OF THE INVENTION
A turbomachine combustion chamber where the invention may be present is represented schematically in FIG. 1 . It should be noted that these combustion chambers are annular about the turbomachine axis, such that FIG. 1 is merely a half-section along the axis. A fillet 1 comprises an outer shell ring 2 , an inner shell ring 3 , both substantially conical and mutually concentric, and an annular chamber back face 4 joining the shell rings 2 and 3 . The inner volume of the combustion chamber, forming a flame tube 16 , is defined by the shell rings 2 and 3 and the chamber back face 4 and opens on the side opposite the chamber back face 4 via an opening 5 . The combustion chamber is surrounded by an outer casing 6 and an inner casing 7 defining a flow stream 10 separated by the fillet 1 into two outer stream portions 8 and 9 bypassing and running along the fillet 1 . The air of the flow stream 10 comes from a nozzle 11 situated opposite an opening 12 provided between rear fillets 13 and 14 of the shell rings 2 and 3 (in this description, “rear” and “front” refer to the direction of the air flow). Fuel injectors 15 extend through the outer casing 6 , the opening 12 and the chamber back face 4 to the flame tube 16 . Plugs 17 also traverse the outer casing 6 to the front of the fuel injectors 15 and also traverse the outer shell ring 1 to level with the flame tube 16 . Most of the air flow thus follows the streams 8 and 9 , even though a portion enters below the fillets 13 and 14 via the opening 12 .
The shell rings 2 and 3 are traversed by numerous holes, including numerous fine ventilation holes 38 and less numerous larger diameter dilution holes 39 , distributed on a circle or a small number of circles. The common effect of these holes is that of allowing air from the streams 8 and 9 to enter the flame tube 16 at a lower pressure for a variety of purposes.
The invention may be used on either of the shell rings 2 and 3 .
Remarks will now be made in relation to FIGS. 2 and 3 . Inserts 40 are arranged on the outer face of the shell ring 2 or 3 and around the dilution holes 39 . They each comprise a main portion 41 extending over the shell ring 2 or 3 , an outer edge 42 surrounding the main portion 41 and attached to the shell ring 2 or 3 , an orifice 43 extending in front of the respective dilution hole 39 but having a smaller radius, an inner edge 44 surrounding the orifice 43 and extending to most of the depth of the dilution hole 39 , and holes 45 through the main portion 41 and opening in front of a portion facing the shell ring 2 or 3 , which is devoid of ventilation holes 38 there. The insert 40 thus defines a chamber 49 almost closed in front of the shell ring 2 or 3 of the respective dilution hole 39 . It can be seen in FIG. 3 that the insert 40 has a somewhat triangular general shape, extending more in the downstream direction of the flow while becoming increasingly narrow, so as to correspond as much as possible to the area of the shell ring 2 or 3 where cracks may appear. The dilution hole 39 is provided with attachment sectors 46 protruding towards the centre of said hole, touching and enclosing the inner edge 44 . This inner edge 44 and the attachment sectors 46 define air flow sectors traversing the holes 45 of the inserts 40 , including, herein, two symmetrical lateral sectors 47 in relation to an axial direction of the shell ring 2 or 3 and a downstream sector 48 . It should be noted that the centres O 1 and O 2 of the inner edge 44 and the dilution hole 39 are axially offset, such that the sectors 47 or 48 have an irregular shape and the downstream sector 48 is wider, promoting the flow from the chamber 49 via this downstream sector 48 and the reconstruction of a boundary ventilation layer downstream from the dilution hole 39 .
The specific flow provided by the insert 40 is as follows. Air from the flow of the flow of the stream 8 or 9 at a high pressure is blown into the chamber 49 via the holes of the inserts 45 and cools the shell ring 2 or 3 around the respective dilution hole 39 , and particularly the portion downstream therefrom, via the outer face thereof. This air then flows into the flame tube 16 via the flow sectors 47 and 48 and particularly through same. On reaching the flame tube 16 , the flow thereof may rapidly return to an axial direction downstream from the combustion chamber and reform a boundary layer in the above-mentioned area of the shell ring 2 or 3 downstream from the dilution hole 38 and helps protect same further.
The main portions 41 of the inserts 40 may be optionally parallel with the portion opposite the shell ring 2 or 3 , and the holes 45 optionally perpendicular to this portion. The main portions 41 may particularly be inclined in relation to the shell ring 2 or 3 , along the contour 41 ′ rising in a downstream direction, to better intercept the flow air by creating a larger obstacle.
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A turbomachine combustion chamber shell ring in which dilution holes in the turbomachine combustion chamber shell ring are covered with inserts defining chambers around same on an inner face of the shell ring. Ventilation holes, through the insert, induce ventilation of portions of the shell ring surrounding the dilution holes, cool the portions, and prevent crack formation.
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RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 60/456,723, filed Mar. 21, 2003, and entitled Keratinocyte-fibrocyte Concomitant Grafting for Immediate Treatment of Severe Wounds: Use of an Air-jet Cell External Seeding Device (ACES).
TECHNICAL FIELD
[0002] The present invention relates to wound healing in general and specifically to a technique and system of seeding cells directly into a wound bed, for instance, using a handheld air-jet sprayer.
BACKGROUND OF THE INVENTION
[0003] Facilitation of the closure of large skin wounds (i.e. burns, traumatic injury, congenital reconstruction) by a variety of methods requires extensive expense and time. Methods currently in use include, but are not limited to, split-thickness grafts from the same individual, the use of specially treated cadaver skin, and autologous cultured skin equivalents. Due to the availability of these materials, it has become clinically feasible to treat skin wounds, particularly burn wounds, with cells cultured from the same patient. This method of treatment is both expensive and time consuming.
[0004] Although autologous grafting solves certain problems inherent in tissue transplantation, such as histocompatibility and the potential need for immunosuppressive agents, major problems still exist. For example, patients must not only suffer the harvesting of significant amounts of skin for autologous culturing, which in itself causes wounding, but must also wait up to six weeks before grafting back to the wound. For the patient, this is just the start of a long and trying process leading towards the healing of the wound.
[0005] The ability to treat skin wounds or congenital defects in which a significant amount of epithelial tissue has been lost or rendered nonfunctional remains an important issue among clinicians. With the advent of effective antibiotics, one major hurdle to effective wound healing, i.e. healing without infection, was effectively overcome. Thus, the use of antibiotics allowed for the routine use of surgical grafting techniques to be developed and applied to a wide range of wounds and defects. Recent history has seen the use of a variety of epithelial graft techniques which have contributed significantly to reducing the morbidity and mortality of individuals with severe skin wounds, including improved aesthetic results.
[0006] Clinical Aspects of Epithelial Grafts. Epithelial grafts fall into three main categories: allografts (same species), xenografts (different species), and autografts (same animal). Over the centuries xenografts from a variety of animals and birds have been used with wide ranging results. For the most part, little success was achieved with the use of different xenografts. The need for a viable alternative prompted the search for better graft material. Cadaver allografts are still in use today, but they are usually restricted to patients with extreme burns.
[0007] When available or practical, autografting from a healthy site on the individual to the wound site is the presently preferred treatment. This, however, may have some drawbacks. For instance, this leaves a donor site which must also be treated as a wound and can lead to increased morbidity of both the donor and graft sites. When only small amounts of tissue are used, free grafts may be transferred to sites that have an adequate blood supply and an intact and functional connective tissue base. For larger wound sites, pedicle grafts may be used. Pedicle grafts are initially allowed to remain attached to the donor site until an adequate collateral blood supply is developed before the connection to the donor site is excised.
[0008] For all of the previously described grafts, the success of the tissue graft is primarily dependent on: (a) immunological response to the graft; (b) size of the graft; (c) anatomical area of graft; (d) condition of underlying tissue at graft site; (e) condition of surrounding tissue at graft site; (f) thickness of graft; and (g) maintenance of sterility of graft tissue and graft site.
[0009] Cultured Epithelial Autografts. With advances in cell culture techniques came new ideas for tissue grafting. These advances in cell culture techniques have made it possible to culture keratinocytes (skin cells) taken from a biopsy of a patient and to ultimately transfer the resulting autologous cultured cells back to the same individual.
[0010] By using autologous cultured grafts, problems in organ transplantation procedures may be solved such as: (a) obtaining histocompatibility of matched tissues; and (b) lack of a graft donor site. In principle, this approach addresses many major problems of tissue transplantation. First, using the patient as their own source of transplant tissue, coupled with expansion of his/her cells in tissue culture, eliminates the problem of tissue availability in the majority of the patients who would benefit. Second, because a patient is treated with his/her own cells, an immunosuppressive mediator is not required, nor is there a requirement for a large donor site. This has opened up a new era in tissue transplantation, especially in the use of autologous cultured tissue grafts to treat severely burned patients. Yet, there are still some disadvantages, for example, the time and expense involved in culturing cells as well as the lack of available donor graft sites (e.g., burn patients with more than 60% tissue involvement). A need is recognized for a readily available source of graftable tissue which may be utilized in major trauma or burn cases.
[0011] Discussion of Epithelial Graft Construction. While the use of cultured cells in treatment of burns patients is now a routine clinical procedure, several problems remain to be solved. When epithelial cells are harvested from biopsy material, the cells that proliferate in culture are mainly connective tissue fibroblasts and keratinocytes. Sweat glands, sebaceous glands, pigment cells, and other cell types that are usually required for a fully functional skin are lost during cell cultivation and, as a result, cell culture derived autologous skin may lack several physiologically important properties.
[0012] The development of tissue engineered epithelial grafts for use in wound repair is an aggressively researched area. While the use of cultured cells in the treatment of burn patients is now an accepted clinical procedure several problems still remain to be solved. The time between the formation of the wound and the application of the graft material has a significant effect on scar formation and re-epithelialization. Using early culture techniques for the stratification of keratinocytes in vitro in the production of skin grafts, the stratification was limited to only a few cell layers without keratinization. Later techniques allowed further differentiation of the keratinocytes into a thicker stratified layer. Recently, keratinization of the cultured epithelial tissue was accomplished by growing confluent stratified cultures at the gas/liquid interface of the culture medium.
[0013] Because these tissues had minimum shear strength due to thickness (<0.5 mm), the grafting of such tissue required the use of a pressure bandage to hold the graft in place until a basement membrane had formed which attached the graft to the wound surface. These grafts were also limited by the type of wound, in that they were only useful as analogues of split-thickness autografts. Split-thickness grafts differ from full-thickness grafts in that the former contains little, if any, tissue below the basement membrane on which the epithelium attaches to the dermis. Therefore split-thickness autografts require grafting sites containing a healthy connective tissue layer. To date no such graft has ever formed secondary structural morphology such as rete ridges or appendageal structures. The lack of such structures makes the grafts highly sensitive to trauma and infection.
[0014] The reconstruction of full-thickness grafts from cultured cells has had limited success and, up until recently, only when autologous donor collagen was used. Recent reports using dermal allografts have had some success, such as the grafting of full-thickness cultured oral mucosal cells in the mouse and dog. This was accomplished by the construction of a bilayer graft containing autologous cultured keratinocytes grown directly on a collagen-gel interspersed with autologous cultured fibroblasts.
[0015] The two major drawbacks to this method have been: (a) the lack of secondary structural morphology (rete ridge formation); and (b) the latent shrinking of the grafted collagen layer. The latter complication has been the most difficult problem in the clinical use of autologous cultured synthetic grafts resulting in the occasional loss of the graft. Researchers have tried to overcome this hurdle by combining the advances in graft tissue design techniques with the use of a cross-linked collagen-GAG matrix and the use of dermal allografts. Preliminary reports using this technique have shown rudimentary rete ridge formation and a decrease in graft contracture.
[0016] Methods to combine the technology of tissue engineering with that of dermal allografts have as yet not been developed. Studies attempting to combine synthetic full-thickness grafts with that of biodegradable polymers and copolymers are in the early stages of development. However, there are many studies utilizing a variety of natural and synthetic materials for use as a matrix support substratum for tissue reconstruction and augmentation. The field of tissue engineering is rapidly gaining ground as an alternative to aggressive surgical techniques for the repair of wounds and other deformities.
SUMMARY OF THE INVENTION
[0017] The present invention relates to methods and systems for depositing cells to form new skin structures. The cells may be deposited in a wound bed or other area lacking normal, healthy skin.
[0018] In one embodiment, the cells deposited include autologous cells, such as keratinocytes, fibrocytes, stem cells. Cells may be deposited in layers of a single cell type or specific mixture of cell types.
[0019] Cells may be deposited in connection with other agents, such as allograft material placed in the wound bed, cytokines, adhesion molecules, and growth factors.
[0020] Deposition of cells according to the present invention may facilitate growth of skin or other three dimensional epithelial tissues. More specifically, it may facilitate wound healing.
[0021] Other methods of the invention relate to harvesting and growing autologous cells for later deposition using a hand help air-jet sprayer.
[0022] The use of a hand held-air jet sprayer may allow easy clinical use of some methods and systems of the present invention. Other methods and systems allow the direct transplant of autologous cells to a wound bed within a few days after wounding. In embodiments employing a dermal allograft as a basic substrate material onto which cells are sprayed, the allograft may facilitate cell growth and integration by providing an improved environment in which cells may grow.
BRIEF DESCRIPTION OF THE DRAWING
[0023] The following figure forms part of the present specification and is included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference this drawing in combination with the description of embodiments presented herein.
[0024] [0024]FIG. 1 presents an isometric view of a hand held air-jet sprayer, according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present invention relates seeding of cells, such as autologous cells directly onto a wound or other area lacking normal, healthy skin with the use of a hand held air-jet sprayer.
[0026] In one embodiment the autologous cells may be transplanted back to the patient within hours to days following the formation of a wound by a variety of mechanisms.
[0027] In another embodiment of this invention a wound/graft model analog for in vitro study is provided.
[0028] To dispense multiple cell lines independently and efficiently, in certain embodiments a hand held air-jet sprayer may be used to deposit one or more different cell types (e.g., keratinocytes, fibrocytes, stem cells, etc.) directly onto a wound bed to facilitate cellular integration within the wound and to accelerate new epithelial growth as part of the wound healing process. In a more specific embodiment, live autologous cells, suspended in autologous serum, are sprayed using a “continuous” air-jet sprayer, directly onto a commercially available allograft placed within the wound bed.
[0029] Air-jet sprayers of the invention operate, in principle, like any common forced-air device. The sprayer uses the velocity of the air flowing through it to create a vacuum that pulls the cell containing media into the air flow resulting in an aerosol spray.
[0030] Referring now to FIG. 1, hand held air-jet sprayer 10 , which represents one type of sprayer than may be used in the present invention, contains cells suspension 16 in container 12 , which is then closed with cover 14 . To spray cell suspension 16 , air from air supply 22 moves through air channel 24 of sprayer tube 20 past the top of hose 18 , drawing cell suspension 16 through hose 18 into sprayer tube 20 where it then exits through nozzle 26 as an aerosol spray.
[0031] The “air” in the air-jet sprayer may be a gas such as carbon dioxide, water vapor, oxygen, nitrogen, argon, helium, neon, or various combinations of any of those gases.
[0032] The air-jet nozzle, such as nozzle 26 in FIG. 1, may include various pore sizes or a range of pore sizes e.g. 50-100 micrometers, 100-500 micrometers, 500-1000 micrometers, 1000-2000 micrometers. In an exemplary embodiment the pore size of the air-jet nozzle is 1000 micrometers. Pore sizes may be chosen to be large enough to allow passage of cells during spraying without significant damage.
[0033] The cells may be suspended in a variety of soluble media including polyvinyl alcohol, albumin, dextrans, plasma, serum, other blood components, polymers of nucleic acids or combinations thereof. The soluble media may be at a temperature between 0° C. and 55° C. In another embodiment the soluble media may be between 34 and 40° C., for example 38° C.
[0034] Antibiotics or other drugs may also be dispensed using the air-jet sprayer with or without cells.
[0035] In another embodiment of the invention extracellular adhesion molecules, cytokines, and growth factors may be used to enhance the graft survival percentage and the rate of tissue differentiation. The rate and extent of graft differentiation, development, and cellular integration in this embodiment may be assessed using histological and immunohistochemical techniques. In a further embodiment of the invention in vitro models may be used to test multilayered/multicellular engineered tissues.
[0036] The following examples are included to demonstrate specific embodiments of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the examples that follow represent techniques discovered by the inventors to function well in the practice of the invention. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments that are disclosed and still obtain a like or similar result without departing from the spirit and scope of the invention.
EXAMPLES
Example 1
Air-Jet Cell External Seeding (ACES)
[0037] The invention may include a technique, termed Air-Jet Cell External Seeding (ACES), in which cells and/or adhesion proteins or growth factors may be seeded onto a dermal substrate by a hand held air-jet sprayer. In brief: (a) a commercially available hand held air-jet sprayer may be used to deposit cells which are suspended in autologous serum or other specified media; (b) the cells are seeded onto a commercially available dermal substrate (allograft) obtained from human cadaver skin; and (c) the construction of the resulting full thickness graft material can occur in vitro or in vivo.
[0038] This technology may utilize some techniques employed in a process known as cytoscribing which utilizes: (a) an ink cartridge of an inkjet printer filled with either fibronectin or other adhesion molecule; and (b) the deposition of the molecule on a substratum by a computer controlled printer. Subsequently, the cells only bind at sites where the adhesion molecule was applied.
Example 2
Harvesting and Culturing of Autologous Skin Graft Material In Vitro
[0039] Engineered tissues of the present invention may contain keratinocytes and fibrocytes harvested from the same wound patient or from other sources. Specifically, keratinocytes may be obtained from a keratinized stratified epithelial surface which is unaffected by trauma or wounding, while fibrocytes may be obtained by liposuction. Keratinocytes may also be cultured from human neonatal foreskins. Fibrocytes may be obtained from adipose and dermal tissue via a tulip syringe during liposuction. Fibrocytes and undifferentiated adipocytes may be separated from the extracted adipose tissue along with collagen by enzymatic digestion and gentle agitation. Fibrocytes may also be obtained from human postpartum umbilical cord or neonatal foreskin dermis. The resultant fibrocytes or keratinocytes may be rinsed and concentrated prior to resuspension in autologous serum (or other media) and subsequent dispersion on the allograft matrix by air-jet spraying.
Example 3
Construction of In Vitro Full Thickness Grafts
[0040] Dermal allograft material may be obtained from human cadavers. This dermal substitute consists primarily of collagen and may be used to construct an in vitro wound model analog by acting as an attachment matrix and in the orientation of a three-dimensional architecture for cell growth. This facilitates the in vitro study and development of clinical techniques in the construction of immediate autologous graft tissues. Autologous constructed tissues may be used in both transplantation studies and investigations into the cell biology of tissue engineering and wound healing.
[0041] ACES may be used to disperse and culture cells on the allograft substratum. Purified cell adhesion proteins and/or growth factors may be pre-incorporated into the allograft dermal matrix. Cell adhesion proteins (fibronectin, vitronectin, laminin, tenascin, fibrin) as well as growth factors (IGF, PDGF, TGF-β) may be used in tissue engineered autologous grafts.
Example 4
Animal Model Testing
[0042] The in vitro constructed synthetic tissue may be transferred to a surgically produced epithelial wound site on a recipient animal host. A critical size defect wound model similar in principle to that known utilizing the nude mouse may be used to test the effectiveness of autologous cultured synthetic tissues as graft materials. A critical size defect is a wound that is beyond a size to allow for normal healing usually resulting in the formation of a scar. In vitro cultured epithelial tissues may be grafted to full thickness epithelial wounds surgically created to mimic severe wound defects or third degree burns. The use of the nude mouse as a test animal offers two major advantages. One advantage is the lack of hair on the mouse which could ultimately restrict or inhibit graft suturing and bandage placement. The primary advantage of the nude mouse as a test animal is the ability to use xenogenic human cells in the production of in vitro cultured grafts.
[0043] Graft studies may be conducted in three stages. First, autologous constructed epithelium derived from keratinocytes and fibrocytes cultured on the allograft in vitro may be grafted to a surgically produced full-thickness wound consisting of an exposed subdermal layer. Second, immediate grafts produced in vitro over a 48 hr period using the ACES technique may also be transferred to the animal model. In the third stage, epithelial grafts may be constructed in vivo by surgically grafting the allograft material to the critical size epithelial wound site followed by the seeding of fibrocytes via air-jet spraying. This is followed by the in vivo seeding 24 hrs later of keratinocytes to the same wound bed and placement of dressings. Histological and immunohistochemical studies may be performed to evaluate the acceptance and incorporation of the graft during various stages of healing using a variety of techniques.
[0044] Studies with larger animals (i.e. pig) may use growth factors incorporated into either the autologous serum (or other suitable media) or the dermal allograft material prior to cell seeding. Autologous tissue engineered epithelial tissues may also be used in cleft lip/cleft palate repair, aesthetic scar removal, replacement of traumatically lost tissues and a variety of other potential surgical applications.
Example 5
New Methods to Harvest and Construct Three-Dimensional Tissues In Vitro.
[0045] Preparation of Fibrocytes. Fibroblasts may be primarily cultured from neonatal foreskin dermis in DMEM with 10% fetal bovine serum, 100 μg/ml ascorbic acid and antibiotics. Fibrocytes and undifferentiated adipocytes may be segregated from tissue obtained via liposuction. The extracted tissue may be washed and treated. The cells may be separated from the extracted tissue by gentle agitation in the presence of a sequential treatment of trypsin and collagenase as reporter.
[0046] Preparation of Keratinocytes. Cell cultures of skin epithelial cells may be prepared from tissue biopsy material, either neonatal foreskin or from blepharoplasty and/or rhytectomy procedures, using 0.125% trypsin (1:250) and 5 mM EDTA. Primary epithelial cell cultures may be grown in FAD medium with 3T3 feeder cells for 1-3 passages. These primary cultures may be grown at 33° C. to inhibit the growth of fibroblasts. The resulting keratinocytes may then be subcultured from single cell suspensions (5×10 6 cells/ml) on a commercially available human dermal allograft substrate composed primarily of Type II collagen (AlloDerm, LifeCell Corporation, The Woodlands, Tex.). Stratification and differentiation of the squamous cell epithelium may be elicited using established methods utilizing Dulbecco's MEM with fetal bovine serum. After significant stratification with cultured epithelial cells, the resulting synthetic tissues may be raised on a grid to the gas/medium interface and incubated at 35° C. to induce epithelium organogenesis. Following amplification of the epithelial tissue mass during this last phase of cell culturing, the resulting composite graft tissue may be transplanted to the animal model.
[0047] Use of a universal dermal allograft. The universal dermal skin allograft (AlloDerm, LifeCell Corporation, The Woodlands, Tex.) is processed from human donor skin, which is used routinely as a temporary covering for extensive burns. Unprocessed human donor skin, however, is rejected in a matter of weeks. The tissue engineering process presently used in the field removes the epidermis, endothelial, and fibroblast cells from the donor skin which are targets for rejection, without altering the highly organized extracellular matrix. This dermal matrix is immunologically inert and, following grafting, becomes repopulated with the patient's own cells. These cells use the dermal template as a guide to remodel the missing skin.
[0048] Use of a new technique to deposit cells onto a commercially available dermal allograft. One may employ a hand held air-jet sprayer (Badger Model 900, Badger Air Sprayer Company, New York, N.Y.) to apply cells onto a substrate in vitro. A dermal allograft may be used as a matrix for cell deposition. For example, a universal dermal tissue graft processed from human donor skin (AlloDerm, LifeCell Corporation, The Woodlands, Tex.) may be used as the basic matrix material for cell growth. Both collagen and biodegradable plastics have been used for skin transplantation studies, however, the use of a dermal allograft is a superior substrata for constructing epithelial tissues for immediate grafting.
[0049] Quantity of cells deposited by the air-jet sprayer may be controlled by the concentration of cells per unit volume, by amount of eluent sprayed, and by the size of the droplet sprayed. The size of the droplet increases as the viscosity of the solution increases. The minimum concentration of cells sprayed is not normally less than 5×10 6 cells/ml for any cell type. Two different cell types, keratinocytes and fibrocytes, may be sprayed to produce a three-dimensional multicellular engineered tissue. Fibrocytes may be sprayed first onto the dermal allograft followed, after a set amount of time predetermined by experimental protocol, keratinocyte seeding. Existing cell culture technology and ACES, may be used to construct epithelial skin tissues suitable for grafting that contain both differentiated keratinocytes and fibrocytes.
[0050] ACES using live cells. The use of air-jet spraying is similar to the segregation of cells by fluorescence activated cell sorters (FACS). The principle technique used in FACS concerns only one nozzle that emits a continuous steam of charged droplets that are targeted by deflector plates. Thus, the technology involved in air-jet spraying is similar to that employed by fluorescence activated cell sorters, but differs in that the droplets are not charged and are considerably larger.
[0051] Preliminary studies have shown that it is possible to use live cells with a jet-air spray device. Initial studies indicate that one may deliver live mammalian cells to a substratum with a hand held air-jet sprayer. The problems of drying droplets and nozzle clogging have been largely overcome by the use of a larger nozzle orifice and by the possible addition of dextran to the cell suspended media. Dextran acts to “tie up” water thereby reducing the vapor pressure of water. The placing of wet dressings may alleviate the problem altogether. In vitro experiments take into account the use of a humidified CO 2 incubator and therefore drying is not a problem.
[0052] The nozzle orifice diameter used in the air-jet sprayer normally exceeds 1000 μm, and is therefore, in excess of the orifice diameters used in FACS or Coulter counters. Methods to deliver living cells to a substratum in vivo using a hand held jet-air sprayer device may be used as a very simple means of constructing tissue engineered skin in an very short time.
[0053] Evaluation of a dermal allograft for use with air-jet spraying devices. Commercially available dermal allograft material obtained from human cadavers may be used as a collagen matrix to construct three-dimensional skin grafts for animal transplantation studies. By utilizing primary cultures of fibrocytes and keratinocytes, a hand held air-jet sprayer may be used to deposit living cells onto a dermal allograft in vitro. Specifically a 2×1 cm piece of dermal allograft presoaked in fetal bovine serum (FBS) may be placed into polycarbonate petri dishes and allowed to sit for approximately two hours at 37° C. prior to ACES with fibrocytes. Immediately following seeding, the covered petri dishes may be placed back into a humidified CO 2 incubator at 37° C. and 10% CO 2 .
[0054] Techniques for the immediate preparation of three-dimensional tissues in vivo. Three-dimensional tissue engineered grafts may be constructed in vivo, easily and efficiently, by using a hand held air-jet spraying device.
[0055] Such procedures may be carried out using a hand held air-jet sprayer technique, coupled with accelerated harvesting techniques. By using the ACES technique, it may be possible to construct epithelial tissues in vivo to immediately repair of large external full-thickness wounds. Multiple layers of the various cell types may be sprayed onto a collagen allograft by multiple passes using the ACES method to vary tissue thickness. The parameters of ACES methods to deposit live cells may be varied. Clinical methodologies may be used for the transplanting of autologous cultured cells and the construction and culturing of tissue engineered epithelial grafts.
[0056] Grafting procedure. Tissue engineered skin from in vitro cultured grafts (n=6), from immediate ACES prepared in vitro grafts (n=6), and from ACES prepared in vivo grafts (n=6), may be grafted. Controls, if used, may consist of surgical wounds without repair (n=6), wounds with only dermal allograft soaked in saline (n=6), wounds repaired with autologous serum soaked allograft (n=6), and wounds repaired with fibrocyte seeded allograft material. Nude mice (balb/c, nu/nu, NIH) may be anesthetized by intraperitoneal injection of ketamine and xylazene (Rumpun 8 ) and a 2 cm longitudinal by a 1 cm vertical incision may be made through the skin and the panniculus carnosus (approximately 1-2 mm) on the lateral side of the back and flank. The tissue engineered grafts may be placed dermis side down and sutured into place prior to rinsing and dressing placement. The protocol for in vivo prepared immediate grafts may differ in that the fibrocytes may be sprayed directly onto the allograft just prior to suturing. Following the placement and suturing of the fibrocyte seeded dermal allograft, keratinocytes may be applied using the ACES technique. Approximately 30 minutes may be allowed for cell adhesion before the placement of the wound dressing.
[0057] Surgical Application, Dressing, and Wound Care. Sites to receive cultured grafts include the flank and back of the nude mouse. Wounds may be excised to viable tissue (fat or deep dermis), as described above, and soaked overnight in wet dressings with Sulfamylon (mafenice acetate) solution prior to placement of in vitro cultured composite grafts. Approximately 24 hrs following surgical wounding, the wound bed may be irrigated thoroughly with sterile saline, and the composite cultured grafts may be placed onto the wound beds and sutured into place with 4-0 fast adsorbing gut (FAG) suture. Grafts may then be covered with wet dressings consisting of fine mesh gauze, cotton gauze, and spandex stapled to the surrounding skin. Wet dressings may be irrigated with antimicrobial solutions administered at 2-hour intervals on a protocol of 0.5% Sulfamylon solution followed by two additions of double antibiotic (DAB; 40 μg/ml neomycin sulfate and 200 units/ml polymyxin B sulfate). Otherwise wet dressings may be changed each day for five consecutive days. Dry dressings placed on day 6 and 7 may consist of Xeroform gauze, cotton gauze bolster, and spandex. Dry dressings may be changed twice daily and may contain 3 parts bacitracin ointment plus 1% silver sulfadiazine cream. On day 8 only a simple gauze dressing may be placed daily containing the regiment of antibiotic ointments detailed above. Grafted wounds may be observed at each dressing change until day 8 and once daily until day 10. After re-epithelialization is completed, pressure garments may be applied to the graft sites.
[0058] Light and Transmission Electron Microscopy (LM and TEM). Biopsies (3 mm punch) may be taken at 14, 30, 60 and 90 days at the graft wound interface. Biopsies may be rinsed in saline, bisected and fixed in 2% glutaraldehyde and 2% paraformaldehyde in a 0.1M Na cacodylate buffer, pH 7.4, and subsequently processed by standard TEM methods.
[0059] Immunofluorescence Staining and Skin Antigens. Antibodies may be used to determine differentiation products of the epidermal layer, basal lamina, anchoring zone, dermis, and the remainder of the extracellular matrix. Specimens for immunostaining may be fixed in acetone for 4-6 hrs and directly embedded in paraffin. Four-micrometer sections may be placed on poly-L-lysine coated slides, baked at 56° C. for 1 hr, and deparaffinized with xylene and acetone. Mouse monoclonal anti-human Type III collagen antibodies (MAb) and mouse MAb of Type VI collagen may be used. Polyclonal rabbit and monoclonal mouse antibodies to Type I, IV, V collagen, decorin, laminin, nidogen, tenasin, fibronectin, elastin, vitronectin, fibrillin and osteonectin are commercially available and may also be used. Epithelial differentiation may be confirmed by the presence of K10-keratin, trichohyalin, and filaggrin antibodies.
[0060] Routine immunohistochemical techniques may be employed as follows: Slides may be: (1) deparaffinized (xylene X 3, 10 minutes in each bath); (2) rehydrated by placing in baths of 100%, 95% and 70% ethanol (10 minutes each); (3) washed with phosphate buffered saline, pH 7.6 (PBS X 3, 5 minutes each); (4) incubated with protein block (1% normal goat serum) for 20 minutes at room temperature (wash with PBS X 3, 5 minutes each); (5) incubated with 3% hydrogen peroxide for 5 minutes to block indigenous peroxidase (wash with PBS X 3, 5 minutes each); and (6) incubated with the primary antibody, for 90 to 120 minutes at room temperature (wash with PBS X 3, 5 minutes each).
[0061] To label the antibody, Biogenex (San Ramon, Calif.) StrAviGen link and label (horseradish peroxidase) and the Biogenex DAB (diaminobenzedine) labeling kit, used according to manufacturers instructions, give consistently strong labeling with little or no background. The link is anti-IgG with an attached biotin. The label is an avidin-biotin complex with horseradish peroxidase. Both of these kits are available either ready to use or in bulk form. The bulk kit is used according to the dilution for Super Sensitive labeling. Mayer's hematoxylin (Sigma) is used for a counterstain.
[0062] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alternations can be made herein without departing from the spirit and scope of the invention as defined by the following claims.
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A system and method for dispersing living cells onto an area of a subject lacking normal, healthy skin, such as an open wound surface, to form three dimensional epithelial tissue is provided. The cells are dispersed using an air-jet sprayer after being suspended in a soluble media such as dextran. The cells may be dispersed directly onto the area or onto a tissue scaffold or synthetic substance that promotes wound healing.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This application is a continuation-in-part application of Ser. No. 385,166, filed Aug. 2, 1973; U.S. Pat. No. 4,048,776.
This invention relates to a steel column base plate member for connecting an H-shaped steel column member of a steel structure to concrete foundation therefor.
2. Description of the Prior Art
Steel column members of architectural buildings or construction structures are connected to concrete foundations, by means of base plates. It is well known that the steel column is stronger than the concrete of the foundation by a factor of not smaller than 10. To compensate for such difference of the strength between the concrete of the foundation and the steel column, the lower end of the column is joined to a steel plate, and the base plate is secured to the concrete foundation by means of anchor bolts embedded in the concrete foundation.
It has been suggested to provide a base for a column having a recess adapted to accommmodate the lower end of the column as shown in U.S. Pat. No. 134,269 issued to J. Gray on Dec. 24, 1872. This base is formed at its center with the recess to reduce its thickness at the center so that the strength against a vertical force may become insufficient to support a load.
It has also been suggested to fit a foot within a lower end of a column which is then inserted into a bed-plate with a sleeve or socket to bring the foot into contact with the bed-plate, disclosed for example as in U.S. Pat. No. 198,072 issued to A. Bonzano on Dec. 11, 1877. This bed-plate will support a vertical force but insufficient to support a bending moment transmitted from the column which will probably been supported by the sleeve.
It has also been suggested to provide a base-socket having a supporting base member and an upwardly projecting portion containing a recess to receive the lower end of a column which is secured within the socket by riveting or the like. Such a socket has been disclosed in the U.S. Pat. No. 1,258,409 issued to T. Hill on Mar. 5, 1918. However, the socket has a configuration prone to give rise to a stress concentration and fails in smooth stress transmission through the socket from the column to a concrete foundation.
Generally speaking, the base plate member is required to fulfill the following conditions.
1. Since the base plate will be subjected to various severe forces resulting from axial force, shearing force and bending movement acting upon the column member, the base plate must be in a configuration to avoid any stress concentration and perform a smooth stress transmission from the column member to the foundation.
2. In order to decrease the cost of a construction as a whole, the working of column member should be minimized only to cutting of both ends thereof. If any grooves for welding are required, the base plate member should be formed with such grooves by the use of means of minimum possible cost.
3. If utilizing any welding method for connecting the base plate member to a column member, the base plate member should be of a configuration capable of applying the most effective welding method which is higher in reliability, minimum of consumed welding rods and carried out with ease. The configuration is also applicable of a combination of welding methods of which characteristics help each other to accomplish the most rational welding arrangement which meets stresses derived from forces and bending moments to which the column member is subjected.
4. The base plate member should be a configuration in agreement with a stress distribution acting thereupon resulting from axial and shearing forces and bending moment to which the column member is subjected.
5. The base plate member should be such a configuration that a base portion of the base plate member in contact with a concrete foundation will not be affected by heating derived from welding of the plate member with the column member.
6. The base plate member should be economical of manufacture and serve to decrease the cost of a construction as a whole.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a steel column base plate member for connecting an H-shaped steel column member to a concrete foundation which overcomes the above disadvantages in the prior art and fulfills the above requirements for this kind of the base plate.
It is another object of the invention to provide a steel column base plate member, which has a novel configuration to avoid any stress concentration to perform a smooth stress transmission from a column member to a foundation and to make it possible to perform a combination of J-shaped groove welding between both flanges of column and base plate and fillet welding between both webs of column and base plate adapted to meet stresses acting upon the base plate.
It is further object of the present invention is to provide a novel base plate member, which is formed by casting or forging in a unitary body with grooves formed on the top surface of projections for effecting the J-shaped groove welding and has a configuration in agreement with a stress distribution acting thereupon and adapted not to be subjected to a detrimental effect of welding heating with the surface in contact with the foundation.
It is still more object of the invention to provide a base plate member for connecting an H-shaped steel column member to a concrete foundation, which is inexpensive of manufacture and serves to decrease the total cost of a construction.
In one aspect, the invention provides a base plate member for connecting an H-shaped steel column member to a concrete foundation, which base plate member is a unitary body comprising a substantially planar bottom plate portion engageable with said concrete foundation, a projection upwardly extending from the planar bottom plate portion and having a top surface whose shape is substantially identical to cross sectional shape of the steel column member, a web part of a top surface of said projection in opposition to a web of said column member having a width broader than that of said web of the column member so as to effect sufficient fillet welding therewith, J-shaped welding grooves formed along both edges of said top surface of said projection facing to lower ends of flanges of said column member extending from outer peripheries of the top surface of said projection so as to effect J-shaped groove welding between said lower ends of the flanges and the J-shaped welding grooves, a sloped top surface formed between said projection to said bottom plate portion so as to increase the thickness thereof as the planar bottom plate portion extends toward said projection, and abutments formed on the planar bottom portion in a sufficient thickness and having anchor bolt holes bored therethrough.
In another aspect, the invention provides a method of connecting an H-shaped steel column member to a base plate member, wherein said base plate member comprises a substantially planar bottom plate portion, a projection extending from the planar bottom plate portion and having a top surface whose shape is substantially identical to cross sectional shape of the steel column member, a web part of a top surface of said projection having a width broader than that of a web of column member, J-shaped welding grooves formed along both edges of said top surface of said projection facing to lower ends of flanges of said column member, the improvement characterized by, the steps of placing the lower end surface of said column member onto said top surface of said base plate member in a desired relation, effecting fillet welding along between lower ends of said web of the column member and said top surface of said base plate member, and effecting J-shaped groove welding along said J-shaped grooves of said base plate member between bottom surfaces of said flanges of the column member and said grooved surfaces of said base plate member.
BRIEF DESCRIPTION OF THE DRAWING
For a better understanding of the invention, reference is made to the accompanying drawing, in which:
FIG. 1 is an elevation of a steel column base plate member for supporting an H-shaped column member, according to the invention;
FIG. 2 is a plan view of the base plate member of FIG. 1;
FIGS. 3 and 4 are schematic partial sectional views, illustrating the manner in which an H-shaped column member is welded to the base plate member of the invention;
FIG. 5 is a schematic sectional view showing J-shaped groove and fillet welded beads for connecting the column member to the base plate member according to the invention;
FIG. 6 is a perspective view illustrating a modified base plate of the invention formed with bosses for facilitating the registration of the column member with the base plate member;
FIG. 7 is a perspective view of the base plate member according to the invention explanatorily illustrating the configuration of the base plate member;
FIG. 8 is a diagrammatical view showing an axial force, a bending moment and a shearing force acting upon an H-shaped column member and a relationship between these forces and flanges and a web of the column member;
FIG. 9 illustrates various reaction distributions depending upon the relation between bending moments and compressive forces; and
FIGS. 10a and 10b are schematic sectional views of J-shaped groove weld and L-shaped groove weld, respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, a steel column base plate member 20 according to the present invention is to join an H-shaped steel column member 1 to a concrete foundation 2. The base plate member 20 itself is secured to the concrete foundation 2 by anchor bolts 17 and nuts 17a.
The base plate member 20 has a planar bottom plate portion 6 whose bottom surface area is large enough to distribute the load of the steel column member 1 to the concrete foundation 2 at a stress which is below an allowable limit to the concrete member of the foundation 2 through the interface between the base plate member and the concrete foundation. A projection 7 is integrally formed with the planar bottom portion 6 so as to form a top surface 7a and 7b whose shape is substantially identical to the cross section of the H-shaped steel column member 1, said top surface of web 7b of projection having a broader width than that of web 1b of the steel column member 1, and a J-shaped groove 5 formed along the edges of top surface 7a of projection, the width of which groove 5 is substantially identical to the bottom surface of flange of the steel column member so as to effect groove welding between the grooved surface of projection and the bottom surface of the flange of steel column member, and a residual top surface 7a of projection extending inwardly toward web from the edge thereof, so as to effect the fillet welding between said top surface 7a of base plate and the lower end of flanges of column member 1.
Referring to FIG. 1, the height H of the projection 7 is determined on the basis of the ease of welding the column member 1 to the top surface 7a and 7b and the suppression of the welding strain or bending of the base plate member 20 due to the welding of the column member 1 thereto.
Smoothly curved surface portions 8 are formed where the projection 7 rises from the planar portion 6, so as to eliminate any stress concentration in the base plate member 20 due to the presence of sharp corners. Thus, the radius of curvature of the curved surface 8 must be chosen on the basis of effective suppression of the stress concentration. Whereby, the smooth transfer of the load of the column member 1 toward the concrete foundation 2 is ensured.
The planar portion 6 has a sloped or tapered top surface 6a, so that the thickness of the planar portion 6 increases as it extends toward the projection 7. With such sloped top surface 6a, the thickness of the planar portion 6 is increased at those parts where the stress is high, while allowing comparatively thin thickness to the less stressed parts thereof. As a result, the rigidity of the projection 7 is enhanced, too. Furthermore, superfluous thickness of the base plate 20 is eliminated.
Abutments 9 are integrally formed at the parts where anchor bolt holes 11 are bored through the base plate member 20. The top surface of the abutment 9 is made parallel to the bottom plane of the planar portion 6, so as to stabilize the contact surface between the nut 17a and the abutment 9. It is, of course, possible to insert suitable washers (not shown) between the abutment and the nuts 17a. Referring to FIGS. 1 and 2, the width and the thickness d of the abutment 9 are so chosen as to ensure smooth transfer of the load of the column member 1 toward the anchor bolts 17. Suitably curved surfaces 10 are formed at the junction between the abutment 9 and the projection 7, for preventing stress concentration thereat.
The steel column base plate member 20 of the aforesaid construction may be made by casting or by forging.
The steel column member, e.g., the H-shaped steel member, is made by rolling in a universal mill. Accordingly, once its nominal dimension is determined, the inside dimensions and the radii of curvature at the junctions of different inside surface portions are fixed, regardless of the difference in the thickness of flanges and webs thereof. In fact, the shapes and dimensions of the steel column members to be used in architectural buildings and construction structures are selected from a limited number of varieties. Accordingly, it is comparatively easy to provide such top surface 7a and 7b of the projection 7 which is of substantially identical shape with the sectional shape of the steel column member 1.
According to the present invention, the web part 7b of the top surface of the projection facing the lower ends of the web of the column member 1 has a width broader than that of the web so as to effect a fillet welding between the web part 7b of the top surface of the projection and the lower end of the web along both sides thereof.
The J-shaped groove 5 is formed along the edges of top surface 7a of projection, the width of which groove 5 is substantially identical to or broader than the bottom surface of the flange of the steel column member so as to effect groove welding between the J-shaped grooved surface of projection and the bottom surface of the flange of steel column member and the residual top surface 7a of projection extending inwardly toward web from the edge of groove so as to effect the fillet welding between said top surface 7a of base plate and the inner lower end of flange of column member 1. The J-shaped welding grooves 5 are formed at the time of casting or forging of the base plate member 20 per se.
The base plate member may be preferably formed with a center line or center lines (not shown) at the time of casting or forging corresponding to scores marked in the column member by a scraper and lines marked in the concrete foundation for facilitating the correct registering of the base plate member 20 relative to the column member and the concrete foundation.
To facilitate the correct registering of the steel column member 1 relative to the base plate member 20, suitable bosses 12 may be provided at the top surface 7a and 7b of the projection as shown in FIG. 6.
In actual construction, fillet welding is performed along the top surface 7b on both sides of the web of the column member to form fillet welding beads 13 as shown in FIGS. 3 and 5 and J-shaped groove welding or butt welding is performed along the J-shaped grooves 5 with the flanges of the H-shaped column member 1 to form groove welding beads 14 as shown in FIGS. 4 and 5. Before the J-shaped groove welding, the fillet welding may be effected successively along the inner lower end of the flanges and the top surface 7a to form fillet welding beads 15 as shown in FIGS. 4 and 5 which serve to increase strength of the welded portions and as sealing beads for the subsequent J-shaped groove welding. It is apparent to those skilled in the art that the use of bosses 12, as shown in FIG. 6, will facilitate the registration or indexing of the column member 1 with the base plate member 20.
In using the base plate member 20 according to the present invention for a construction, the top surface 7a and 7b of projection of base plate is brought into contact with the lower end of an H-shaped column member 1 with the aid of the center lines of the plate member in registry with the scores of the column member. Tack welding is effected at several locations between the column member and the base plate member, for example, two points at the web of the column member and four points at the inner lower end of the flanges of the column member for fixing a relative position therebetween to facilitate the subsequent welding. Then fillet welding is performed along on both sides of the web of the column member to form the bead 13. Fillet welding is preferably effected successively along the inner lower ends of the flanges of the column member to form beads 15 which serve to provide an additional reinforcement for the flange portion and prevent the J-shaped groove weld bead 14 from dropping over. The beads 15 serve additionally to minimize of shrinkage of the member after the prosecution of welding in conjunction with the metallic touch of the top surface of the base plate member with the lower end of the column. The beads 15 often extend through a clearance between the flange and the top surface 7a into a space of the J-grooves. Such an excess bead extending into the groove 5 is then gouged or removed. Then, J-shaped groove welding or butt welding is effected to form beads 14 between the flanges of the column member and the protrusion 7.
The column member and the base plate member thus united are brought onto a concrete foundation such that anchor bolts 17 extending from the foundation pass through the anchor bolt holes 11 and the center lines of the base plate member are in registry with the lines marked in the concrete foundation. The nuts 17a are threadedly engaged with the anchor bolts 17 and then tightened with a determined amount of torque by means of a suitable equipment such as a constant torque wrench.
The base plate member for the H-shaped column member according to the present invention has following characteristics distinguishable over those in the prior art.
1. Outer Configuration
The base plate member according to the present invention has the configuration as shown in FIGS. 1, 2 and 7. There are smoothly curved surface portions 8 at the junctions between the projection 7 and the sloped top surface 6a and further smoothly curved surface portions at the junctions 10 between the abutments 9 and the planar bottom portion 6. These smooth surfaces prevent any stress concentration and serve to transmit smoothly the load from the column member to the concrete foundation.
The area shown in chain lines 22 in FIG. 7 illustrates the contact surface in contact with the bottom of the column member which provides a metal contact which serves to keep an accuracy of the height of the column member and makes it easy to set the column member on the concrete foundation.
The J-shaped grooves for butt welding are integrally formed in the base plate in casting or forging so that the forming of the J-shaped grooves scarcely increases the cost of the base plate and the column member is not required to have any worked portion for butt welding. Accordingly, the working of column members will be simplified to save time and cost for manufacturing the construction.
2. The Combination of Fillet and Butt Weldings
It has been known that shearing strengths of fillet and butt welded portions at their throats are substantially equal to each other, while the tensile strength of the butt welded portion is generally higher than that of the fillet welded portion. The present invention utilizes these characteristics in strength to enable the base plate to support a load in the most effective manner.
In general, a column is simultaneously subjected to an axial force N, a bending moment M and a shearing force Q as shown in FIG. 8 which diagrammatically shows the axial force, the bending moment and the shearing force acting upon the column member. An H-shaped column member is generally so arranged that the flanges of the column member will receive the bending moment M and the web will receive the shearing force Q. Accordingly, the welded portions of the flanges will be subjected to tensile forces and the welded portions of the web will be subjected to a shearing force. By welding the flange by the butt welding and the web by the fillet welding the most effective welding arrangement can be accomplished which beneficially meets stresses derived from the forces and moments to which the column member is subjected. The base plate member according to the present invention has a configuration suitable to carry out the above the combination of fillet and butt weldings. In more detail, the base plate member comprises the H-shaped top surface 7a and 7b whose shape is substantially identical to cross sectional shape of the steel column member, a top surface 7b of projection in opposition to the web of the column member having a broader width than that of web of column member sufficient to effect fillet welding between the web of the column member and the top surface 7b, and J-shaped welding grooves 5 formed along the edges of the top surfaces 7a in opposition to the flanges of the column member for J-groove welding with it.
The fillet welding at the web may be effected in succession along the inner lower end of the flanges and the top surface 7a to form the fillet welding beads 15 which serve to prevent the J-shaped groove weld from droppings during the course of welding and provide an additional reinforcement for the web portion.
3. Dynamics on the Base Plate
The column member is subjected to the axial force N, the bending moment M and the shearing force Q which act between the base plate and the concrete foundation as shown in FIG. 8. Depending upon the magnitude of these forces and their combination, a reaction force between the base plate and the foundation varies in distribution and amount as shown in FIG. 9. FIG. 9A shows the reaction force in case of the bending moment is relatively small in comparison with the compressive force, FIG. 9B is in case of the bending moment is normal or intermediate and FIG. 9C is in case of the moment is a great value. In any case, these compressive force, bending moment and shearing force simultaneously act upon the column member, so that reaction forces are caused between the base plate member and the column member as shown in arrows in FIG. 9 wherein solid lines of the arrows show theoretical distribution of the reactions and dot-and-dash lines show actual distributions. In case of FIG. 9C, due to the great moment, one flange of the column member tends to raise to cause a great tensile force in anchor bolts.
When the base plate member is subjected to a great contact force in an axial direction of the column member which causes a bending action (a positive bending moment) on the plate member, so that the plate member is required to have sufficient yield strength and rigidity to resist to the bending action.
When the anchor bolts are subjected to a great tensile force as shown in FIG. 9C, a great reaction force is caused in the proximity of the holes for the bolts formed in the base plate and results in a bending action (a negative bending moment) on the plate member, so that the member is required to have sufficient yield strength and rigidity to resist to the action.
The bending moment and the shearing force generally act on the base plate member as alternate stresses. Accordingly, the base plate member is generally required to have a symmetrical yield strength and rigidity. The yield strength will resist to the stress so as not to be broken and the rigidity will resist to the stress so as to restrain a deformation.
At any rate, when the base plate member is subjected to reaction forces as shown in FIGS. 9A, 9B and 9C, the base plate will be subjected to a bending action of which bending stress is maximum at the place on the base plate member in opposition to the flanges and web of the column member.
Accordingly, the feature of the projection 7 of the base plate projecting from the base portion and corresponding to the sectional area of the column member and the feature of decreasing the thickness of the bottom plate portion toward the outer ends thereof provided a rational configuration in agreement with the stress distribution. In addition, with the configuration the top surface of the projection to be welded to the lower end of the column member is remote from the base portion of the base plate member so as to be remote from the portions subjected to violent heating for welding, thereby preventing the base portion from deforming in welding. The base plate member having a changing thickness can be advantageously made by casting or forging.
4. Advantages of J-shaped Groove Welding
An amount of weld metal or deposited metal in the J-shaped welding is less than those in any other welding methods for the same purpose. The reliability in penetration or weld penetration in the proximity of the root of J-shaped groove weld is higher than those in any other methods and also higher than that in L-shaped groove weld as shown in FIG. 10b. The J-shaped groove welding operation can be carried out with ease. In spite of these advantages, the J-shaped groove welding requires to form J-shaped grooves which are apt to increase the cost of welding. According to the invention by casting and forging the base plate member, J-shaped grooves can easily be formed in the base plate member, so that the base plate member can utilize the advantages of the J-shaped groove welding without increasing cost for providing the J-shaped grooves.
5. Cost Comparison
We compared the cost of the cast steel base plate members according to the invention with that of the prior art steel base plates for H-shaped column members 450 (web) × 300 (flange) mm. One example of the comparison is indicated in Table I.
Table I__________________________________________________________________________ Cast steel base plate Steel base plate (Present invention) (Prior art) Total Total Total Total Unit price weight cost weight cost__________________________________________________________________________Casting $0.605/lb ( Y=400/kg) 430 lbs $260 0 0 (195 kgs) ( Y=78,000) 0MaterialSteel plate $0.151/lb ( Y=100/kg) 0 0 1,043 lbs $158cost (473 kgs) ( Y=47,300)Welding rod $0.423/lb ( Y=280/kg) 0 0 132 lbs $56 (60 kgs) ( Y=16,800)Total 430 lbs $260 1,175 lbs $214 (195 kgs) ( Y=78,000) (533 kgs) ( Y=64,100)WorkingLabor cost $33.3/man ( Y=10,000/man)cost Indirect $16.7/man ( Y=5,000/man) 0 0 3.97 men $199cost ( Y=59,595)Total $260 Y=78,000) $412.3 ( Y=123,695)Economical Comparison 63% 100%__________________________________________________________________________
A number of cast steel base plates of totally 430 lbs according to the invention were used in the comparison, which only require casting operation but not require any other operation such as working or welding operation for providing the base plates themselves. Accordingly, the total cost was $260. In contrast herewith the steel base plates of the prior art require the steel plates of 1,043 lbs and welding rods of 132 lbs for providing the number of the base plates equal to the above cast steel plates and further require the working operation with direct and indirect costs, so that the total cost was $412.3. The cost of the cast steel base plate according to the invention is only 63% of that of the welded steel base plate of the prior art.
As can be seen from the above description, the base plate member according to the invention has a various of novel features of the configuration making it possible to effect a combination of fillet and butt welding to meet the stress condition acting upon the column member and the base plate; preventing the base portion from deforming in welding by arranging the welding portion on the top of the protrusion remote from the base portion; having an effective sectional shape to meet the bending stress distribution; and making it possible to effect the effective J-shaped groove welding.
It is understood by those skilled in the art that the foregoing description is a preferred embodiment of the disclosed base plate and that various changes and modifications may be made in the invention without departing from the spirit and scope thereof.
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A steel column base member for connecting an H-shaped structural steel column member to a concrete foundation, which base plate member is an integral cast or forged body comprising a bottom plate member to engage the foundation, an H-shaped projection upwardly extending from the bottom plate member and having J-shaped grooves formed along both edges of top surface of projection the width of web of projection being broader than that of web of column member, so as to effect groove welding between the bottom surface of the steel column member and the J-shaped grooved surfaces, and fillet welding both side of web of the column member and base plate member. A method of connecting an H-shaped steel column member to a base plate member is characterized by, effecting fillet welding along between lower ends of a web of column member and a top surface of base plate member, effecting J-shaped groove welding along between J-shaped groove surfaces of base plate member and the bottom surfaces of flanges of steel column member, and fillet welding along between the inner lower ends of flanges of a steel column member and the top surfaces of flanges of projection.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cabinets for appliances, and in particular to removable cabinets for front-serviceable appliances.
2. Description of the Prior Art
Most domestic appliances, such as automatic washers, have internal operative components covered by a cabinet which is attached to a frame supporting the internal components. Servicing of the appliance is hampered because the internal components are inaccessible unless the cabinet is removed. Such cabinets are held in place by screws, bolts, or other attachment means which must be manually disengaged before the cabinet can be removed. An additional problem is that frequently some internal components are attached in some way to the cabinet so that once the cabinet is removed those parts become nonfunctional, and must be rigged for operation without the cabinet in order to service the appliance.
SUMMARY OF THE INVENTION
In accordance with the principles of the present invention a removable cabinet for a front-serviceable laundry appliance has a cabinet wrapper including a front and two sides joined to a top. The cabinet wrapper is fitted over a base frame supporting internal components and to which an upwardly extending rear panel is attached. The bottom portions of the cabinet sides have apertures or slots therein for receiving upwardly extending alignment tabs on side members of the base frame. The front of the cabinet has a bottom portion having a flange which overlaps and extends beneath an outwardly extending front member of the frame to prevent upward movement of the front of the cabinet when it rests on the base.
The appliance has a control housing having a control panel which is hingedly attached to an upper portion of the rear panel so that the control housing can be pivoted from a position on top of the cabinet to a position above the rear panel. The sides of the control housing have downwardly extending tabs for engaging aligned slots in the top of the cabinet.
A pair of spring clips, normally covered by the control housing, are exposed when the housing is lifted. Each clip has a rear flange which engages the rear panel and a series of curved portions for engaging slots in the top of the cabinet and locking the cabinet in place. A first curved portion abuts the top of the cabinet, another curved portion extends into a first slot in the cabinet, and a last curved portion extends through another slot in the cabinet and has a rearwardly extending portion which engages an edge of the slot to exert retaining tension on the clip.
Removal of the cabinet is easily achieved by disengaging the control housing and lifting it upwards to expose the clips, releasing the clips, rocking the cabinet forward off of the alignment tabs, and moving the cabinet forward to disengage the front flange from the base. With the exception of the necessity of jumping a lid safety switch, the exposed components are functionally intact, so that maintenance can be undertaken without further preparation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view, partly broken away, of a laundry appliance having a removable cabinet embodying the principles of the present invention.
FIG. 2 is a fragmentary plan view, partly in section, of the appliance of FIG. 1.
FIG. 3 is an enlarged fragmentary sectional view of the appliance taken along line III--III of FIG. 2.
FIG. 4 is an enlarged sectional view of a clip engaging the removable cabinet of FIG. 1 showing a suggested method of disengagement.
FIG. 5 is a detail sectional view of a clip engaging the cabinet of FIG. 1 showing a suggested method of engagement.
FIG. 6 is a fragmentary side elevational view, partly in section, of the appliance of FIG. 1.
FIG. 7 is an enlarged sectional view taken along line VII--VII of FIG. 6.
FIG. 8 is a fragmentary side view of the appliance of FIG. 1 with the control housing elevated to show an engaged clip.
FIG. 9 is a fragmentary side view of the appliance of FIG. 1 with the control housing elevated and the retaining clip disengaged.
FIG. 10 is a schematic side view showing the method of removing the cabinet of FIG. 1.
FIG. 11 is an enlarged fragmentary sectional view of the lower front of the appliance of FIG. 10.
FIG. 12 shows the exposed internal components of the appliance of FIG. 1 after removal of the cabinet.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A laundry appliance of the vertical axis type embodying the principles of the present invention is shown generally at 10 in FIG. 1. The appliance 10 has a removable outer cabinet 11 including a cabinet wrapper consisting of two side panels 11d and an integral front panel 11a, and a control housing 12 having a control panel 13 thereon. The cabinet 11 houses a stationary tub 14 therein, containing a perforate spin basket 16. An agitator 17 is vertically disposed inside the spin basket 16. A generally circular opening 15 in the top of the tub 14 for entry and removal of laundry is covered by a hinged cabinet lid 18 in a cabinet top 19.
The appliance 10 includes internally supported functional components comprising a motor and drive means 24 which is supported on an interior frame 25. The frame 25 is in turn supported in tripod fashion by three struts 23 (FIGS. 1 and 12). A suspension mechanism 26 minimizes transfer of vibrations from the moving interior parts of the cabinet 11.
A base frame 9 is attached to the struts 23 consisting of a front member 20, a left side member 21, a right side member 22 and a rear member 9a (FIG. 12) connecting the side members to each other and to rear strut 23. As shown in FIGS. 6 and 7, the left frame member 21 has a horizontal portion 21a having an upwardly extending rear tab 62 and a front tab 63. The tabs 62 and 63 respectively engage apertures or slots 64 and 65 in a bottom side flange 11c of the cabinet side lid.
As also shown in FIG. 6, the base further consists of frame members 61, attached to the side member 21 and also side member 22 (not shown) and feet 60 which may be adjustable to level the appliance 10.
Each of the front struts 23 has an extension 23a thereon to which the front base frame member 20 is attached. The front 11a of the cabinet 11 terminates in overlapping relationship to front member 20 and has a horizontal flange 11b which extends beneath the extension 23a and the front member 20 to prevent upward movement of the cabinet 11 at the front portion thereof.
Referring to FIGS. 2, 3 and 12 a rear panel 30 is attached by suitable means such as screws to the base frame rear member 9a and extends upwardly therefrom. Referring to FIG. 9, the rear panel 30 extends a distance beyond the top 19 of the cabinet 11 a distance equal to the height of a side 12a of the control housing 12. The control housing 12 is attached to the top of the rear panel 30 by a hinge 67. When the control housing 12 is in the position shown in FIGS. 1, 2 and 3 a downwardly extending rear tab 38 engages a slot 36 in the top 19, and a downwardly extending front tab 39 engages a slot 37. As shown in FIG. 3, a horizontal strip 53 at the bottom of the control housing 12 has screws 55 extending therethrough and received in plastic members 54 attached to the cabinet top 19 for further securing the control housing 12 to the top.
The control housing 12 covers two identical configurations on opposite sides of the top 19 for receiving a cosinusoidal shaped retainer clip 35. Each configuration is integral with the top 19 and consists of two parallel ridges 31 extending normal to the rear panel 30. A second pair of parallel ridges 32 and 32a, perpendicular to the ridges 31, divide the area between the ridges 31 into three sections. A slot 33 is disposed in a middle section, and a slot 34 is disposed in a section farthest from the rear panel 30. The ridges 31 and 32 provide added strength to the top 19 of the area around slots 33 and 34, but need not be utilized if the added strength is not required.
The slots 33 and 34 receive portions of the retainer spring clip 35 as shown in detail in FIGS. 3, 4 and 5. A flanged end 40 of the clip 35 extends through the rear panel 30 at aperture 40a to provide a stop against which the spring clip 35 can be tensioned. The clip 35 has a first curved portion 41 which abuts a portion of the top 19 between the rear panel 30 and ridge 32. A second curved portion 42 extends over the ridge 32 and joins a third curved portion 43 which extends into and bears against an edge 33b of the slot 33. A fourth curved portion 44 of the clip 35 extends over the ridge 32a and joins a retaining means for holding the clip 35 in place comprising a short horizontal portion 45 which is held by spring tension immediately beneath and parallel to the top 19 in slot 34. The section 45 joins a straight section 46 which terminates in a curved flange 47.
A suggested method of disengaging the clip 35 from the slots 33 and 34 in the top 19 is shown in FIG. 4. The blade 50 of a screw driver or other suitable tool is inserted in the flanged end 47 of the clip 35 and a force is applied in the direction indicated by the arrow using the lower part of the curved portion 44 as a fulcrum to disengage the portion 45 from the top 19. Once the section 45 has been disengaged the clip 35 is rotated clockwise as shown in FIG. 4 about flanged end 40 to release curved portion 43 from the edge 33b and thus spring tension is no longer exerted at the stop so that the clip 35 may be easily removed.
A suggested method of engaging the clip 35 with the top 19 is shown in FIG. 5. Aligned apertures 48 and 49 in the clip 35 receive a rod 51 or other suitable straight tool. After inserting end 40 in rear panel aperture 40a, a generally downward force is applied in the direction of the arrow forcing the clip downward by lever action until the portion 45 engages the top 19.
When the clip 35 is in the position shown in FIGS. 2, 3 and 4 it exerts a downward bias force at curved portion 41 to retain the cabinet 11 against the base frame 9. The clip 35 also biases a flange 19a extending downwardly at a right angle to the top 19, against the rear panel 30 through the force created by third curved portion 43 against edge 33b of top 19 when the clip is tensioned between edge 33b and panel 30. Thus, the retaining clips provide the only connecting means for joining the cabinet 11 to the rear panel 30, and further provides a biasing means biasing the and cabinet wrapper against the base frame 9.
A method for removal of the cabinet 11 is sequentially shown in FIGS. 8 through 12. The screws 55 are removed and the control housing 12 is pivoted on the hinge 67 from the broken line position 66 to the position shown in FIG. 8. Electrical wires 68 connecting the operating components to the control components in the control housing 12 are sufficiently long that they need not be disconnected or jumped, and all functions controlled by the control panel 13 are still operative. The only electrical wire that need be disconnected is a wire 78, having a separable connector 80, connecting a cabinet wrapper mounted safety lid switch 79 to the control panel. The clips 35 are thus exposed by pivoting the control housing 12 and can be disengaged by the method shown in FIG. 4 to the position shown in FIG. 9.
After disengagement of the clip 35 from the rear panel 30, and disconnection of electrical wire 78 at connector 80, the cabinet 11 is rocked forward in the direction of the arrow shown in FIG. 10 from the broken line normal position 75 to a position 76 so that the alignment tabs 62 and 63 are respectively disengaged from the receptacles 64 and 65 in bottom flange 11c. When the cabinet is rocked as shown in FIGS. 10 and 11, tabs 63 and 62 are freed from their respective slots 65 and 64 and the front flange 11b can be slid from beneath the front base member 20 and the cabinet 11 removed as shown in FIG. 12. The control housing 12 can then be moved back to its usual position, and the appliance 10 is operable for servicing. The only additional preparation which need be done is to jump across the open portion of line 78 at connector 80 to simulate a closed lid safety switch which normally allows operation of the appliance 10 only when the switch and the lid 18 are closed.
Although the above description shows use of the cabinet 11 and attachment method with a vertical axis laundry appliance, it will be understood that the inventive concept herein is equally applicable to all types of appliances.
Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent hereon any changes and modifications as reasonably and properly come within the scope of their contribution to the art.
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In a front-serviceable appliance having a base frame supporting internal components, the base frame having a front member and side members and a rear panel attached thereto, a removable cabinet has a front bottom flange overlapping and extending beneath the front base frame member, and receptacles for receiving upwardly extending tabs from the side members to position the cabinet with respect to the base. The cabinet is held in position on the base by a pair of spring clips engaging the rear panel and each having a portion abutting a top of the cabinet and curved portions extending into the cabinet through aligned slots in the top thereof to maintain a spring tension. The cabinet is thus retained without the use of screws and its removal does not impair the functional operation of the internal components.
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BACKGROUND
Modern electronic equipment, and in particular handheld equipment, is often used in harsh environments in which the equipment is subjected to potential electrostatic discharge (ESD). For instance, data exchange ports such as those employed with universal serial bus (USB) or high-definition multimedia interface (HDMI) receiver/transceiver circuits are directly connected to external pins of electronic equipment. Current pulses from electrostatic discharge can have extremely fast rising slopes, such that protecting against such pulses requires rapid switching in order to shunt the current. In many instances, circuits are not robust enough to withstand the stress caused by ESD.
To address these problems, a variety of different types of ESD protection devices have been used, often implemented on a printed circuit board between external contacts and the integrated circuit of the device being protected. Such ESD protection devices generally shunt excessive currents to ground and clamp stress voltages to a level that the circuit to be protected can withstand. If the constraints on parasitic capacitance of the protection device are not stringent, simple p-n-junction diodes have been used.
If parasitic capacitance is desirably low (e.g., in order to not disturb high data rate signals), rail-to-rail or similar types of devices have been used. In such devices, two small steering diodes with small capacitance are often used for each channel, to shunt the stress current either to ground or to a large clamping device that shunts current further to ground while achieving a standoff voltage. Such clamping devices may include a simple diode or a more complex device, such as those in which a simple diode is used as a triggering component. The standoff voltage and the clamping voltage of the clamping device define the possible application.
The leakage current of the protection device at the standoff voltage (usually the supply voltage of the IC to be protected plus a safety offset) is desirably low where power consumption is a concern. Generally, the clamping voltage has to be kept lower than the acceptable voltage of the integrated circuit in which the device is used. Modern integrated circuits, however, have ever decreasing supply voltages and are more susceptible to high clamp voltages. Diode-based ESD devices often do not break down or otherwise operate satisfactorily at low operating voltages (e.g., below 6V). Other ESD devices can be difficult to manufacture in conjunction with standard integrated circuit processes.
Accordingly, achieving robust clamping while operating at low power has been challenging for a variety of circuits and ESD applications. These and other matters have presented challenges to ESD circuit protection, and related device operation.
SUMMARY
Various example embodiments are directed to electrostatic discharge (ESD) protection for a variety of devices.
In connection with an example embodiment, an electrostatic discharge (ESD) circuit includes a plurality of regions of opposite polarity sharing p-n junctions therebetween, the regions including an input region connected to an internal node susceptible to ESD pulses, an output region connected to ground, and at least one region in series between the input and output regions. An underlying doped region is adjacent one of the plurality of regions and, in response to a breakdown voltage at one of the junctions, shunts current between the input region and the output region, bypassing p-n junctions of the regions between the input and output regions.
Another example embodiment is directed to an electrostatic discharge (ESD) circuit having a doped collector region in a substrate, two base regions in the collector region and separated from one another, and two emitter regions in each base region. The base regions are doped to a polarity that is opposite the polarity of the collector region, and the emitter regions are doped to the polarity of the collector region. The emitter regions include an input emitter in one of the base regions and connected to an input pin, and a grounded emitter in the other one of the base regions and connected to ground. An interconnect directly connects the emitter regions that are not connected to the input pin or to ground.
Another example embodiment is directed to an ESD circuit for discharging current from an input node susceptible to ESD pulses. The circuit includes a doped substrate, a diode circuit in the doped substrate and having a threshold breakdown voltage, a plurality of doped regions and a thyristor. The plurality of doped regions are of opposite polarity and form p-n junctions connected in series with the diode between the input node and ground. The diode and plurality of doped regions pass a leakage current between the input node and ground at voltage levels below the threshold breakdown voltage. The thyristor includes a portion of the doped substrate and shunts current from the input node to ground, bypassing at least some of the plurality of doped regions, in response to the diode circuit breaking down.
The above discussion is not intended to describe each embodiment or every implementation of the present disclosure. The figures and following description also exemplify various embodiments.
FIGURES
Various example embodiments may be more completely understood in consideration of the following detailed description in connection with the accompanying drawings, in which:
FIG. 1 shows a cross-section of a thyristor-based diode circuit for ESD protection, according to an example embodiment of the present invention;
FIG. 2 shows a plot characterizing the operation of a thyristor-based diode circuit for ESD protection, according to another example embodiment of the present invention;
FIG. 3 shows a multi-channel thyristor-based diode circuit, according to another example embodiment of the present invention;
FIG. 4 shows a multi-channel thyristor-based diode circuit with channel-specific diodes, according to another example embodiment of the present invention;
FIG. 5 shows a two-stage thyristor-based diode circuit for ESD protection, according to another example embodiment of the present invention;
FIG. 6 shows a thyristor-based diode circuit with a diode-triggered bipolar transistor clamping circuit, according to another example embodiment of the present invention;
FIG. 7 shows a thyristor-based diode circuit with a diode-triggered silicon-controlled rectifier (SCR) clamping circuit, according to another example embodiment of the present invention;
FIG. 8 shows a circuit diagram of an ESD circuit, according to another example embodiment of the present invention;
FIG. 9 shows another circuit diagram of an ESD circuit, according to another example embodiment of the present invention;
FIG. 10 shows a cross-section of a thyristor-based diode circuit for ESD protection under an ESD condition, according to another example embodiment of the present invention; and
FIG. 11 shows another circuit diagram of an ESD circuit, according to another example embodiment of the present invention.
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention including aspects defined in the claims.
DETAILED DESCRIPTION
The present invention is believed to be applicable to a variety of different types of processes, devices and arrangements for use with various circuits, including integrated circuits susceptible to electrostatic discharge (ESD), and related processes. While the present invention is not necessarily so limited, various aspects of the invention may be appreciated through a discussion of examples using this context.
According to an example embodiment, an ESD circuit includes multiple regions of opposite polarity configured to flow current in different current paths during an ESD event and under conditions in which an ESD event is not occurring. Under normal (non-ESD) conditions, the circuit flows current through a series of emitters separated from one another by base regions having a polarity that is opposite the polarity of the emitters. The current flows from a first (input) emitter in the series of emitters, to a last (grounded) emitter that is connected to ground. By flowing current through the respective junctions in series, the leakage of the overall circuit is limited by the leakage at one of the junctions.
When an ESD event occurs, current flows from the input emitter, into a base region that forms a junction with the emitter, and into an underlying collector. From the collector, the current flows into the base region adjacent the grounded emitter, and to ground via the grounded emitter. This ESD event current path facilitates a low-resistance path to shunt current from input to ground, which triggers with the triggering at the p-n junction between the input emitter and the base region adjacent thereto.
In connection with other example embodiments, a plurality of regions of opposite polarity having junctions therebetween are arranged in series between an internal node and ground, to mitigate the flow of leakage current in a below-threshold operating state, with one of the regions forming part of a p-n junction that breaks down at low voltage for shunting an ESD pulse to ground via an underlying substrate. For example, a p-n junction having a low breakdown voltage (e.g., 3 or 4 V) is used for shunting current as above, with additional p-n junctions arranged in series therewith to mitigate high leakage current to which the low-breakdown junction is susceptible. The opposite regions and corresponding junctions are configured such that an externally applied voltage is shared between the junctions in series, so that each junction withstands half of the applied voltage. As the leakage current decreases exponentially with lowered voltage, the leakage current is drastically reduced accordingly.
To mitigate corresponding effects of increased clamping voltage, the aforesaid junction being used to conduct current under an ESD condition is used to limit the clamping voltage of the device to the clamping voltage of the junction plus a relatively small clamping voltage of a thyristor formed in series with the junction via the underlying substrate.
Turning now to the Figures, FIG. 1 shows a cross-section of a thyristor-based diode ESD protection circuit 100 , according to another example embodiment of the present invention. The circuit 100 is configured to pass current between an input 102 , such as an internal VDD, and ground 104 . The circuit 100 includes a substrate having multiple doped regions of opposite polarity, each region being doped relative to the others to suit particular applications. A region 111 of the substrate is doped to a first polarity, a collector 112 is doped to an opposite polarity. Two base diffusion regions 113 and 114 are formed in the collector 112 and doped to the first polarity. Within each of the base diffusion regions 113 and 114 is a pair of emitter regions, including emitter regions 115 and 116 in base diffusion region 113 , and emitter regions 117 and 118 in base diffusion region 114 . The respective emitter regions are doped to a polarity that is opposite that of the base diffusion regions. The collector 112 and the base diffusion regions 113 and 114 are left floating (e.g., they are not electrically connected to another potential).
Contacts are respectively made to the input 102 and ground 104 at an input emitter contact 120 and an output/grounded emitter contact 126 , which are respectively connected to input emitter region 115 and a grounded emitter region 118 . Contacts 122 and 124 are connected/shorted to one another via interconnect 123 and respectively connected to emitter regions 116 and 117 .
For readability, the following discussion is made in the context of a particular doping approach in which the substrate 111 is p-doped substrate, the collector 112 is n-doped, base regions 113 / 114 are p-doped, and emitter regions 115 - 118 are n-doped. However, it is to be understood that different doping can be used to achieve a similar result, with an appropriate arrangement of the doped regions.
If a relatively low positive voltage is applied to the input 102 (e.g., 3V), the first emitter 115 is reverse biased to its base 113 , and the third emitter 117 is reverse biased to its base 114 , with the bias voltage being slightly smaller than half of the external applied voltage of 3V. The leakage current of each of these junctions is low (e.g., about 30 nA). The junctions are connected in series, so the total leakage current is similar to the leakage current of one of the junctions. The leakage current flows from the input 102 , to the input emitter 115 via contact 120 , to its base 113 , to emitter 116 , and into emitter 117 though contact 122 , interconnect 123 and contact 124 . From the emitter 117 , the leakage current flows through the base 114 and into the output/grounded emitter 118 , and to ground via contact 126 .
Under an ESD condition in which the voltage at the input 102 rises (e.g., exceeds a trigger voltage), ESD current flows from the input 102 via contact 120 into the input emitter 115 , and then into the base region 113 that forms a junction with the emitter. From the base regions 113 , the ESD current flows into the underlying collector 112 and into the base region 114 via an effective bipolar junction transistor 150 . The current flows via base region 114 and collector 112 to emitter 118 via an effective bipolar junction transistor 152 , and therein to ground 104 via contact 126 . Accordingly, in response to the trigger voltage an intrinsic thyristor including the base region 113 , collector region 112 , base region 114 and emitter region 118 (e.g., p-n-p-n) switches into its low resistance state. This ESD event current path facilitates a low-resistance path to shunt current from input to ground, which triggers with the triggering at the p-n junction between the input emitter 115 and the base region 113 .
The trigger voltage is set or implemented, based upon the application. For example, the doping concentration of the various regions as shown in FIG. 1 can be altered to suit different applications, and may set characteristics of the device 100 including breakdown and leakage as discussed herein. The voltages and currents described above are thus exemplary, with the understanding that different values may be achieved to suit different applications.
FIG. 2 shows a plot 200 characterizing the operation of a thyristor-based diode circuit for ESD protection, according to another example embodiment of the present invention. The plot 200 shows a transmission line pulse (TLP) with a 100 ns length, with a 3.7 V device holding voltage, and leakage current at 3 V reverse bias of 30 nA. The increase in current is shown as the voltage increases beyond the holding voltage, with voltage on the horizontal axis and current on the vertical axis.
FIG. 3 shows a multi-channel thyristor-based diode circuit 300 , according to another example embodiment of the present invention. The circuit 300 is configured for use with two inputs at nodes 310 and 320 , and may be applicable to use with one node, or more than two nodes. This applicability is also consistent with the example embodiments shown in FIGS. 4-7 and discussed further below. For each input node, two diodes are connected thereto, including a diode ( 312 , 322 ) having its anode connected to the input node and its cathode to an internal node (e.g., VDD), and another diode ( 314 , 324 ) having its anode connected to ground and its cathode to the input node.
The diode circuit 330 is configured for operation in accordance with one or more embodiments as described herein, for providing (with circuitry coupled as shown) alternating regions of opposite polarity that mitigate leakage current below a threshold voltage, with a breakdown voltage that permits the discharge of current from the internal node to ground at a relatively low clamping voltage. As shown, the circuit 300 is applicable to multi-channel (e.g., two channel) rail-to-rail protection with desirable holding voltage (e.g., 4 V) and low leakage (e.g., at 3 V). In some implementations, all diodes are integrated on one chip, with the steering diodes realized using the diffusions that are used for building the diode 330 .
FIG. 4 shows a multi-channel thyristor-based diode circuit 400 with channel-specific diodes, according to another example embodiment of the present invention. Similar to FIG. 3 , the circuit 400 includes two diodes for each input node, including diodes 412 and 414 for node 410 , and diodes 422 and 424 for node 420 . Diode circuits 430 and 432 are configured for operation in accordance with one or more embodiments as described herein, for providing alternating regions of opposite polarity that mitigate leakage current below a threshold voltage, and to exhibit a breakdown voltage that permits the discharge of current from the internal node to ground at a relatively low clamping voltage. The circuit 400 is applicable to multi-channel (e.g., two channel) rail-to-rail protection with desirable holding voltage (e.g., 4 V) and low leakage (e.g., at 3 V), with an exclusive diode ( 430 , 432 ) for each channel.
FIG. 5 shows a two-stage thyristor-based diode circuit 500 for ESD protection, according to another example embodiment of the present invention. The circuit 500 is applicable to both single-channel and multi-channel two-stage protection, with the embodiment shown characterizing one channel with input node 510 and output node 520 , and having an impedance 540 (or impedance network) therebetween. Similar to the input nodes 310 and 320 , each of the input and output nodes 510 and 520 are connected to the anode of a diode connected between the nodes and an internal node, and to the cathode of a diode connected between ground and the nodes. Diodes 530 and 532 are similar in function to diode 330 , to facilitate both the mitigation of leakage current and a low breakdown voltage in respective operating states.
FIG. 6 shows a thyristor-based diode circuit 600 with a diode-triggered bipolar transistor clamping circuit 650 , 660 , according to another example embodiment of the present invention. The circuit 600 is similar to the circuit shown in FIG. 3 , with input nodes 610 and 620 corresponding to input nodes 310 and 320 , and diodes 612 , 614 , 622 and 624 correspond thereto.
Diode 630 is similar to diode 330 , exhibiting a low breakdown voltage and connected (as shown) to mitigate leakage below the breakdown voltage. The clamping circuit includes a bipolar junction transistor 650 and a resistor 660 , connected between an internal node and ground as shown. When the breakdown voltage is achieved, the clamping circuit turns on and shunts current accordingly.
FIG. 7 shows a thyristor-based diode circuit 700 with a diode-triggered silicon-controlled rectifier (SCR) clamping circuit, according to another example embodiment of the present invention. As with the circuit 600 in FIG. 6 , the circuit 700 is similar to the circuit 300 in FIG. 3 , with respect to input nodes 710 and 720 , and corresponding diodes 712 , 714 , 722 and 724 . Diode 730 is similar to diode 330 , exhibiting low breakdown voltage and connected to mitigate leakage below the breakdown voltage. The circuit 700 is connected to two channels for rail-to-rail protection, with the diode 730 being configured to trigger a silicon-controlled rectifier circuit including bipolar transistors 770 and 775 , as well as resistor 760 .
FIG. 8 shows an ESD circuit 800 , according to another example embodiment of the present invention. The circuit 800 includes a plurality of regions of opposite polarity that form bipolar junction transistors connected between an input node 802 and ground 804 . The transistors include n-p-n transistors 810 and 820 connected to an input region at the input node 802 . The base of n-p-n transistor 820 and the base of n-p-n transistor 810 are connected to the emitter of p-n-p transistor 830 , which is connected via its base to the collector of n-p-n transistor 840 and to the emitter of n-p-n transistor 810 . The emitter of n-p-n transistor 820 is connected to the collector of n-p-n transistor 850 . The bases of n-p-n transistors 840 and 850 are both connected to the collector of p-n-p transistor 830 . The emitters of n-p-n transistors 840 and 850 are both connected to ground 804 .
In some embodiments, the ESD circuit 800 is implemented using a thyristor-based diode circuit as shown in FIG. 1 . In these embodiments, the transistors are formed as follows. The collector 112 forms the emitter of transistor 810 , the base of transistor 830 and the emitter of transistor 840 . Base diffusion 113 forms the base of transistors 810 and 820 , and the emitter of transistor 830 . Base diffusion 114 forms the collector of transistor 830 , and the base of transistors 840 and 850 . The emitter 115 forms the collector of transistors 810 and 820 . Emitter 116 forms the emitter of transistor 820 , and is connected via conductor 823 (respectively 123 in FIG. 1 ) to emitter 117 , which forms the collector of transistor 850 . Emitter 118 forms the emitter of transistors 840 and 850 .
FIG. 9 shows an ESD circuit 900 , according to another example embodiment of the present invention. The circuit 900 includes transistors 910 , 920 , 930 and 940 connected between an input node 902 and ground 904 as shown, with the base of transistor 910 connected to the collector of transistor 940 via conductor 923 . The circuit 900 may be formed using a thyristor-based diode circuit similar to the circuit 100 shown in FIG. 1 , with emitter 116 removed. In such an embodiment, the collector 112 forms the emitter of transistor 910 , the base of transistor 920 and the collector of transistor 930 . Base diffusion 113 forms the base of transistor 910 and the emitter of transistor 920 . Base diffusion 114 forms the collector of transistor 920 and the base of transistors 930 and 940 . The emitter 115 forms the collector of transistor 910 , and emitter 117 forms the collector of transistor 940 . Emitter 118 forms the emitter of transistors 930 and 940 .
FIG. 10 shows a cross-section of a thyristor-based diode circuit 1000 for ESD protection under an ESD condition, according to another example embodiment of the present invention. The circuit 1000 is formed in a manner similar to that as with the circuit 100 in FIG. 1 , with similar portions labeled with similar reference numbers and the description thereof omitted for brevity. The emitter 116 in FIG. 1 is no longer present in FIG. 10 , and the emitter 117 has been extended beyond base 114 to form emitter 1017 as shown.
FIG. 11 shows another ESD circuit 1100 , according to another example embodiment of the present invention. The circuit 1100 may, for example, be implemented in connection with the circuit 1000 shown in FIG. 10 . The circuit 1100 includes a plurality of transistors 1110 , 1120 , 1130 and 1140 connected between an input node 1102 and ground 1104 . When implemented in accordance with the circuit 1000 shown in FIG. 10 , the circuit 1100 is as follows. The collector 112 forms the emitter of transistor 1110 , the base of transistor 1120 and the collector of transistor 1130 . Base diffusion 113 forms the base of transistor 1110 and the emitter of transistor 1120 . Base diffusion 114 forms the collector of transistor 1120 and the base of transistors 1130 and 1140 . The emitter 115 forms the collector of transistor 1110 , and emitter 1017 forms the collector of transistor 1140 . Emitter 118 forms the emitter of transistors 1130 and 1140 . Connection 1123 is realized by the overlap of emitter 1017 and collector 112 .
Based upon the above discussion and illustrations, those skilled in the art will readily recognize that various modifications and changes may be made to the present invention without strictly following the exemplary embodiments and applications illustrated and described herein. For example, different types of thyristors, arranged to effect the functions herein may be implemented with different orderings of semiconductor material types. Such modifications do not depart from the true spirit and scope of the present invention, including that set forth in the following claims.
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An integrated circuit device provides electrostatic discharge (ESD) protection. In connection with various example embodiments, an ESD protection circuit includes a diode-type circuit having a p-n junction that exhibits a low breakdown voltage. Connected in series with the diode between an internal node susceptible to an ESD pulse and ground, are regions of opposite polarity having junctions therebetween for mitigating the passage of leakage current via voltage sharing with the diode's junction. Upon reaching the breakdown voltage, the diode shunts current to ground via another substrate region, bypassing one or more junctions of the regions of opposite polarity and facilitating a low clamping voltage.
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BACKGROUND OF THE INVENTION
The present invention relates to a 3'-deamino-3'-(2"-substituted-4"-morpholino) derivative of 13-deoxo-10-hydroxycarminomycin (hereinafter referred to as "R20X2") which is an anthracycline compound having antitumor activity.
Anthracycline compounds heretofore known are, for example, daunomycin (U.S. Pat. No. 3,616,242) and adriamycin (U.S. Pat. No. 3,590,028) obtained from the culture broths of actinomycetes, and these compounds are widely used for clinical purposes as antitumor agents.
Yoshimoto et al. obtained R20X2 which exhibits antitumor activity from the culture broth of Streptomyces sp. D-788 (Japanese Patent Application Laid-Open Pub. No. 33194/1986).
Further, various derivatives of adriamycin, daunomycin and carminomycin were synthesized as morpholino derivatives of anthracycline compounds and have been reported to have antitumor activity (Japanese Patent Application Laid-Open Pub. No. 163393/1982; U.S. Pat. No. 4,301,277; Japanese Patent Application Laid-Open Pub. No. 212484/1984; and Japanese Patent Application Laid-Open Pub. No. 212499/1984).
We also synthesized morpholino derivatives of 13-deoxocarminomycin, 13-deoxo-11-deoxycarminomycin and 13-deoxo-10-hydroxycarminomycin (R20X2) and have reported that these compounds possess remarkable antitumor activity (Japanese Patent Application Laid-Open Pub. Nos. 167696/1986 and 16495/1987 and U.S. Pat. No. 4,710,564).
Anthracycline compounds form a group of useful antitumor agents, so that there has been constant demand for better anthracycline compounds.
SUMMARY OF THE INVENTION
The present invention contributes toward meeting the above-mentioned demand by introducing a substituent on the 2"-position of the morpholino group in the morpholino derivative of R20X2 mentioned above.
More particularly, the anthracycline compound according to the present invention or an acid addition salt thereof is represented by the formula (I) or (II) shown below.
The present invention also relates to uses of the anthracycline compound or an acid addition salt thereof. Thus the antitumor agent according to the present invention comprises as an active ingredient a safe and effective amount of an anthracycline compound of the following formula (I) or (II) or an acid addition salt thereof and a pharmaceutically acceptable carrier.
The present invention further relates to a method of treating tumors in subjects which comprises administering to a subject in need of such treatment a safe and effective amount of an anthracycline compound of the following formula (I) or (II) or an acid addition salt thereof. ##STR5## wherein Ra is --R l , ##STR6## or --OR 3 , R 1 being (1) alkyl, alkenyl, alkynyl, fluoroalkyl, aryl or aralkyl, or (2) alkyl, alkenyl, alkynyl,fluoroalkyl, aryl or aralkyl having carboxyl, azido, amino, hydroxy, alkoxy or a halogen atom; R 2 being R 1 , a hydrogen atom or hydroxy; and R 3 , which may be the same or different when one substituent has two R 3 's, being R l or a hydrogen atom. ##STR7## wherein Rb is --R 1 , ##STR8## or --OR 3 , R 1 , R 2 and R 3 being as defined above, and R 4 being the same as R 3 except that methyl is not included.
The anthracycline compound of the present invention has a structure wherein a substituent is introduced on the 2"-position of a morpholino derivative of 13-deoxo-10-hydroxycarminomycin (R20X2) and exhibits even higher antitumor activity against some types of tumors than the base compound, morpholino derivative of R20X2.
DETAILED DESCRIPTION OF THE INVENTION
3'-Deamino-3'-(2"-substituted-4"-morpholino)anthracycline compound
The 3'-deamino-3'-(2"-substituted-4"-morpholino)anthracycline compound according to the present invention is represented by the above shown formula (I) or (II) wherein the substituents are as defined earlier. In the definition of R 1 , the phrase "(2) . . . having carboxyl, azido, amino, hydroxy, alkoxy or a halogen atom" is intended to mean that the stated groups have one or more of these groups and atom.
The alkyl in R 1 in Ra and Rb has 1 to 10, preferably 1 to 4, carbon atoms. The alkenyl and alkynyl have 2 to 10, preferably 2 to 4, carbon atoms. The fluoroalkyl has 1 to 10, preferably 1 to 4, carbon atoms and 1 to 21, preferably 1 to 9, fluorine atoms, perfluoroalkyl such as trifluoromethyl being especially preferred. The aryls are preferably phenyl or naphthyl and lower alkyl nucleosubstituted phenyl or naphthyl. Preferred aralkyls comprise an aryl moiety of phenyl or lower alkyl nucleosubstituted phenyl and an alkyl moiety of 1 to 4, preferably 1 to 2, carbon atoms.
As mentioned previously, R 1 may be any of the above listed groups having the substituent defined earlier. Preferred halogens as substituents are fluorine, chlorine and bromine.
Preferred for Ra is alkyl, alkyl having hydroxy, alkyl having a halogen atom, --N 3 , ##STR9## or --OR 3 while for Rb is --N 3 , ##STR10## or --OR 3 .
The anthracycline compound of the present invention described above contains basic nitrogen and therefore can form an acid addition salt thereof. Either organic or inorganic acids can be used for the formation of acid addition salts but, when the salts are intended for use as pharmaceutical preparations such as antitumor agents, pharmaceutically acceptable acids should be employed.
Examples of such acids are inorganic acids, e.g., hydrochloric acid, sulfuric acid and phosphoric acid, or organic acids, e.g., acetic acid, propionic acid, maleic acid, oleic acid, palmitic acid, citric acid, succinic acid, tartaric acid, fumaric acid, glutamic acid, pantothenic acid and laurylsulfonic acid.
Typical examples of the anthracycline compound of the formula (I) or (II) according to the present invention include:
(1) 3'-Deamino-3'-[(2"R)-2"-methyl-4"-morpholino]-13-deoxo-10-hydroxycarminomycin (i.e., 3'-deamino-3'-[(2"R)-2"-methyl-4"-morpholino]-R20X2) or an acid addition salt thereof.
(2) 3'-Deamino-3'-[(2"S) -2"-hydroxymethyl-4"-morpholino]-13-deoxo-10-hydroxycarminomycin (i.e., 3'-deamino-3'-[(2"S)-2"-hydroxymethyl-4"-morpholino]-R20X2) or an acid addition salt thereof.
(3) 3'-Deamino-3'-[(2"S)-2"-chloromethyl-4"-morpholino]-13-deoxo-10-hydroxycarminomycin (i.e., 3'-deamino-3'-[(2"S)-2"-chloromethyl-4"-morpholino]-R20X2) or an acid addition salt thereof.
(4) 3'-Deamino-3'-[(2"S)-2"-azido-4"-morpholino]-13-deoxo-10-hydroxycarminomycin (i.e., 3'-deamino-3'-[(2"S)-2"-azido-4"-morpholino]-R20X2) or an acid addition salt thereof.
(5) 3'-Deamino-3'-[(2"S)-2"-acetamido-4"-morpholino]-13-deoxo-10-hydroxycarminomycin (i.e., 3'-deamino-3'-[(2"S)-2"-acetamido-4"-morpholino]-R20X2) or an acid addition salt thereof.
(6) 3'-Deamino-3'-[(2"S)-2"-trifluoroacetamido-4"-morpholino]-13-deoxo-10-hydroxycarminomycin (i.e., 3'-deamino-3'-[(2"S)-2"-trifluoroacetamido-4"-morpholino]-R20X2) or an acid addition salt thereof.
(7) 3'-Deamino-3'-[(2"S)-2"-methoxy-4"-morpholino]-13-deoxo-10-hydroxycarminomycin (i.e., 3'-deamino-3'-[(2"S)-2"methoxy-4"-morpholino]-R20X2) or an acid addition salt thereof.
(8) 3'-Deamino-3'-[(2"R)-2"-azido-4"-morpholino]-13-deoxo-10-hydroxycarminomycin (i.e., 3'-deamino-3'-[(2"R)-2"-azido-4"-morpholino]-R20X2) or an acid addition salt thereof.
(9) 3'-Deamino-3'-[(2"R)-2"-trifluoroacetamido-4"-morpholino]-13-deoxo-10-hydroxycarminomycin (i.e., 3'-deamino-3'-[(2"R)-2"-trifluoroacetamido-4"-morpholino]-R20X2) or an acid addition salt thereof.
(10) 3'-Deamino-3'-[(2"R)-2"-methoxy-4"-morpholino]-13-deoxo-10-hydroxycarminomycin (i.e., 3'-deamino-3'-[(2"R)-2"-methoxy-4"-morpholino]-R20X2) or an acid addition salt thereof.
Production of 3'-deamino-3'-(2"-substituted-4"-morpholino)-anthracycline compound
(1) Outline
The 3'-deamino-3'-(2"-substituted-4"-morpholino)anthracycline compound of the formula (I) or (II) according to the present invention can be produced by any process suitable for the purpose of intramolecularly forming bonds and/or introducing substituents. One instance of such processes comprises chemical modification of R20X2 of the following formula (III) obtained by the cultivation of microorganisms. ##STR11##
(2) Preparation of R20X2
R20X2 which is the parent compound of the compound of the formula (I) or (II) shown hereinbefore is a known substance and can be prepared by any process suitable for the purpose of intramolecularly forming bonds and/or introducing substituents.
A preferred process for the preparation of R20X2 and its physicochemical properties are described, for example, in Japanese Patent Application Laid-Open Pub. Nos. 167696/1986 and 16495/1987 and U.S. Pat. No. 4,710,564. In the process a specific microorganism, Actinomadura roseoviolacea 1029-AVl (strain R20), is used for the preparation of R20X2. This strain was originally deposited on July 5, 1983 with the Fermentation Research Institute, then assigned, on Dec. 4, 1985, the accession number FERM BP-945 under the terms of the Budapest Treaty and is therefore readily available to the public.
(3) Production of derivatives
As has been set forth earlier, the anthracycline compound of the present invention can be produced by any process suitable for the purpose of intramolecularly forming bonds and/or introducing substituents. In one exemplary process, R20X2 is used as a base compound to produce derivatives, i.e., the anthracycline compounds of the present invention.
The anthracycline compound of the present invention can be obtained by reacting a xylone derivative of any of the following formulae (IV), (V), (VI) and (VII) with sodium metaperiodate, and further reacting the reaction mixture with R20X2 of the formula (II). ##STR12## wherein the substituent Ra is as defined previously, and ##STR13## wherein the substituent Rb is as defined previously.
All of the xylose derivatives of the above shown formula (IV), (V), (VI) or (VII) used for the anthracycline compound of the present invention are known compounds or can be prepared by a known synthesis procedure.
The reaction between the reaction mixture obtained by reacting a xylose derivative of the formula (IV), (V), (VI) or (VII) with sodium metaperiodate and R20X2 of the formula (III) is typically carried out in a solvent. Examples of suitable solvents include acetonitrile, methanol, ethanol, water, chloroform, dichloromethane, carbon tetrachloride, benzene, dioxane, and tetrahydrofuran singly or in a mixture, a chloroformmethanol mixture being especially preferred.
Ordinarily, it is preferable that this reaction is conducted in the presence of a reducing agent, for example, sodium borohydride (NaBH 4 ) or sodium cyanoborohydride (NaBH 3 CN). The amount of the reducing agent used is not critical, and the agent can be used in an amount of at least 1 mol, preferably from 1 to 3 mols, per mol of R20X2.
An appropriate reaction temperature is generally in the range of from the solidifying point of the solvent used to 50°, room temperature being particularly appropriate.
Under the foregoing reaction conditions, the reaction of converting the amino group in R20X2 into 2"-substituted-4"-morpholino group can be terminated within about 10 minutes to 7 hours.
In accordance with the above described process, 3'-deamino-3'-(2"-substituted-4"-morpholino) derivatives can be obtained in crude form through the reaction between the reaction mixture obtained by reacting a xylose derivative of the formula (IV), (V), (VI) or (VII) with sodium metaperiodate and R20X2 of the formula (III). The crude product thus obtained can be purified to isolate the desired compound of the present invention by a known purification procedure utilized in the preparation of anthracyclines or glycoside derivatives thereof. For example, the crude product is extracted with an organic solvent which is immiscible with water, preferably chloroform or methylene chloride. The solvent layer is then concentrated and subjected either to separation based on adsorption such as silica gel column chromatography or thin layer chromatography for isolation or to separation by gel filtration using Sephadex LH20 and the like for purification purposes, whereby the desired substance can be isolated in pure form.
The compound of the formula (I) or (II) according to the present invention can be converted into an acid addition salt thereof, for example, through a treatment with an inorganic acid such as hydrochloric acid, sulfuric acid or phosphoric acid or an organic acid such as acetic acid, propionic acid, maleic acid, oleic acid, palmitic acid, citric acid, succinic acid, tartaric acid, fumaric acid, glutamic acid, pantothenic acid or laurylsulfonic acid following a per se known method.
Utility of the derivatives
The 3'-deamino-3'-(2"-substituted-4"-morpholino)anthracycline compounds of the present invention have carcinostatic activity and thus are useful as medicines.
(1) Physiological activities
(1) Anti-proliferative activity against cultivated P388 mouse leukemia cells:
The 3'-deamino-3'-(2"-substituted-4"-morpholino)anthracycline compounds of the present invention possess outstanding anti-proliferative activity against P388 mouse leukemia cells.
More specifically, a medium RPMI 1640 (Rosewell Park Memorial Institute medium 1640) containing a given amount of the 3'-deamino-3'-(2"-substituted-4"-morpholino) anthracycline compound and 10% fetal bovine serum was inoculated with cultivated P388 5×10 4 cells/ml. Incubation was carried out at 37° C. in a CO 2 incubator, and the number of the cells in each medium was then counted to determine 50% proliferation-inhibitory concentration (IC 50 , ng/ml) relative to the control (no test compounds added). The results obtained are summarized below.
______________________________________ IC.sub.50Compound (ng/ml)______________________________________3'-Deamino-3'-[(2"R)-2"-methyl-4"- 34.0morpholino]-R20X23'-Deamino-3'-[(2"S)-2"-hydroxymethyl-4"- 20.0morpholino]-R20X23'-Deamino-3'-[(2"S)-2"-chloromethyl-4"- 36.0morpholino]-R20X23'-Deamino-3'-[(2"S)-2"-azido-4"- 24.0morpholino]-R20X23'-Deamino-3'-[(2"S)-2"-acetamido-4"- 83.0morpholino]-R20X23'-Deamino-3'-[(2"S)-2"- 52.0trifluoroacetamide-4"-morpholino]-R20X23'-Deamino-3'-[(2"S)-2"-methoxy-4"- 18.0morpholino]-R20X23'-Deamino-3'-[(2"R)-2"-azido-4"- 18.9morpholino]-R20X23'-Deamino-3'-[(2"R)-2"- 22.5trifluoroacetamido-4"-morpholino]-R20X23'-Deamino-3'-[(2"R)-2"-methoxy-4"- 9.0morpholino]-R20X2______________________________________
(2) Antitumor activity:
The 3'-deamino-3'-(2"-substituted-4"-morpholino)anthracycline compounds of the present invention exhibited antitumor activity against experimental tumors in subject animals.
For example, into CDF 2 mice were intraperitoneally transplanted P388 leukemia 1×10 6 cells/mouse as a suspension, and the 3'-deamino-3'-(2"-substituted-4"-morpholino) anthracycline compounds were administered to the mice intraveneously 1 day and 5 days respectively after the transplantation. The effects of the test anthracycline compounds are shown below in terms of T/C (%), the survival days of the control mice to which physiological saline solutions was administered being specified as 100.
______________________________________ Number of cured mice/ Dose T/C Number ofCompound (mg/kg) (%) test mice______________________________________3'-Deamino-3'- 0.5 122 0/6[(2"S)-2"-azido-4"- 1 163 0/6morpholino]-R20X2 2 231 0/6 4 355* 1/63'-Deamino-3'- 2 124 0/6[(2"S)-2"- 4 124 0/6acetamido-4"- 8 146 0/6morpholino]-R20X2 16 340 0/63'-Deamino-3'- 2 136 0/6[(2"S)-2"- 4 181 0/6trifluoroacetamido- 8 229 0/64"-morpholino]- 16 263* 0/6R20X23'-Deamino-3'- 0.125 103 0/6[(2"S)-2"-methoxy- 0.25 182 0/64"-morpholino]- 0.5 196 0/6R20X2 1 182* 0/63'-Deamino-3'- 0.25 115 0/6[(2"R)-2"-azido-4"- 0.5 163 0/6morpholino]-R20X2 1 196 0/6 2 294 0/6 4 124 0/63'-Deamino-3'- 2 120 0/6[(2"R)-2"- 4 150 0/6trifluoroacetamido- 8 165 0/64"-morpholino]- 16 319 2/6R20X23'-Deamino-3'- 0.125 119 0/6[(2"R)-2"-methoxy- 0.25 149 0/64"-morpholino]- 0.5 172 0/6R20X2 1 181 0/6 2 36* 0/63'Deamino-3'- 0.29 110 0/6morpholino-R20X2 0.44 143 0/6 0.66 162 0/6 0.99 173 0/6 1.48 189 0/6 2.22 189 0/6 3.33 240 0/6 5.00 135 0/6______________________________________ *administered only day 1
(2) Antitumor agent
As has been set forth hereinabove, the 3'-deamino-3'-(2"-substituted-4"-morpholino) anthracycline compounds were found to have antitumor activity against tumors, particularly malignant tumors in subjects
Accordingly, the 3'-deamino-3'-(2"-substituted-4"-morpholino) anthracycline compounds of the present invention can be used as antitumor agents or pharmaceutical agents for treating tumors. That is, the antitumor agents according to the, present invention comprise as active ingredients 3'-deamino-3'-(2"-substituted-4"-morpholino) anthracycline compounds of the previously shown formula (I) or (II) or acid addition salts thereof.
The 3'-deamino-3'-(2"-substituted-4"-morpholino) anthracycline compounds as antitumor agents can be administered via any route suited for the desired purpose in a dosage form determined by the route of administration. Ordinarily, the compounds diluted with pharmaceutically acceptable carriers or diluents are administered as drugs.
One of typical methods of administering the 3'-deamino-3'-(2"-substituted-4"-morpholino) anthracycline compounds as antitumor agents is by injection or oral administration of solutions thereof in distilled water for injection use or in physiological saline solution. In clinical applications, the compounds in solution are administered by injection such as intraperitoneal injection, subcutaneous injection, intravenous or intraarterial injection, and topical administration in case of animals; and by intravenous or intraarterial injection, topical administration by injection, and oral administration in case of humans.
The doses of the 3'-deamino-3'-(2"-substituted-4"-morpholino) anthracycline compounds are determined in view of the results of animal experiments and varying circumstances in such a manner that the total of doses given continuously or intermittently in each case will not exceed a predetermined limit. Needless to say, particular doses required may vary depending on the mode of administration; situations of subjects to be treated, such as age, sex, body weight, and susceptibility; food; times of administration; concurrently administered drugs; and conditions of subjects or severity of their diseases. The optimum doses and frequency of administration under certain conditions must be determined by experts' optimum dose determination tests on the basis of the abovementioned parameters. For example, the compound is administered to an adult at a dose of about 0.1 to 1 g/day.
The antitumor agents according to the present invention comprise as active ingredients anthracycline compounds of the formula (I) or (II) or acid addition salts thereof as has been mentioned earlier, and typical examples of the anthracycline compounds are compounds (1) through (10) listed in the paragraph headed 3'-deamino-3'-(2"-substituted-4"-morpholino) anthracycline compound.
With respect to the type of the anthracycline compound which constitutes the antitumor agent of the present invention, a group of compounds represented by the formula (I), a group of compounds represented by the formula (II), and a group of acid addition salts thereof can be used either singly or in a combination of two or more members selected from within a single group of compounds and/or from among two or more groups of compounds.
EXPERIMENTAL EXAMPLES
In the following examples, "%" is "w/v %".
EXAMPLE 1:
Production of R20X2
(1) Inoculum Preparation
A medium used to grow a primary inoculum was prepared by dissolving the following ingredients in 1 liter of water and adjusting the pH of the resultant solution to 7.2.
______________________________________ Polypeptone 10 g Molasses 10 g Meat extract 10 g______________________________________
100 ml of the medium thus prepared was sterilized in a 500-ml Erlenmeyer flask and inoculated with a loopful of spores collected from a slant culture of Actinomadura roseoviolacea R20. The inoculated medium was subjected to shake culture for 5 days at 27° C. on a rotary shaker (200 r.p.m.) to prepare an inoculum.
(2) Cultivation
A fermentation medium was prepared by dissolving the following ingredients in 1 liter of water and adjusting the pH of the resultant solution to 7.4.
______________________________________Glucose 25 gSoybean meal 15 gDry yeast 2 gCalcium carbonate 4 g(precipitated)______________________________________
25 liters of the fermentation medium thus prepared was sterilized in a 50-l jar fermenter and inoculated with 3 vials of the inoculums prepared as described above. The fermentation was carried out at 27° C. for 7 days at 1 v.v.m. and 200 r.p.m.
(3) Recovery of R20X2
The fermented mash thus obtained was adjusted to pH 10 and filtered to separate the microorganism cells from the filtrate. The filtrate was adjusted to pH 2, and the precipitate formed was separated by centrifugation and then dried to obtain a dry solid.
The dry solid obtained was dissolved in 1 liter of 2.8% aqueous ammonia. To this solution was added 5 liters of acetone, and the resulting solution was left standing at room temperature for 2 hours and then concentrated.
The residue was extracted three times with chloroform-methanol (10:1). The chloroform-methanol layer was dehydrated over anhydrous sodium sulfate, concentrated, and chromatographed on a column of silica gel using as eluant chloroform-methanol (10:1) to obtain 0.75 g of R20X2.
The supernatant obtained by the centrifugation of the filtrate of the fermented mash, on the other hand, was adsorbed onto "Diaion HP-20" (supplied by Mitsubishi Kasei K.K., Japan) and washed with water. The adsorbate was eluted with 2.8% aqueous ammonia-acetone (1:5). A colored fraction thus eluted was concentrated, and the residue was neutralized with 1N hydrochloric acid and extracted three times with chloroform-methanol (10:1). The chloroform-methanol layer was dehydrated over anhydrous sodium sulfate, concentrated to dryness, and chromatographed on silica gel using as eluant chloroformmethanol (10:1) to obtain 1.35 g of R20X2.
EXAMPLE 2
(1) Synthesis of 3'-deamino-3'-[(2"R)-2"-methyl-4"-morpholino]-R20X2
48.5 mg (0.36 mmol) of 1,5-anhydro-6-deoxy-D-glucitol was dissolved in 5 ml of methanol, and 210 mg (0.98 mmol) of sodium metaperiodate was added. The mixture was stirred at room temperature for 15 hours in the dark. The reaction mixture was then filtered and the filtrate was concentrated under reduced pressure. The residue was dissolved in a mixture of 5 ml each of chloroform and methanol. To the solution were added 77.0 mg (0.15 mmol) of R20X2 and then 18.8 mg (0.30 mmol) of sodium cyanoborohydride, and the mixture was stirred at room temperature for 5 hours. The reaction mixture was then concentrated under reduced pressure and the residue extracted with chloroform (100 ml) and washed with water (80 ml). After washing, the chloroform layer was dehydrated over anhydrous sodium sulfate and concentrated under reduced pressure. The residue was developed on thin-layer chromatography (TLC) (Merck & Co., Inc., No. 5744) using chloroform-methanol (10:1). A band having an Rf value of approximately 0.6 was scraped off and extracted with chloroform-methanol (10:1) to obtain the desired compound which was then crystallized from chloroform-hexane to obtain 20.8 mg (0.035 mmol, 23% yield) of the title compound as a brown powder.
(2) Physicochemical properties of 3'-deamino-3'-[(2"R)-2"-methyl-4"-morpholino]-R20X2
(1) Melting point: 161°-164° C. (decomposed)
(2) [α] D 25 =+140° (C=0.06, CHCl 3 )
(3) Elementary analysis:
______________________________________C H N______________________________________Calcd. 62.09 6.22 2.34 (C.sub.31 H.sub.37 NO.sub.11)Found 61.83 6.31 2.33 (%)______________________________________
(4) FD-MS m/z=599 (M + )
(5) Infrared absorption spectrum (KBr)(cm -1 ): 3450, 1610
(6) 1 H-Nuclear magnetic resonance spectrum (500 MHz, in deuterochloroform) (δ (ppm)):
13.63 (1H, s, 11-OH), 12.86 (1H, s, 6-OH), 12.16 (1H, s, 4-OH), 7.91 (1H, dd, J=1.5, 7.3 Hz, H-1), 7.73 (1H, t, J=7.3 Hz, H-2), 7.34 (1H, dd, J=1.5, 7.3 Hz, H-3), 5.52 (1H, brs, H-1'), 5.16 (1H, brs, H-7), 4.92 (1H, brs, H-10), 4.09 (1H, q, J=5.7 Hz, H-5'), 4.00 (1H, s, 9-OH), 3.84 (1H, brd, J=11.0 Hz, H-6"a), 3.70 (1H, brs, H-4'), 3.65-3.50 (2H, H-2", H-6"b), 2.89 (1H, d, J=11.0 Hz, H-5"a), 2.72-2.64 (2H, H-3"a, 10-OH), 2.38 (1H, m, H-3'), 2.25 (1H, d, J=14.6 Hz, H-8a), 2.12 (1H, dd, J=3.7, 14.6 Hz, H-8b), 2.06 (1H, dt, J=3.0, 11.0 Hz, H-5"b), 1.95-1.74 (5H, H-13, H-2', H-3"b), 1.40 (3H, d, J=5.7 Hz, H-6'), 1.12 (3H, t, J=7.3 Hz, H-14), 1.09 (3H, d, J=6.1Hz, H-7")
EXAMPLE 3
(1) Synthesis of 3'-deamino-3'-[(2"S)-2"-hydroxymethyl-4"-morpholino]-R20X2
337.5 mg (2.06 mmol) of 1,5-anhydro-D-glucitol was dissolved in 30 ml of methanol, and 1.32 g (6.17 mmol) of sodium metaperiodate was added. The mixture was allowed to react at room temperature for 21 hours in the dark. The reaction mixture was then filtered and the filtrate concentrated under reduced pressure. The residue was dissolved in a mixture of 5 ml each of chloroform and methanol. To the solution were added 67.9 mg (0.13 mmol) of R20X2 and 85.6 mg (0.40 mmol) of sodium cyanoborohydride, and the mixture was allowed to react for 6 hours. The reaction mixture was then concentrated and the residue extracted with chloroform (200 ml). The chloroform layer was washed with water (200 ml), dehydrated over anhydrous sodium sulfate and concentrated under reduced pressure. The residue was developed on TLC (Merck & Co., Inc., No. 5744) using chloroform-methanol (10:1). A red band having an Rf value of approximately 0.58 was scraped off and extracted with chloroformmethanol (10:1) to obtain the desired compound which was then crystallized from chloroform-hexane (by dissolution in chloroform followed by addition of hexane until the compound was precipitated) to obtain 39.7 mg (0.06 mmol, 50% yield) of the title compound as a brown powder.
(2) Physicochemical properties of 3'-deamino-3'-[(2"S)-2"-hydroxymethyl-4"-morpholino]-R20X2
(1) Melting point: 164.5°-165.5° C. (decomposed)
(2) [α] D 25 =+355° (C=0.11, chloroform)
(3) Elementary analysis:
______________________________________C H N______________________________________Calcd. 60.48 6.06 2.28 (C.sub.31 H.sub.37 NO.sub.12)Found 60.26 6.12 2.25 (%)______________________________________
(4) FD-MS m/z=616 (M + 1)
(5) Infrared absorption spectrum (KBr)(cm -1 ): 3400, 1600
(6) 1 H-Nuclear magnetic resonance spectrum (500 MHz, in deuterochloroform) (δ (ppm)):
13.63 (1H, s, 11-OH), 12.87 (1H, s, 6-OH), 12.15 (1H, s, 4-OH), 7.91 (1H, d, J=7.8 Hz, H-1), 7.73 (1H, t, J=7.8 Hz, H-2), 7.34 (1H, d, J=7.8 Hz, H-3), 5.52 (1H, brs, H-1'), 5.15 (1H, brs, H-7), 4.92 (1H, brs, H-10), 4.09 (1H, q, J=6.6 Hz, H-5'), 3.97 (1H, s, 9-OH), 3.90 (1H, brd, H-6"a), 3.71 (1H, brs, H-4'), 3.65-3.53 (3H, H-6"b, H-7"), 3.50 (1H, dd, J=5.9, 10.9 Hz, H-2"), 2.92 (1H, d, J=10.9 Hz, H-5"a), 2.70 (1H, d, J=10.9 Hz, H-3"a), 2.69 (1H, s, 10-OH), 2.40 (1H, ddd, J=2.5, 6.3, 10.9 Hz, H-3'), 2.26 (1H, d, J=15.3 Hz, H-8a), 2.12 (1H, dd, J=3.8, 15.3 Hz, H-8b), 2.07 (1H, dd, J=3.8, 10.9 Hz, H-5"b), 1.98 (1H, t, J=10.9 Hz, H-3"b), 1.90-1.75 (4H, H-13, H-2'), 1.40 (3H, d, J=6.6 Hz, H-6'), 1.12 (3H, t, J=6.9 Hz, H-14)
EXAMPLE 4
(1) Synthesis of 3'-deamino-3'-[(2"S)-2"-chloromethyl-4"-morpholino]-R20X2
895 mg (3.08 mmol) of 1,5-anhydro-2,3,4-tri-O-acetyl-D-glucitol was dissolved in 30 ml of pyridine, and 1.95 g (7.4 mmol) of triphenylphosphine and 10 ml of carbon tetrachloride were added. The mixture was allowed to react at 45° to 50° C. for 2 hours. The reaction mixture was then concentrated under reduced pressure and the residue extracted with chloroform (80 ml). The chloroform layer was washed with 1N aqueous hydrochloric acid solution (80 ml) and water (80 ml), dehydrated over anhydrous sodium sulfate and concentrated under reduced pressure. The residue was subjected to column chromatography (Waggle C-200, 40 g) and eluted with chloroform-methanol (300:1). The eluate was crystallized from ethyl acetate-hexane to obtain 562 mg (1.82 mmol, 59%) of 1,5-anhydro-6-chloro-6-deoxy-2,3,4-tri-O-acetyl-D-glucitol as a colorless needle crystal. Shown below are physicochemical properties of the crystalline compound thus obtained.
Melting point: 129°-131° C.
[α] D 24 =+38° (C=0.3, CHCl 3 )
FD-MS: m/z=309 (M + +1)
Infrared absorption spectrum (KBr)(cm -1 ): 1730
1 H-Nuclear magnetic resonance spectrum (500 MHz, in deuterochloroform) (δ (ppm)):
5.21 (1H, t, J=9.1 Hz, H-3), 5.05-4.98 (2H, H-2, H-4), 4.18 (1H, dd, J=6.3, 11.4 Hz, H-1a), 3.66-3.62 (2H, H-5, H-6a), 3.52 (1H, dd, J=6.3, 11.4 Hz, H-6b), 3.33 (1H, t, J=11.4 Hz, H-lb), 2.06 (3H, s, COCH 3 ), 2.04 (3H, s, COCH 3 ), 2.03 (3H, s, COCH 3 )
Subsequently, 94 mg (0.30 mmol) of this 1,5-anhydro-6-chloro-6-deoxy-2,3,4-tri-O-acetyl-D-glucitol was dissolved in 5 ml of methanol, and 0.1 ml of sodium methoxide was added. The mixture was allowed to react at 0° C. for 30 minutes, and thereafter neutralized with an acidic ion exchange resin, Amberlite IR-120B. The resin was removed by filtration, and 194 mg (0.91 mmol) of sodium metaperiodate was added to the filtrate. The resultant filtrate was allowed to react at room temperature for 20 hours in the dark. The reaction solution was then filtered and the filtrate concentrated under reduced pressure. The residue was dissolved in a mixture of 5 ml each of chloroform and methanol. To the solution were added 51.6 mg (0.10 mmol) of R20X2 and then 18.9 mg (0.30 mmol) of sodium cyanoborohydride, and the mixture was allowed to react at room temperature for 4 hours. The reaction mixture was then concentrated to dryness and the residue extracted with chloroform (100 ml). The chloroform layer was washed with water (100 ml), dehydrated over anhydrous sodium sulfate and concentrated under reduced pressure. The residue was developed on TLC (Merck & Co., Inc., No. 5744) using chloroform-methanol (10:1). A red band having an Rf value of approximately 0.62 was scraped off and extracted with chloroform-methanol (10:1) to obtain the desired compound which was then crystallized from chloroformhexane to obtain 28.2 mg (0.04 mmol, 44% yield) of the title compound as a brown powder.
(2) Physicochemical properties of 3'-deamino-3'-[(2"S)-2"-chloromethyl-4"-morpholino]-R20X2
(1) Melting point: 148°-150° C. (decomposed)
(2) [α] D 24 =+60° (C=0.09, CHCl 3 )
(3) Elementary analysis:
______________________________________C H N______________________________________Calcd. 58.72 5.72 2.21 (C.sub.31 H.sub.36 NO.sub.11 Cl)Found 58.49 5.79 2.19 (%)______________________________________
(4) FD-MS m/z=634 (M + )
(5) Infrared absorption spectrum (KBr)(cm -1 ): 3420, 1600
(6) 1 H-Nuclear magnetic resonance spectrum (500 MHz, in deuterochloroform) (δ (ppm)):
13.63 (1H, s, 11-OH), 12.87 (1H, s, 6-OH), 12.16 (1H, s, 4-OH), 7.90 (1H, d, J=8.1Hz, H-1), 7.73 (1H, t, J=8.1 Hz, H-2), 7.34 (1H, d, J=8.1 Hz, H-3), 5.53 (1H, brs, H-1'), 5.17 (1H, brs, H-7), 4.92 (1H, s, H-10), 4.10 (1H, q, J=6.6 Hz, H-5'), 3.98 (1H, s, 9-OH), 3.92 (1H, d, J=12.2 Hz, H-6"a), 3.72 (1H, brs, H-4'), 3.68 (1H, m, H-2"), 3.62 (1H, dt, J=3.1, 12.2 Hz, H-6"b), 3.49 (1H, dd, J=4.7, 11.6 Hz, H-7"a), 3.43 (1H, dd, J=5.9, 11.6 Hz, H-7"b), 2.89 (2H, H-3"a, H-5"a), 2.69 (1H, s, 10-OH), 2.44 (1H, m, H-3'), 2.25 (1H, d, J=15.6 Hz, H-8a), 2.16-2.09 (2H, H-8b, H-5"b), 1.97 (1H, t, J=10.0 Hz, H-3"b), 1.90-1.74 (4H, H-13, H-2'), 1.41 (3H, d, J=6.6 Hz, H-6'), 1.13 (3H, t, J=7.8 Hz, H-14)
EXAMPLE 5
(1) Synthesis of 3'-deamino-3'-[(2"S)-2"-azido-4"-morpholino]-R20X2
4.88 g (12.2 mmol) of 2,3,4-tri-O-acetyl-α-L-xylopyranosyl bromide was dissolved in 40 ml of N,N-dimethylformamide, and 4.5 g (69.2 mmol) of sodium azide was added. The mixture was allowed to react at room temperature for 18 hours. The reaction mixture was then concentrated under reduced pressure and the residue extracted with chloroform (250 ml). The chloroform layer was washed with water (250 ml), dehydrated over anhydrous sodium sulfate and concentrated under reduced pressure. The residue was subjected to column chromatography (Waggle C-200, 40 g) and eluted with chloroform-methanol (100:1). The eluate was crystallized from ethyl acetate-hexane to obtain 2.95 g (9.79 mmol, 68%) of 2,3,4-tri-O-acetyl-β-L-xylopyranosyl azide as a colorless needle crystal. The following are the physicochemical properties of this crystalline compound.
Melting point: 83° C.
[α] D 24 =30 119° (C=1.0, chloroform)
Infrared absorption spectrum (KBr)(cm -1 ): 2130, 1750
FD-MS: m/z=302 (M + +1)
1 H-Nuclear magnetic resonance spectrum (500 MHz, in deuterochloroform) (δ(ppm)):
5.20 (1H, t, J=9.0 Hz, H-3), 4.98 (1H, ddd, J=5.0, 9.0, 10.0 Hz, H-4), 4.88 (1H, t, J=9.0 Hz, H-2), 4.64 (1H, d, J=9.0 Hz, H-1), 4.22 (1H, dd, J=5.0, 13.0 Hz, H-5a), 3.44 (1H, dd, J=10.0, 13.0 Hz, H-5b), 2.08 (3H, s, COCH 3 ), 2.05 (3H, s, COCH 3 ), 2.04 (3H, s, COCH 3 )
Subsequently, 309.0 mg (1.03 mmol) of the 2,3,4-tri-O-acetyl-β-L-xylopyranosyl azide was dissolved in 5 ml of methanol, and 0.1 ml of sodium methoxide was added. The mixture was stirred at room temperature for 3 hours, and thereafter the reaction solution was neutralized with an acidic ion exchange resin, Amberlite IR-120B. The resin was removed by filtration, and 517.7 mg (2.42 mmol) of sodium metaperiodate was added to the filtrate. The resultant filtrate was allowed to react at room temperature for 22 hours in the dark. The reaction solution was then filtered and the filtrate concentrated under reduced pressure. The residue was dissolved in 10 ml each of chloroform and methanol. To the solution were added 130.0 mg (0.25 mmol) of R20X2 and 47.5 mg (0.76 mmol) of sodium cyanoborohydride, and the mixture was stirred at room temperature for 6 hours. The reaction mixture was then concentrated under reduced pressure and the residue extracted with chloroform (150 ml). The chloroform layer was washed with water (150 ml), dehydrated over anhydrous sodium sulfate and concentrated under reduced pressure. The residue was developed on TLC (Merck & Co., Inc., No. 5744) using chloroform-methanol (15:1). A red band having an Rf value of approximately 0.48 was scraped off and extracted with chloroformmethanol (10:1) to obtain the desired compound which was then crystallized from chloroform-hexane to obtain 60.8 mg (0.10 mmol, 38% yield) of the title compound as a brown powder.
(2) Physicochemical properties of 3'-deamino-3'-[(2"S)-2"-azido-4"-morpholino]-R20X2
(1) Melting point: 138°-139° C. (decomposed)
(2) [α] D 24 =+78° (C=0.11, CHCl 3 )
(3) Elementary analysis:
______________________________________C H N______________________________________Calcd. 57.50 5.47 8.94 (C.sub.30 H.sub.34 N.sub.4 O.sub.11)Found 57.63 5.22 8.70 (%)______________________________________
(4) FD-MS 627 (M + +1)
(5) Infrared absorption spectrum (KBr)(cm -1 ): 3450, 2100, 1600
(6) 1 H-Nuclear magnetic resonance spectrum (500 MHz, in deuterochloroform) (δ (ppm)):
13.62 (1H, s, 11-OH), 12.85 (1H, s, 6-OH), 12.14 (1H, s, 4-OH), 7.90 (1H, d, J=7.4 Hz, H-1), 7.73 (1H, t, J=7.4 Hz, H-2), 7.33 (1H, d, J=7.4 Hz, H-3), 5.51 (1H, s, H-1'), 5.15 (1H, s, H-7), 4.97 (1H, brs, H-2"), 4.92 (1H, s, H-10), 4.08 (1H, q, J=6.5 Hz, H-5'), 4.01 (1H, m, H-6"a), 3.94 (1H, s, 9-OH), 3.71-3.64 (2H, H-4', H-6"b), 2.62-2.3-5 (5H, H-3', H-3", H-5"), 2.25 (1H, d, J= 14.3 Hz, H-8a), 2.12 (1H, dd, J=4.2, 14.3 Hz, H-8b), 1.90-1.73 (4H, H-13, H-2'), 1.40 (3H, d, J=6.5 Hz, H-6'), 1.12 (3H, t, J=7.4 Hz, H-14)
EXAMPLE 6
(1) Synthesis of 3'-deamino-3'-[(2"S)-2"-acetamido-4"-morpholino]-R20X2
997.2 mg (3.31 mmol) of 2,3,4-tri-O-acetyl-β-L-xylopyranosyl azide was dissolved in 30 ml of methanol, and the solution was allowed to react at 45° to 50° C. for 2 hours in a hydrogen gas stream in the presence of 300 mg of 5% palladium carbon catalyst. The reaction solution was then filtered and the filtrate concentrated under reduced pressure. The residue was dissolved in 60 ml of pyridine, and 10 ml of acetic anhydride was added. The mixture was allowed to react at room temperature for 4 hours. The reaction mixture was then concentrated under reduced pressure and the residue extracted with chloroform (100 ml). The chloroform layer was washed with 2N aqueous hydrochloric acid solution (100 ml), 10% aqueous sodium carbonate solution (100 ml) and water in the stated order, dehydrated over anhydrous sodium sulfate and concentrated under reduced pressure. The residue was subjected to column chromatography (Waggle C-200, 30 g) and eluted with chloroform-methanol (300:1). The eluate was crystallized from ethyl acetate-hexane to obtain 309.9 mg (0.98 mmol, 30%) of 2,3,4-tri-O-acetyl-β-L-xylopyranosylamine as a colorless needle crystal. The physicochemical properties of this crystalline compound were as follows.
Melting point: 148°-149° C.
[α] D 24 =-24° (C=1.0, methanol)
Infrared absorption spectrum (KBr)(cm -1 ): 1760, 1740, 1660
FD-MS m/z=317 (M + )
1 H-Nuclear magnetic resonance spectrum (500 MHz, in deuterochloroform) (δ (ppm)):
6.48 (1H, d, J=10.0 Hz, NH), 5.30 (1H, t, J=10.0 Hz, H-1), 5.17 (1H, t, J=10.0 Hz, H-3), 4.98 (1H, ddd, J=5.5, 10.0, 11.0 Hz, H-4), 4.88 (1H, t, J=10.0 Hz, H-2), 4.07 (1H, dd, J=5.5, 11.0 Hz, H-5a), 3.45 (1H, t, J=11.0 Hz, H-5b), 2.07 (3H, s, OCOCH 3 ), 2.05 (3H, s, OCOCH 3 ), 2.04 (3H, s, OCOCH 3 ), 2.00 (3H, s, NHCOCH 3 )
309.9 mg (0.98 mmol) of this N-acetyl-2,3,4-tri-O-acetyl-β-L-xylopyranosylamine was then dissolved in 30 ml of methanol, and 0.1 ml of sodium methoxide was added. The mixture was stirred at room temperature for 2 hours, and thereafter neutralized with an acidic ion exchange resin, Amberlite IR-120B. The resin was removed by filtration, and 626.7 mg (2.93 mmol) of sodium metaperiodate was added to the filtrate. The resultant filtrate was allowed to react at room temperature for 18 hours in the dark. The reaction solution was then filtered and the filtrate concentrated under reduced pressure. The residue was dissolved in a mixture of 10 ml each of chloroform and methanol. To the solution were added 150 mg (0.29 mmol) of R20X2 and 91.4 mg (1.45 mmol) of sodium cyanoborohydride, and the mixture was allowed to react at room temperature for 6 hours. The reaction mixture was then concentrated under reduced pressure and the residue extracted with chloroform (150 ml). The chloroform layer was washed with water (150 ml), dehydrated over anhydrous sodium sulfate and concentrated under reduced pressure. The residue was developed on TLC (Merck & Co., Inc., No. 5744) using chloroform-methanol (10:1). A red band having an Rf value of approximately 0.58 was scraped off and extracted with chloroformmethanol (10:1) to obtain the desired compound which was then crystallized from chloroform-hexane to obtain 113.9 mg (0.177 mmol, 61% yield) of the title compound as a brown powder.
(2) Physicochemical properties of 3'-deamino-3'-[(2"S)-2"-acetamide-4"-morpholino]-R20X2
(1) Melting point: 173°-174° C. (decomposed)
(2) [α] D 24 =+58° (C=0.08, CHCl 3 )
(3) Elementary analysis:
______________________________________C H N______________________________________Calcd. 59.81 5.96 4.36 (C.sub.32 H.sub.38 N.sub.2 O.sub.12)Found 59.95 5.87 4.21 (%)______________________________________
(4) FD-MS 643 (M + +1)
(5) Infrared absorption spectrum (KBr)(cm -1 ): 3420, 1660, 1600
(6) 1 H-Nuclear magnetic resonance spectrum (500 MHz, in deuterochloroform) (δ (ppm)):
13.63 (1H, s, 11-OH), 12.85 (1H, s, 6-OH), 12.15 (1H, s, 4-OH), 7.90 (1H, d, J=7.3 Hz, H-1), 7.74 (1H, t, J=7.3 Hz, H-2), 7.35 (1H, d, J=7.3 Hz, H-3), 6.03 (1H, brs, NH), 5.52 (1H, s, H-1'), 5.31 (1H, brs, H-2"), 5.15 (1H, s, H-7), 4.92 (1H, s, H-10), 4.09 (1H, q, J=6.3 Hz, H-5'), 3.93 (1H, s, 9-OH), 3.86 (1H, m, H-6"a), 3.70 (1H, s, H-4'), 3.67 (1H, m, H-6"b), 2.83-2.69 (3H, 10-OH, H-3"a, H- 5"a), 2.45 (1H, m, H-3'), 2.35-2.10 (4H, H-8, H-3"b, H-5"b), 1.98 (3H, s, COCH 3 ), 1.91-1.72 (4H, H-13, H-2'), 1.39 (3H, d, J=6.3 Hz, H-6'), 1.12 (3H, t, J=7.8 Hz, H-14)
EXAMPLE 7
(1) Synthesis of 3'-deam ino -3'-[(2"S) - 2"-trifluoroacetamido-4"-morpholino]-R20X2
1.13 g (3.76 mmol) of 2,3,4-tri-O-acetyl-β-Lxylopyranosyl azide was dissolved in 30 ml of methanol, and the solution was stirred at 45° to 50° C. for 2 hours in a hydrogen gas stream in the presence of 300 mg of 5% palladium carbon catalyst. The reaction solution was then filtered and the filtrate concentrated under reduced pressure. The residue was dissolved in pyridine (20 ml), and 2 ml of trifluoroacetic anhydride was added. The mixture was allowed to react at room temperature for 1.5 hours. The reaction mixture was then concentrated under reduced pressure and the residue extracted with chloroform (250 ml). The chloroform layer was washed with 2N aqueous hydrochloric acid solution (250 ml), 5% aqueous sodium carbonate solution (250 ml) and water (200 ml) in the stated order, dehydrated over anhydrous sodium sulfate and concentrated under reduced pressure. The residue was subjected to column chromatography (Wakogel C-200, 20 g) and eluted with chloroform-methanol (300:1). The eluate was crystallized from ethyl acetate-hexane to obtain 411.7 mg (1.11 mmol, 29%) of N-trifluoroacetamido-2,3,4-tri-O-acetyl-β-L-xylopyranosylamine as a colorless needle crystal. Presented below are the physicochemical properties of this crystalline compound.
Melting point: 106° C.
[α] D 24 =-38° (C=1.0, chloroform)
Infrared absorption spectrum (KBr)(cm -1 ): 1730, 1560
FD-MS m/z=372 (M + +1)
1 H-Nuclear magnetic resonance spectrum (500 MHz, in deuterochloroform) (δ (ppm)):
7.28 (1H, d, J=8.5 Hz, NH), 5.34 (1H, t, J=9.2 Hz, H-3), 5.15 (1H, dd, J=8.5, 9.2 Hz, H-1), 5.01 (1H, dt, J=5.5, 9.2 Hz, H-4), 4.98 (1H, t, J=9.2 Hz, H-2), 4.13 (1H, dd, J=5.5, 11.6 Hz, H-5a), 3.46 (1H, dd, J=9.2, 11.6 Hz, H-5b), 2.07 (6H, s, 2XOCOCH 3 ), 2.05 (3H, s, OCOCH 3 )
Subsequently, 331.0 mg (0.89 mmol) of this N-trifluoroacetamido-2,3,4-tri-O-acety-β-L-xylopyranosylamine was dissolved in 10 ml of methanol, and 0.1 ml of sodium methoxide was added. The mixture was allowed to react at room temperature for 1 hour, and thereafter neutralized with an acidic ion exchange resin, Amberlite IR-120B. The resin was removed by filtration, and 578 mg (2.70 mmol) of sodium metaperiodate was added to the filtrate. The resultant filtrate was allowed to react at room temperature for 4 hours in the dark. The reaction solution was then filtered and the filtrate concentrated under reduced pressure. The residue was dissolved in 5 ml each of chloroform and methanol. To the solution were added 93.3 mg (0.18 mmol) of R20X2 and 43.1 mg (0.69 mmol) of sodium cyanoborohydride, and the mixture was allowed to react at room temperature for 4 hours. The reaction mixture was then concentrated under reduced pressure and the residue extracted with chloroform (150 ml). The chloroform layer was washed with water (100 ml), dehydrated over anhydrous sodium sulfate and concentrated under reduced pressure. The residue was developed on TLC (Merck & Co., Inc., No. 5744) using chloroform-methanol (10:1). A red band having an Rf value of approximately 0.60 was scraped off and extracted with chloroform-methanol (10:1) to obtain the desired compound which was then crystallized from chloroform-hexane to obtain 25.6 mg (0.04 mmol, 20% yield) of the title compound as a brown powder.
(2) Physicochemical properties of 3'-deamino-3'-[(2"S)-2"-trifluoroacetamide-4"-morpholino]-R20X2
(1) Melting point: 153°-154° C. (decomposed)
(2) [α] D 24 =-18° (C=0.16, CHCl 3 )
(3) Elementary analysis:
______________________________________C H N______________________________________Calcd. 55.17 5.06 4.02 (C.sub.32 H.sub.35 N.sub.2 O.sub.12 F.sub.3)Found 55.32 5.00 3.88 (%)______________________________________
(4) FD-MS 697 (M + +1)
(5) Infrared absorption spectrum (KBr)(cm -1 ): 3450, 1730, 1600
(6) 1 H-Nuclear magnetic resonance spectrum (500 MHz, in deuterochloroform) (δ (ppm)):
13.64 (1H, s, 11-OH), 12.88 (1H, s, 6-OH), 12.16 (1H, s, 4-OH), 7.91 (1H, d, J=7.3 Hz, H-1), 7.74 (1H, t, J=7.3 Hz, H-2), 7.35 (1H, d, J=7.3 Hz, H-3), 7.03 (1H, brs, NH), 5.54 (1H, s, H-1'), 5.36 (1H, m, H-2"), 5.16 (1H, s, H-7), 4.92 (1H, d, J=4.3 Hz, H-10), 4.11 (1H, q, J=6.9 Hz, H-5'), 3.92 (1H, s, 9-OH), 3.87 (1H, m, H-6"a), 3.72 (1H, s, H-4'), 3.70 (1H, m, H-6"b), 2.82 (1H, d, J=10.6 Hz, H-3"a), 2.70 (1H, m, H-5"a), 2.68 (1H, d, J=4.3 Hz, 10-OH), 2.49 (1H, m, H-3'), 2.45-2.28 (2H, H-3"b, H-5"b), 2.23 (1H, d, J=15.1Hz, H-8a), 2.14 (1H, dd, J=4.6, 15.1Hz, H-8b), 1.91-1.73 (4H, H-13, H-2'), 1.38 (3H, d, J=6.9 Hz, H-6'), 1.12 (3H, t, J=7.4 Hz, H-14)
EXAMPLE 8
(1) Synthesis of 3'-deamino-3'-[(2"S)-2"methoxy-4"-morpholino]-R20X2
150 mg (0.91 mmol) of methyl-α-D-xylopyranoside was dissolved in 30 ml of methanol, and 590 mg (2.76 mmol) of sodium metaperiodate was added. The mixture was allowed to react at room temperature for 14 hours in the dark. The reaction mixture was then filtered and the filtrate concentrated under reduced pressure. The residue was dissolved in 5 ml each of chloroform and methanol. To the solution were added 134 mg (0.26 mmol) of R20X2 and 50.3 mg (0.80 mmol) of sodium cyanoborohydride, and the mixture was allowed to react at room temperature for 16 hours. The reaction mixture was then concentrated under reduced pressure and the residue extracted with chloroform (100 ml). The chloroform layer was washed with water (100 ml), dehydrated over anhydrous sodium sulfate and concentrated under reduced pressure. The residue was developed on TLC (Merck & Co., Inc., No. 5744) using chloroform-methanol (10:1). A red band having an Rf value of approximately 0.5 was scraped off and extracted with chloroform-methanol (10:1) to obtain the desired compound which was then crystallized from chloroform-hexane to obtain 88.0 mg (0.14 mmol, 54% yield) of the title compound as a brown powder.
(2) Physicochemical properties of 3'-deamino-3'-[(2"S)-2"-methoxy-4"-morpholino]-R20X2
(1) Melting point: 150°-151° C. (decomposed)
(2) [α] D 24 =+53° (C=0.06, CHCl 3 )
(3) Elementary analysis:
______________________________________C H N______________________________________Calcd. 60.48 6.06 2.28 (C.sub.31 H.sub.37 NO.sub.12)Found 60.71 5.91 2.04 (%)______________________________________
(4) FD-MS 616 (M + +1)
(5) Infrared absorption spectrum (KBr)(cm -1 ): 3420, 1600
(6) 1 H-Nuclear magnetic resonance spectrum (500 MHz, in deuterochloroform) (δ (ppm)):
13.61 (1H, s, 11-OH), 12.83 (1H, s, 6-OH), 12.13 (1H, s, 4-OH), 7.88 (1H, d, J=7.9 Hz, H-1), 7.72 (1H, t, J=7.9 Hz, H-2), 7.33 (1H, d, J=7.9 Hz, H-3), 5.50 (1H, s, H-1'), 5.14 (1H, brs, H-7), 4.91 (1H, s, H-10), 4.48 (1H, dd, J=3.2, 4.3 Hz, H-2"), 4.08 (1H, q, J=7.2 Hz, H-5'), 3.97 (1H, s, 9-OH), 3.92 (1H, ddd, J=3.0, 7.2, 11.8 Hz, H-6"a), 3.67 (1H, brs, H-4'), 3.54 (1H, ddd, J=3.3, 6.3, 11.8 Hz, H-6"b), 3.38 (3H, s, OCH 3 ), 2.57-2.36 (5H, H-3', H-3", H-5"), 2.25 (1H, d, J=15.5 Hz, H-8a), 2.12 (1H, dd, J=3.9, 15.5 Hz, H-8b), 1.90-1.73 (4H, H-13, H-2'), 1.39 (3H, d, J=7.2 Hz, H-6'), 1.12 (3H, t, J=7.2 Hz, H-14)
EXAMPLE 9
(1) Synthesis of 3'-deamino-3'-[(2"R)-2"-azido-4"-morpholino]-R20X2
249.5 mg (1.42 mmol) of β-D-xylopyranosyl azide was dissolved in 10 ml of methanol, and 914.3 mg (4.27 mmol) of sodium metaperiodate was added. The mixture was allowed to react at room temperature for 19 hours in the dark. The reaction mixture was then concentrated under reduced pressure and the residue dissolved in 10 ml of methanol. To the solution were added 60.0 mg (0.12 mmol) of R20X2 and 21.9 mg (0.10 mmol) of sodium cyanoborohydride, and the mixture was allowed to react at room temperature for 2 hours. The reaction mixture was thereafter concentrated under reduced pressure and the residue extracted with chloroform (100 ml). The chloroform layer was washed with water (100 ml), dehydrated over anhydrous sodium sulfate and concentrated under reduced pressure. The residue was developed on TLC (Merck & Co., Inc., No. 5744) using chloroform-methanol (10:1). A red band having an Rf value of approximately 0.65 was scraped off and extracted with chloroform-methanol (10:1) to obtain the desired compound which was then crystallized from chloroform-hexane to obtain 27.1 mg (0.04 mmol, 37% yield) of the title compound as a brown powder.
(2) Physicochemical properties of 3'-deamino-3'-[(2"R)-2"-azido-4"-morpholino]-R20X2
(1) Melting point: 150°-152° C. (decomposed)
(2) [α] D 24 =+122° (C=0.07, CHCl 3 )
(3) Elementary analysis:
______________________________________C H N______________________________________Calcd. 57.50 5.47 8.94 (C.sub.30 H.sub.34 N.sub.4 O.sub.11)Found 57.78 5.33 8.68 (%)______________________________________
(4) FD-MS m/z=627 (M+1 + )
(5) Infrared absorption spectrum (KBr)(cm -1 ): 3430, 2100, 1600
(6) 1 H-Nuclear magnetic resonance spectrum (500 MHz, in deuterochloroform) (δ (ppm)):
13.62 (1H, s, 11-OH), 12.85 (1H, s, 6-OH), 12.15 (1H, s, 4-OH), 7.91 (1H, d, J=8.1Hz, H-1), 7.73 (1H, t, J=8.1Hz, H-2), 7.34 (1H, d, J=8.1 Hz, H-3), 5.52 (1H, brs, H-1'), 5.15 (1H, brs, H-7), 4.92 (2H, H-10, H-2"), 4.08 (1H, q, J=6.3 Hz, H-5'), 4.00 (1H, m, H-6'a), 3.92 (1H, s, 9-OH), 3.69 (1H, brs, H-4'), 3.67 (1H, m, H-6"b), 2.70-2.40 (4H, H-3", H-5"), 2.37 (1H, dd, J=5.0, 11.9 Hz, H- 3'), 2.24 (1H, d, J=15.6 Hz, H-8a), 2.13 (1H, dd, J=4.4, 15.6 Hz, H-8b), 1.90-1.73 (4H, H-13, H-2'), 1.40 (3H, d, J=6.3 Hz, H-6'), 1.12 (3H, t, J=7.5 Hz, H-14)
EXAMPLE 10
(1) Synthesis of 3'-deamino-3'-[(2"R)- 2"-trifluoroacetamido-4"-morpholino]-R20X2
188.2 mg (0.76 mmol) of N-trifluoroacetyl-β-D-xylopyranosylamine was dissolved in 10 ml of methanol, and 493 mg (2.30 mmol) of sodium metaperiodate was added. The mixture was allowed to react at room temperature for 18 hours in the dark. The reaction mixture was then filtered and the filtrate concentrated under reduced pressure. The residue was dissolved in 5 ml each of chloroform and methanol. To the solution were added 241.1 mg (0.47 mmol) of R20X2 and 43.9 mg (0.70 mmol) of sodium cyanoborohydride, and the mixture was allowed to react at room temperature for 3 hours. The reaction mixture was then concentrated under reduced pressure and the residue extracted with chloroform (400 ml). The chloroform layer was washed with water (400 ml), dehydrated over anhydrous sodium sulfate and concentrated under reduced pressure. The residue was developed on TLC (Merck & Co., Inc., No. 5744) using chloroform-methanol (10:1). A red band having an Rf value of approximately 0.62 was scraped off and extracted with chloroform-methanol (10:1) to obtain the desired compound which was then crystallized from chloroform-hexane to obtain 78.5 mg (0.11 mmol, 24% yield) of the title compound as a brown powder.
(2) Physicochemical properties of 3'-deamino-3'-[(2"R)-2"-trifluoroacetamido-4"-morpholino]-R20X2
(1) Melting point: 170°-171° C. (decomposed)
(2) [α] D 25 =+189° (C=0.11, chloroform)
(3) Elementary analysis:
______________________________________C H N______________________________________Calcd. 55.17 5.06 4.02 (C.sub.32 H.sub.35 N.sub.2 O.sub.12 F.sub.3)Found 54.88 5.18 3.97 (%)______________________________________
(4) FD-MS m/z=697 (M+1 + )
(5) Infrared absorption spectrum (KBr)(cm -1 ): 3450, 1730, 1610
(6) 1 H-Nuclear magnetic resonance spectrum (500 MHz, in deuterochloroform) (δ (ppm)):
13.63 (1H, s, 11-OH), 12.87 (1H, s, 6-OH), 12.15 (1H, s, 4-OH), 7.92 (1H, d, J=8.9 Hz, H-1), 7.74 (1H, t, J=8.9 Hz, H-2), 7.34 (1H, d, J=8.9 Hz, H-3), 7.04 (1H, d, J=6.9 Hz, NH), 5.53 (1H, d, J=3.4 Hz, H-1'), 5.37 (1H, m, H-2"), 5.15 (1H, brs, H-7), 4.92 (1H, d, J=4.3 Hz, H-10), 4.12 (1H, q, J=5.7 Hz, H-5'), 3.89 (1H, s, 9-OH), 3.84 (1H, dt, J=5.7, 11.7 Hz, H-6"a), 3.74 (1H, brs, H-4'), 3.70 (1H, dt, J=5.1, 11.7 Hz, H-6"b), 2.87 (1H, dd, J=2.3, 11.7 Hz, H-3"a), 2.67 (1H, d, J=4.3 Hz, 10-OH), 2.55 (2H, H-5"), 2.48 (1H, ddd, J=2.3, 4.9, 11.7 Hz, H-3"b), 2.42 (1H, dd, J=5.1, 12.0 Hz, H-3'), 2.32 (1H, d, J=2.3 Hz, 4'-OH), 2.23 (1H, d, J=14.6 Hz, H-8a), 2.13 (1H, dd, J=4.9, 14.6 Hz, H-8b), 1.95-1.70 (4H, H-13, H-2'), 1.38 (3H, d, J=5.7 Hz, H-6'), 1.12 (3H, t, J=7.1Hz, H-14)
EXAMPLE 11
(1) Synthesis of 3'-deamino-3'-[(2"R)-2"-methoxy-4"-morpholino]-R20X2
500 mg (3.05 mmol) of methyl-β-D-xylopyranoside was dissolved in 10 ml of methanol, and 1.95 g (9.12 mmol) of sodium metaperiodate was added. The mixture was allowed to react at room temperature for 23 hours in the dark. The reaction mixture was then filtered and the filtrate concentrated under reduced pressure. The residue was dissolved in 5 ml each of chloroform and methanol. To the solution were added 130 mg (0.25 mmol) of R20X2 and 143 mg (0.67 mmol) of sodium cyanoborohydride, and the mixture was allowed to react at room temperature for 3 hours. The reaction mixture was then concentrated under reduced pressure and the residue extracted with chloroform (200 ml). The chloroform layer was washed with water (200 ml), dehydrated over anhydrous sodium sulfate and concentrated under reduced pressure The residue was developed on TLC (Merck & Co., Inc., No. 5744) using chloroform-methanol (10:1). A red band having an Rf value of approximately 0.53 was scraped off and extracted with chloroform-methanol (10:1) to obtain the desired compound which was then crystallized from chloroform-hexane to obtain 59.9 mg (0.10 mmol, 39% yield) of the title compound as a brown powder.
(2) Physicochemical properties of 3'-deamino-3'-[(2"R)-2"-methoxy-4"-morpholino]-R20X2
(1) Melting point: 147°-148° C. (decomposed)
(2) [α] D 24 =+150° (C=0.10, CHCl 3 )
(3) Elementary analysis:
______________________________________C H N______________________________________Calcd. 60.48 6.06 2.28 (C.sub.31 H.sub.37 NO.sub.12)Found 60.66 6.01 2.05 (%)______________________________________
(4) FD-MS m/z=615 (M + )
(5) Infrared absorption spectrum (KBr)(cm -1 ): 3420, 1600
(6) 1 H-Nuclear magnetic resonance spectrum (500 MHz, in deuterochloroform) (δ (ppm)):
13.63 (1H, s, 11-OH), 12.85 (1H, s, 6-OH), 12.16 (1H, s, 4-OH), 7.90 (1H, d, J=7.2 Hz, H-1), 7.73 (1H, t, J=7.2 Hz, H-2), 7.34 (1H, d, J=7.2 Hz, H-3), 5.51 (1H, s, H-1'), 5.15 (1H, s, H-7), 4.92 (1H, d, J=3.6 Hz, H-10), 4.45 (1H, dd, J=2.3, 4.9 Hz, H-2"), 4.07 (1H, q, J=6.6 Hz, H-5'), 3.97 (1H, s, 9-OH), 3.92 (1H, ddd, J=3.0, 6.9, 11.8 Hz, H-6"a), 3.70 (1H, s, H-4'), 3.56 (1H, ddd, J=3.3, 6.3, 11.8 Hz, H-6 'b), 3.40 (3H, s, OCH 3 ), 2.67 (1H, d, J=3.6 Hz, 10-OH), 2.63 (1H, dd, J=2.3, 11.8 Hz, H-3"a), 2.55 (1H, m, H-5"a), 2.42-2.36 (3H, H-3', H-3"b, H-5"b), 2.25 (1H, d, J=14.1 Hz, H-8a), 2.12 (1H, dd, J=4.6, 14.1 Hz, H-8b), 1.90-1.75 (4H, H-13, H-2'), 1.40 (3H, d, J=6.6 Hz, H-6'), 1.12 (3H, t, J=7.2 Hz, H-14)
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Disclosed is an anthracycline compound of the formula (I): ##STR1## wherein Ra is -R 1 , ##STR2## or --OR 3 , R 1 being (1) alkyl, alkenyl, alkynyl, fluoroalkyl, aryl or aralkyl, or (2) alkyl, alkenyl, alkynyl. fluoroalkyl, aryl or aralkyl having carboxyl, azido, amino, hydroxy, alkoxy or a halogen atom; R 2 being R 1 , a hydrogen atom or hydroxy; and R 3 , which may be the same or different when one substituent has two R 3 's, being R 1 or a hydrogen atom; or the formula (II): ##STR3## wherein Rb is -R 1 , ##STR4## or --OR 3 , R 1 , R 2 and R 3 being as defined above; and R 4 being the same as R 3 except that methyl is not included; or an acid addition salt thereof.
This compound can be contained as an active ingredient in an antitumor agent, whereby good results are attainable.
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BACKGROUND OF THE INVENTION
The present invention relates to a method of rinsing fabric in an automatic clothes washer and more particularly to a spinning and tumbling rinse method in a horizontal axis clothes washer.
Attempts have been made to provide an automatic clothes washer which provides comparable or superior wash results to present commercially available automatic washers, yet which uses less energy and water. For example, such devices and wash processes in a vertical axis machine are shown and described in U.S. Pat. Nos. 4,784,666 and 4,987,627, both assigned to the assignee of the present application, and incorporated herein by reference.
The basis of these systems stems from the optimization of the equation where wash performance is defined by a balance between the chemical (the detergent efficiency and water quality), thermal (energy to heat water), and mechanical (application of fluid flow through--fluid flow over--fluid impact--fabric flexing) energy inputs to the system. Any reduction in one or more energy forms requires an increase in one or more of the other energy inputs to produce comparable levels of wash performance.
U.S. Pat. No. 4,489,455 discloses a horizontal axis washer which utilizes a reduced amount of wash fluid in a washing cycle in which the wash fluid is applied on to the fabric load and then the load is tumbled in the presence of the wash fluid for a given period of time. Recirculation of the wash liquid does not occur.
U.S. Pat. No. 3,197,980, assigned to the assignee of the present invention, discloses a horizontal washer and wash cycle in which the clothes load is subjected first to a deep fill to thoroughly wet all of the clothes, half the water is then removed from the washer and a normal detergent supply is introduced into the remaining wash bath. Thus, a "concentrated" detergent solution in the range of 0.40 to 0.50% by weight is applied to the clothes load during a tumbling agitation of the clothes. Recirculation of the wash fluid during this "concentrated" wash cycle is also disclosed. Following the "concentrated" portion of the wash cycle, the tub is refilled to a deep fill volume which dilutes the detergent concentration to the normal concentration of 0.20 to 0.25%. An additional tumble period at the normally recommended detergent concentration then occurs.
Various rinse techniques have been proposed for removing detergent and dirt from the clothes load after the washing cycle, however, most of those rinse methods use a large amount of water or are not effective to remove a highly concentrated detergent solution or avoid redeposition of removed dirt onto the clothes load.
Significantly greater savings in water usage and energy usage than is achieved by heretofore disclosed wash systems and methods would be highly desirable.
SUMMARY OF THE INVENTION
A horizontal axis washer system incorporating the principles of the present invention utilizes a basket structure and fluid conduits and valves which complement specifically increasing the level of chemical contributions to the wash system, therefore permitting the reduction of both mechanical and thermal inputs.
The utilization of concentrated detergent solution concepts in the wash portion of the cycle permits the appliance manufacturer to significantly reduce the amount of thermal and mechanical energy applied to the clothes load, through the increase of chemistry a minimum of thirteen fold and maximum up to at least sixty-four fold, while approximating "traditional" cleaning levels, yet reducing the energy and water usage. This translates to washing with reduced water heating, reduced water consumption, and minimal mechanical wash action to physically dislodge soils. A concentrated detergent solution is defined in U.S. Pat. No. 4,784,666 as 0.5% to 4% detergent by weight. It is anticipated now, however, that a concentrated detergent solution may be as high as 12% by weight.
The present invention contemplates a rinse process which can be used with any wash cycle, but which has particular utility following a wash cycle have a highly concentrated detergent solution.
The method of rinsing fabric provided by the present invention is useful in a washer having a wash chamber rotatable about a horizontal axis. The steps undertaken in the method begin with loading fabric to be washed into the wash chamber of the washer. The fabric is then washed in a detergent solution while rotating the wash chamber about its horizontal axis for a first period of time. Next the detergent solution is drained from the wash chamber. The fabric is then rinsed by adding water to the wash chamber while spinning the wash chamber at a speed to effect less than a one gravity centrifugal force on the fabric such that the fabric will tumble within the wash chamber as it spins. Finally, the wash chamber is drained of the rinse water.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of an automatic washer, partially cut away to illustrate various interior components.
FIG. 2 is a partial front elevational view of the washer of FIG. 1 with the outer wrapper removed to illustrate the interior components.
FIG. 3 is a schematic illustration of the fluid conduits and valves associated with the automatic washer.
FIG. 4 is a flow chart diagram of the steps incorporated in the concentrated wash cycle.
FIG. 5A is a sectional view of the wash tub illustration an electrical probe liquid level sensor.
FIG. 5B is a side sectional view of the use of a pressure dome as a liquid level sensor in the wash tub.
FIG. 6A is a flow chart diagram of a recirculation rinse cycle.
FIG. 6B is a flow chart diagram of a flush rinse cycle.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Washer and Fluid Flow Path Construction
In FIG. 1, reference numeral 20 indicates generally a washing machine of the automatic type, i.e., a machine having a pre-settable sequential control means for operating a washer through a preselected program of automatic washing, rinsing and extracting operations in which the present invention may be embodied. The machine 20 includes a frame 22 carrying vertical panels 24 forming the sides 24a, top 24b, front 24c and back of the cabinet 25 for the washing machine 20. A hinged door 26 is provided in the usual manner to provide access to the interior or treatment zone 27 of the washing machine 20. The washing machine 20 has a console 28 including a timer dial 30 or other timing mechanism and a temperature selector 32 as well as a cycle selector 33 and other selectors as desired.
Internally of the machine 20 described herein by way of exemplifications, there is disposed an imperforate fluid containing tub 34 within which is a spin basket 35 with perforations or holes 36 therein, while a pump 38 is provided below the tub 34. The spin basket 35 defines a wash chamber. A motor 39 is operatively connected to the basket 35 to rotate the basket relative to the stationary tub 34.
Water is supplied to the imperforate tub 34 by hot and cold water supply inlets 40 and 42 (FIG. 3). Mixing valves 44 and 45 in the illustrated dispenser design are connected to conduit 48. There are provided a plurality of wash additive dispensers 60, 62 and 64 as seen in FIG. 3. Dispensers 60 and 62 can be used for dispensing additives such as bleach or fabric softeners and dispenser 64 can be used to dispense detergent (either liquid or granular) into the wash load at the appropriate time in the automatic: wash cycle. As shown schematically in FIG. 3, each of the dispensers 60, 62 and 64 are supplied with liquid (generally fresh water or wash liquid) through a separate, dedicated conduit 66, 68, 70 respectively. Each of the conduits 66, 68 and 70 may be connected to a fluid source in a conventional manner, as by respective solenoid operated valves (72, 74 and 76 FIG. 3), which contain built-in flow devices to give the same flow rate over wide ranges of inlet pressures, connecting each conduit to the manifold conduit 48.
A mixing tank 80, as shown in FIG. 3, forms a zone for receiving and storing a concentrated solution of detergent during the wash cycle, and is used in some embodiments of the invention. As will be described in greater detail below, the mixing tank 80 communicates at a top end with the wash tub 34 and at a lower end communicates with the pump 38, a drain line or conduit 82 and a recirculating conduit 84. The mixing tank 80 may be similar to that disclosed in U.S. Pat. No. 4,784,666.
As described above, the detergent dispenser 64 is provided with a supply of fresh water through conduit 70. Other types of detergent dispensers can, of course, be used with the present invention, including dispensers which hold more than a single charge of detergent and dispense a single charge for each wash cycle.
Positioned within the tub 34, near a bottom wall 139 thereof is a liquid sensor means which may be in the form of a liquid level sensor 140. Such a sensor can be of a number of different types of sensors including a conductivity probe 142 (FIG. 5A), a temperature thermistor 144 (FIG. 3) or a pressure dome 146 (FIG. 5B). Regardless of the liquid sensor type, the liquid sensor must be able to detect either the presence of liquid detergent solution and/or the presence of suds within the tub. A sensor which detects the depth of liquid within the tub may also be utilized. When the sensor makes the required detection, it sends an appropriate signal to a control device 141, as is known in the art, to provide the appropriate control signals to operate the various valves as required at that portion of the wash cycle. As is described in greater detail below, the liquid sensor 140 is used to maintain a desired level of wash liquid within the tub 34 during the recirculating portion of the concentrated wash cycle.
The probe sensor 142, shown in FIG. 5A, consists of two insulated stainless steel electrodes 148 having only the tips 150 exposed in the tub 34. When the detergent solution or suds level raises high enough to contact both electrodes, the low voltage circuit is completed indicating the sensor is satisfied.
A thermistor system 144, as generally indicated in FIG. 3, is also located in the tub 34 and is triggered when the water or suds level rises to the designated level, thus cooling the sensor element.
A pressure dome sensor 146, as shown in FIG. 5B and FIG. 3, is similar to pressure domes normally utilized determining liquid level within an automatic washer tub, however it is the positioning of the dome near the bottom of the tub 34 or in a sump, rather than on the upper side of the tub which is the major difference between its usage here and its traditional usage. If a pressure dome sensor 146 is utilized, it must have a setting for spin/spray usage. An indirect inference of water level in the tumble portion of the cycle based on the level of the detergent liquor can be used via algorithms. A pressure dome sensor may also be beneficial as a sensor to detect an over sudsing condition. If the suds level is too high, then the sensor does not reset. The failure to reset is a means for terminating a spray/spin wash proceeding with the tumble portion of the wash cycle.
Basket Construction
The washer basket 35 has a plurality of inwardly directed baffles 37 to engage and lift the fabric as the basket rotates about its horizontal axis. The wash basket also is provided with a series of apertures 36 therethrough to permit fluid flow through the basket. When the basket rotates at a sufficiently high speed, the fabric will be held against the wall of the basket in that a centrifugal force in excess of the force of gravity will be applied to the fabric, thus preventing the fabric from moving relative to the basket wall. However, when the basket is rotated below a predetermined speed, less than one gravity of centrifugal force will be applied to the fabric, thus permitting the fabric to tumble within the basket. As described below, one or both of these spin actions may be applied during the preferred wash cycle.
An optional in-line water heater 400 (FIG. 3), or an immersion heater in the sump, offers the ability to increase the concentrated wash liquor to an elevated temperature level, thus providing high temperature wash performance at the reduced cost of heating one to one and half gallons of water. This compares to the cost of heating four to five gallons of water in a traditional horizontal washer. The controlled use of an in-line heater 400 combined with high concentrated wash liquor offers special opportunities for specific optimization of detergent ingredients which are activated only in specific temperature ranges. Furthermore, the elevated water temperatures offer the ability to specifically target oily soil removal and reduce the build-up of both saturated and poly-unsaturated oils in fabrics laundered in cold water.
The use of an in-line lint, button, sand and foreign object trap or filter 402 significantly reduces the potential for problems associated with recirculating fluid systems carrying soils and foreign materials. Such a filter is disclosed in U.S. Pat. No. 4,485,645, assigned to the assignee of the present invention, and incorporated herein by reference. Such optional devices would be utilized in a preferred system.
Wash Cycle
An improved wash and rinse cycle is provided in accordance with the present invention and is shown schematically in FIG. 4. In step 500, the washer is loaded with clothes as would be standard in any horizontal axis washer. In step 502, the detergent; liquid, powdered, and/or other detergent forms, is added to the washer, preferably through a detergent dispenser, such as the detergent dispenser 64 illustrated, and mixing tank, such as tank 80, at the dosage recommended by the detergent manufacturer for a particular sized wash load. It is possible to add the detergent directly to washer through the basket or directly into the tub through a direct path. The consumer then selects the desired cycle and water temperature in step 504.
A 3-way drain valve 166 and a 3-way detergent mixing valve 170 are turned on and the detergent tank control valve 128 and the detergent water valve 76 are opened. A time delay (approximately 30 seconds) is used to input wash water after which the detergent water valve 76 is closed. As the washer fills, the detergent is washed from the dispenser 64 into the tub 34, past the drain and mixing tank valves 166, and into the mixing tank 80. A time delay (approximately 15 seconds) provide mixing of the detergent with wash water by recirculating the solution in a loop controlled by the valves as indicated by step 506. The detergent is only diluted to a highly concentrated level of approximately 0.5 to 12% by weight detergent. The washer basket 35 begins a low speed spin. The preferred speed allows uniform coverage of the concentrated detergent liquor onto the clothes load. Concentrated Wash Cycle
In step 508, the detergent tank control valve 128 is closed and a time delay of approximately 15 seconds, but dependent on the size of the mixing tank 80, causes the mixing tank to fill with the detergent solution. The detergent mixing valve 170 is turned off permitting the detergent solution to leave the closed loop and to be sprayed onto the spinning clothes load via a nozzle 51 whose arrangement can be from any point internal to the basket. The preferred position provides a spray pattern perpendicular to the clothes load tumbling path in both bidirectional and unidirectional tumbling systems.
During the initial introduction of concentrated detergent solution on to the clothes load, the wash basket is spun at a speed slow enough to effect less than a one gravity centrifugal force on the clothes load, thus resulting in the clothes load tumbling within the basket. After the concentrated detergent solution is sprayed on the clothes, the solution then travels through the basket 35, into the tub 34, down through the pump 38 to be sprayed through the nozzle 51 creating a recirculation loop. The preferred system utilizes a pump exclusively for the recirculation. This ensures sufficient concentrated liquid flow rates without losses due to slower pump speeds associated directly with the drive system. Less effective systems could also use the main pump of the wash system.
This step concentrates the effectiveness of the chemistry thus permitting maximum soil removal and minimum soil redeposition even under adverse washing conditions. The high concentrations of detergent ingredients significantly increases the effectiveness of micelle formation and sequestration of oily and particulate soils and water hardness minerals, thus providing improved performance of surfactants, enzymes, oxygen bleaches, and builder systems beyond level achievable under traditional concentrations.
The water level sensor 140, located near the tub bottom, or in the sump, begins to monitor water level concurrent with the opening of the detergent mixing valve 170. Water level control is critical. Too much detergent solution added will create an over sudsing condition by allowing the spinning basket to contact detergent solution in the bottom of the tub. The preferred method of control is to maintain a minimum level of detergent liquor in the bottom of the tub through the water level sensor. While results suggest that some type of tub modifications (resulting in a sump) permits the washer to function under a wide range of conditions, there are many more common conditions which do not require a tub sump.
A satisfied sensor 140 indicates the system does not require any additional detergent solution at this point in the cycle and the detergent tank valve 128 is closed to maintain the current level of detergent. A satisfied water level sensor 140 early in the wash cycle generally indicates either a no clothes load situation or a very small clothes load. If the sensor is not satisfied, then the detergent tank control valve 128 is opened permitting the addition of detergent solution followed by a five second time delay before again checking the water level sensor 140. If the sensor 140 is satisfied, the detergent tank control valve 128 is closed to maintain the new level of detergent and a thirty second time delay begins to permit the clothes load a chance to come to equilibrium with respect to water retention and the centrifugal forces of extraction created by the spinning basket.
In the preferred embodiment of the invention a mixing tank in not utilized, rather, the detergent is mixed in the bottom of the tub or in the sump if there is one. The water level control is provided by a pressure switch in the bottom of the tub, or in the sump, which does provide water level control as a function of clothes load.
In a preferred wash method, the spin speed is then increased to a level to cause a centrifugal force to be applied against the clothes load in excess of one gravity so that the clothes load will be held against the spinning basket wall. The concentrated detergent solution is forced through the clothes load and through the basket holes due to the centrifugal forced imparted by the spinning basket with potential significant contributions by mechanical fluid flow through the fabric defined by the pumping rate of the detergent liquor. During this step (510) the concentrated detergent solution will be recirculated through the clothes load for some predetermined period of time specified by the cycle type. That is, a cycle seeking maximum performance may recirculate the detergent solution through the clothes for 14 minutes or more, while a more delicate or less soiled load will attempt to minimize the length of spinning. The water level sensor 140 monitors the tub 34, adding additional detergent solution from the mixing tank 80 as required. The larger the clothes load the more detergent solution is required. Once the mixing tank 80 is emptied, fresh water is added through the detergent water valve 40,42 and 76 as required by the water level sensor 140.
Tumble Wash Cycle
The high speed spin/recirculation portion of the cycle is terminated after the designated time and the detergent tank control valve 128 is opened with a five second time delay to permit the draining of any remaining detergent solution into the tub 34. The detergent mixing valve 170 is turned on and the detergent water valves and water fill valves 45, 76 are opened to rinse out the detergent mixing tank 80 and begin a dilution fill as shown in step 512.
The fill volume for the tumble wash for step 514 can be indirectly inferred through volume of water used in the concentrated spray wash portion of the cycle in a system utilizing computer control. In more traditional electromechanical control systems, some other method or methods must be used to regulate the fill; i.e., flow regulated timed fill for maximum load volumes, motor torque, and pressure switches.
This second concentrated detergent solution spray portion of the wash cycle differs from the first in that the spin speed should now be reduced below that which will create a one gravity centrifugal force, to ensure the clothes load can loosely tumble, while a somewhat diluted yet still concentrated spray liquor is applied. In this step (514), the concentrated detergent solution is diluted somewhat, but not so much as to reduce the concentration to the normal concentration level of 0.05-0.28%. Thus, the detergent concentration in this step will be above 0.28%. The additional water dilution is necessary due to the reduced extraction in the tumble mode versus the high speed spin mode. That is, with the centrifugal force reduced, the clothes load will hold a greater volume of wash fluid prior to saturation. This preferred second mode permits a further improvement in the level of uniformity of application of concentrated liquor and ultimately the uniform removal of soils. During the second mode of concentration liquor application, significant performance levels can be achieved due to specific designing/engineering of the application of thermal inputs to capitalize on the chemical benefits for specific detergent components not normally available in traditional horizontal wash systems.
The utilization of the recirculated spray throughout the tumble portion of the wash recycles wash liquor draining through holes 36 in either the fully perforated basket or the nearly solid basket provides water conservation, and further assists in the application of wash liquor flow through and over the wash load. The hardware utilized for the concentrated spray wash portion of the cycle effectively fits the requirements.
There are opportunities for modifications to the tub and sump to minimize suds lock conditions and more efficient spray applications by directing the wash liquor return directly and promptly to the pump with minimal aeration of the detergent liquor. Accumulation of concentrated detergent liquor in areas other than the orifice to the pump, such as between the tub and the basket, increases the risk of the spinning/tumbling basket contacting the liquor and mechanically aerating it to the point which negatively affects recirculated spray flow patterns and remaining detergent liquor throughout the recirculation plumbing.
The tumbling portion of the cycle has the objective to provide sufficient detergent liquor fluid flow "through" and "over" the clothes load combined with fabric flexing and flagging. The resulting wash liquor flow patterns appear as complex non-laminar flow, fundamental in classical removal of micelle formations sequestering both oily and particulate soils.
One of the objectives of this wash system is to minimize water consumption. While the preferred design utilizes a perforated basket, other system could utilize nearly solid baskets. Opportunities by a near solid basket include increased ease of maintain concentrated wash liquor in the clothes load and basket. The lack of basket holes reduces the rate and level of extraction of wash liquor and allows the wash liquor to increase its contact time with the clothes instead of reduced contact time required for recirculation through plumbing.
Other designs utilize non-perforated baskets or nearly solid baskets without recirculation. Such designs increase the ability of the system to achieve higher levels of chemical effectiveness in the basket and the clothes load without losses due to plumbing hardware. These washability performance achievements and accompanying reductions in the total water consumption are obtained by the elimination of the volume of the recirculation system, thus the remaining chemistry is concentrated in a lower volume of water.
The gentle tumbling wash action even of this elevated detergent concentration solution provides barely enough mechanical energy input to offer consumers only a minimally acceptable wash performance. Thus, the preferred cycle includes the use of an initial highly concentrated detergent solution wash step as described above.
The type and length of tumbling action varies with the cycle desired. For example, maximum time may be selected for maximum soil removal, while lesser times offer less fluid flow and fabric flexing for delicates, silks, wools, sweaters, and other fine washables. If bleach is being added, then valves 45, 74 are opened to allow a maximum of one quarter cup of liquid chlorine bleach. The physical size of the bleach dispenser 62 can be used to prevent over dosage or a bulk dispenser can be used to regulate dispensing at the appropriate ratio to the volume of water used in the concentrated detergent solution tumble portion of the wash cycle.
In some embodiments where extremely high temperatures are used during the tumble wash, water is added at the end of the tumble wash cycle to cool the clothes load, and the wash water.
The end of the concentrated tumble wash is characterized by a tumble drain followed by complete extraction of wash liquor from the clothes load, basket 35 and tub 34 in step 516. The spin speeds are staged so that the load balances itself and reduces the undesired opportunities for suds lock conditions.
All systems described above can use either spray, spray tumble, flush rinses, and/or combinations for effective rinsing and water conservation. The perforated basket design can also use a flush rinse technique.
THE RINSE CYCLE
Recirculated Spray Rinse Cycle
The recirculated spray rinse portion of the cycle, whether the basket is spun at a high speed to effect a centrifugal force greater than gravity or a slower speed to cause the fabric load to tumble as illustrated in FIG. 6A, represents a water conservation feature for any horizontal axis washer. Its preferred usage is in combination with concentrated detergent solution concepts to reduce the risk of potential soil redeposition, but is not limited to those designs or methods. The exact hardware utilized for high performance spray washing can be utilized without modification to provide rinsing performance comparable to a classical deep tumble rinse of approximately twenty gallons. The horizontal recirculated spray rinse cycle uses six to twelve serial recirculated spray rinse cycles, consuming approximately one gallon of water each, to provide rinsing, defined by removal of LAS containing surfactants, of a level comparable to that achieved by three to five deep tumble rinses of four to five gallons each. A combination of spin recirculated and tumble recirculated rinses provides more uniform rinsing with improved uniformity of final results.
The basket continues to spin after the final extract of the wash liquor with a fifteen second time delay to assure that all of the wash liquor has been pumped down the drain as shown in step 520. In step 522, the cold water valve 45 and 76 are opened until the water level sensor 140 is satisfied and then closed.
In step 524, the fresh water is sprayed directly onto the spinning clothes load. The water dilutes the detergent in the clothes as it passes through the load and basket. The rinse water drains down into the tub and is pumped back through the nozzle 51 to form a recirculation loop. The solution extracts additional detergent from the load with each pass. Each recirculation loop is delayed thirty seconds, after which the drain valve 166 is turned off and the solution is discharged to the drain as shown in step 526. The drain valve 166 is turned on and the spray rinse loop is repeated for the specified number of spray recirculations.
In the preferred embodiment, rinse water is added while the clothes tumble in the basket, and water is sprayed on the clothes load. When the water level control is satisfied, the basket accelerates to a speed sufficient to effect a centrifugal force in excess of one gravity. After some time, the rinse water is drained and the basket slows to tumble speed. The cycle is repeated for the specified number of spray recirculations.
On the last spray rinse the fabric softener valve 72, and cold water fill valve 45 is opened for thirty seconds permitting the fabric softener to be rinsed into the tub 34 and pump 38. Cold water and fabric softener valves 45, 72 are closed and the fabric softener is mixed with the last recirculating rinse water. The resulting solution is sprayed onto the clothes load in a recirculation loop for an additional two minutes to assure uniform application of the fabric softener. Additional fresh water is added through the cold water fill valve 42 if the water level sensor 140 becomes unsatisfied. In the final step 526, the drain valve 166 is turned off permitting the final extraction of water and excess softener for sixty seconds.
SPRAY FLUSH RINSE CYCLE
Spray flush as shown in FIG. 6B offer a less than optimum performance option for perforated basket designs. The limiting parameter for this system results from the lack of uniform spray coverage and problems associated with the lack of guaranteed water line pressures. The design does not require any additional hardware and consumes small volumes of water in matching the rinse performance of a deep rinse.
In step 540 the basket 35 continues to spin after the final extract of the wash liquor with a fifteen second time delay to assure all of the wash liquor has been pumped down the drain. The cold water valve 45 is opened until the timer is satisfied and then closed. In step 542, the fresh water is sprayed directly onto the spinning clothes load and directly down the drain by means of the closed drain valve 166. On the last flush spray rinse the fabric softener valve 72 and fill valve 45 are opened for thirty seconds permitting the fabric softener to be rinsed into the tub 34 and pump. Cold water and fabric softener valves 45, 72, are closed and the fabric softener is mixed with the last recirculating rinse water. The resulting solution is sprayed onto the clothes load in a recirculation loop for an additional two minutes to assure uniform application of the fabric softener. Additional fresh water is added through the cold water fill valve 45 if the water level sensor 140 becomes unsatisfied. The drain valve 166 is turned off permitting the final extraction of water and excess softener for sixty seconds in step 544.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification an description. It should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art.
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The present invention contemplates a rinse process which can be used with any wash cycle, but which has particular utility following a wash cycle have a highly concentrated detergent solution.
The method of rinsing fabric provided by the present invention is useful in a washer having a wash chamber rotatable about a horizontal axis. The steps undertaken in the method begin with loading fabric to be washed into the wash chamber of the washer. The fabric is then washed in a detergent solution while rotating the wash chamber about its horizontal axis for a first period of time. Next the detergent solution is drained from the wash chamber. The fabric is then rinsed by adding water to the wash chamber while spinning the wash chamber at a speed to effect less than a one gravity centrifugal force on the fabric such that the fabric will tumble within the wash chamber as it spins. Finally, the wash chamber is drained of the rinse water.
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The present invention claims benefit under 35 U.S.C §119(e) of a U.S. Provisional Patent Application of Dwayne Yount et al. entitled “Hardware and Electronics Architecture for a Flow Cytometer”, Ser. No. 60/203,515, filed May 11, 2000, of a U.S. Provisional Patent Application of Michael Lock et al. entitled “Cluster Finder Algorithm for Flow Cytometer”, Ser. No. 60/203,590, filed May 11, 2000, of a U.S. Provisional Patent Application of Michael Goldberg et al. entitled “User Interface and Network Architecture for Flow Cytometer”, Ser. No. 60/203,585, filed May 11, 2000, and of a U.S. Provisional Patent Application of John Cardott et al. entitled “Digital Flow Cytometer”, Ser. No. 60/203,577, filed May 11, 2000, the entire contents of each of said provisional patent applications being incorporated herein by reference.
CROSS-REFERENCE TO RELATED APPLICATIONS
Related subject matter is disclosed in a copending U.S. Patent Application of Pierce O. Norton entitled “Apparatus and Method for Verifying Drop Delay in a Flow Cytometer”, Ser. No. 09/346,692, filed Jul. 2, 1999, in a copending U.S. Patent Application of Kenneth F. Uffenheimer et al. entitled “Apparatus and Method for Processing Sample Materials Contained in a Plurality of Sample Tubes”, Ser. No. 09/447,804, filed Nov. 23, 1999, and in a copending U.S. Patent Application of Michael D. Lock et al. entitled “System for Identifying Clusters in Scatter Plots Using Smoothed Polygons with Optimal Boundaries”, Ser. No. 09/853,037, filed even date herewith, the entire contents of each of these applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system and method for providing improved event reading, data processing and system configuration capabilities in a flow cytometer. In particular, the present invention provides a system and method for use with a flow cytometer that enables the event reading components of the flow cytometer to capture and digitize substantially the entire optical waveform of each detected event, and provides improved, near real-time processing of the digitized waveform data and automated system configuration assessment capabilities.
2. Description of the Related Art
Flow cytometers known in the art are used for analyzing and sorting particles in a fluid sample, such as cells of a blood sample or particles of interest in any other type of biological or chemical sample. A flow cytometer typically includes a sample reservoir for receiving a fluid sample, such as a blood sample, and a sheath reservoir containing a sheath fluid. The flow cytometer transports the particles (hereinafter called “cells”) in the fluid sample as a cell stream to a flow cell, while also directing the sheath fluid to the flow cell.
Within the flow cell, a liquid sheath is formed around the cell stream to impart a substantially uniform velocity on the cell stream. The flow cell hydrodynamically focuses the cells within the stream to pass through the center of a laser beam. The point at which the cells intersect the laser beam, commonly known as the interrogation point, can be inside or outside the flow cell. As a cell moves through the interrogation point, it causes the laser light to scatter. The laser light also excites components in the cell stream that have fluorescent properties, such as fluorescent markers that have been added to the fluid sample and adhered to certain cells of interest, or fluorescent beads mixed into the stream.
The flow cytometer further includes an appropriate detection system consisting of photomultipliers tubes, photodiodes or other light detecting devices, which are focused at the intersection point. The flow cytometer analyzes the detected light to measure physical and fluorescent properties of the cell. The flow cytometer can further sort the cells based on these measured properties.
To sort cells by an electrostatic method, the desired cell must be contained within an electrically charged droplet. To produce droplets, the flow cell is rapidly vibrated by an acoustic device, such as a piezoelectric element. The droplets form after the cell stream exits the flow cell and at a distance downstream from the interrogation point. Hence, a time delay exists from when the cell is at the interrogation point until the cell reaches the actual break-off point of the droplet. The magnitude of the time delay is a function of the manner in which the flow cell is vibrated to produce the droplets, and generally can be manually adjusted, if necessary.
To charge the droplet, the flow cell includes a charging element whose electrical potential can be rapidly changed. Due to the time delay which occurs while the cell travels from the interrogation point to the droplet break-off point, the flow cytometer must invoke a delay period between when the cell is detected to when the electrical potential is applied to the charging element. This charging delay is commonly referred to as the “drop delay”, and should coincide with the travel time delay for the cell between the interrogation point and the droplet break-off point to insure that the cell of interest is in the droplet being charged.
At the instant the desired cell is in the droplet just breaking away from the cell stream, the charging element is brought up to the appropriate potential, thereby causing the droplet to isolate the charge once it is broken off from the stream. The electrostatic potential from the charging circuit cycles between different potentials to appropriately charge each droplet as it is broken off from the cell stream.
Because the cell stream exits the flow cell in a substantially downward vertical direction, the droplets also propagate in that direction after they are formed. To sort the charged droplet containing the desired cell, the flow cytometer includes two or more deflection plates held at a constant electrical potential difference. The deflection plates form an electrostatic field which deflects the trajectory of charged droplets from that of uncharged droplets as they pass through the electrostatic field. Positively charged droplets are attracted by the negative plate and repelled by the positive plate, while negatively charged droplets are attracted to the positive plate and repelled by the negative plate. The lengths of the deflection plates are small enough so that the droplets which are traveling at high velocity clear the electrostatic field before striking the plates. Accordingly, the droplets and the cells contained therein can be collected in appropriate collection vessels downstream of the plates.
Known flow cytometers similar to the type described above are described, for example, in U.S. Pat. Nos. 3,960,449, 4,347,935, 4,667,830, 5,464,581, 5,483,469, 5,602,039, 5,643,796 and 5,700,692, the entire contents of each patent being incorporated by reference herein. Other types of known flow cytometer, are the FACSVantage™, FACSort™, FACSCount™, FACScan™ and FACSCalibur ™ systems, each manufactured by Becton Dickinson and Company, the assignee of the present invention.
Although the flow cytometers described above can be suitable for reading events as intended, these existing systems do suffer from certain drawbacks. For example, in these types of instruments, the controller or central processing unit (CPU) does not ordinarily process the data obtained from reading the events in “real time”. However, it is desirable to process the data in real time or near real time to improve the efficiency of the flow cytometer and the ability to compare the readings of the events on a real-time or near real-time basis.
These existing systems also do not capture the entire image of the event. That is, when each event is read by detecting, for example, light fluorescing from the cell or particle of interest, these systems capture the “peak point” or peak intensity of the detected light. These systems also typically measure the duration during which the light is detected. By detecting these two parameters, the existing systems can use this data to determine characteristics of the event, such as the identity and size of a cell of interest. However, these techniques do not enable the existing systems to sample individual regions of the cell or particle of interest, nor are they capable of being performed on a real-time or near real-time basis. Furthermore, these systems are typically incapable of comparing data from multiple events effectively and in a real time or near real-time manner.
In addition, these types of existing systems do not provide a mechanism that indicates the configuration of the system to the operator effectively. For example, these types of systems are typically configured with multiple detector and filter arrangements that enable the different detectors to detect light having wavelengths within different wavelength regions. In such an arrangement, one detector can detect light with having a wavelength within the range of blue light, for example, while another detector can detect light having a wavelength within the range of green light. However, if an incorrect filter is placed in front of a particular detector, the detector will detect the incorrect light (e.g., green light instead of blue light). The system will therefore give erroneous results. However, the operator of the system will have difficulty determining which filters are arranged incorrectly, and in the worst case, the error may go unnoticed.
Accordingly, a need exists for an improved system and method for use with a flow cytometer to improve the event reading and data processing features of the flow cytometer to eliminate the above drawbacks.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a system and method for use with a flow cytometer to improve event reading and data processing capabilities of the flow cytometer, while also providing efficient system configuration assessment capabilities.
Another object of the present invention is to provide a system and method that enables a flow cytometer to capture and sample an entire waveform representative of an event being read, and which provides improved processing and analysis of the sampled data in a real-time or near real-time basis.
A further object of the present invention is to provide a system and method that is capable of indicating the configuration of a flow cytometer to an operator in an efficient and effective manner.
These and other objects are substantially achieved by providing a system and method for processing at least one signal representative of an event detected by at least one detector in a flow cytometer. The system and method employs a sampling device which is adapted to receive portions of the signal from the detector in time sequence and to generate a respective value representative of the respective magnitude of each respective portion of the signal as the respective portion of the signal is being received. The system and method further employ a storage device which is adapted to store the values generated by the sampling device. The sampling device can receive substantially all of the signal, and can generate the values which represent the portions of substantially all of the signal. The signal can be an analog signal representative of a light signal emitted from the event as detected by the detector. The system and method can further employ an arithmetic device which is adapted to, for example, subtract a designated value from each of the values generated by the sampling device. The designated value can be representative of an unwanted signal, such as crosstalk, detected by the detector, or can be representative of a characteristic of the detector. The sampling device can further be adapted to receive portions of a second signal from a second detector in time sequence and to generate a respective second value representative of the respective magnitude of each respective portion of the second signal as the respective portion of the second signal is being received, and the storage device can store the second values generated by the sampling device. The sampling device can receive the portions of the signal at a time different from that during which it receives at least some of the portions of the second signal, and the system and method can employ a comparator which is adapted to compare each of the second values with a respective one of the values to compare the signal to the second signal.
These and other objects are further substantially achieved by providing a system and for identifying a configuration of a detector unit of a flow cytometer. The system and method employ a port which is adapted to couple to a removable device that includes an optical clement, such as a mirror or filter, and a memory adapted to store information pertaining to the optical element. The system and method further employ a reader which is adapted to read the information stored in the memory when the removable device is coupled to the port. The system and method can also employ an indicator which adapted to provide an indication of the information read by the reader.
These and other objects are also substantially achieved by providing a removable device which is adapted for coupling with a port of a flow cytometer, and comprises an optical element, such as a filter or mirror, and a memory adapted to store information pertaining to the optical element.
BRIEF DESCRIPTION OF THE DRAWINGS
The various objects, advantages and novel features of the present invention will now be more readily appreciated from the following detailed description when read in conjunction with the accompanying drawings, in which:
FIG. 1 is a conceptual block diagram of the flow cytometer employing a system and method according to an embodiment of the present invention;
FIG. 2 is a cross-sectional view of the flow cytometer shown in FIG. 1;
FIG. 3 is a detailed view of an example of an emission block according to an embodiment of the present invention which is employed in the flow cytometer shown in FIGS. 1 and 2;
FIG. 4 is a top perspective view of an example of a support ring and flex circuits employed in the emission block shown in FIG. 3;
FIG. 5 is a bottom perspective view of the support ring and flex circuits shown in FIG. 4;
FIG. 6 is a side view of the support ring and flex circuits shown in FIGS. 4 and 5;
FIG. 7 is a conceptual top plan view of the emission block shown in FIG. 3;
FIG. 8 is a perspective view of an example of a removable mirror assembly for use with the emission block shown in FIG. 3 in accordance with an embodiment of the present invention;
FIG. 9 is a perspective view of an example of a removable mirror assembly for use with the emission block shown in FIG. 3 in accordance with an embodiment of the present invention;
FIG. 10 is a conceptual top view of the emission block shown in FIG. 3 illustrating exemplary paths in which light entering the emission block is reflected and propagates;
FIG. 11 is a block diagram illustrating an example of the electronic components employed in the flow cytometer shown in FIGS. 1 and 2 according to an embodiment of the present invention;
FIG. 12 is a block diagram illustrating anther example of the electronic components employed in the flow cytometer shown in FIGS. 1 and 2 according to another embodiment of the present invention;
FIGS. 13-16 are conceptual illustrations of an exemplary relationship between multiple lasers and multiple emission blocks in the flow cytometer shown in FIGS. 1 and 2 according to an embodiment of the present invention;
FIGS. 17-20 are conceptual block diagrams showing exemplary relationship between certain components shown in FIGS. 11 and 12;
FIG. 21 illustrates an example of a waveform as captured and sampled by the circuitry shown in FIGS. 11 and 12;
FIG. 22 is a conceptual block diagram of control circuitry for a PMT detector; and
FIGS. 23-27 illustrate exemplary waveforms and their processing by the circuitry shown in FIGS. 11 and 12 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A flow cytometer 100 employing an embodiment of the present invention is illustrated in FIGS. 1 and 2. As discussed in the background section above, the flow cytometer 100 includes a nozzle 102 having a flow cell 104 therein. The flow cytometer further includes a sample reservoir 106 for receiving a fluid sample, such as a blood sample, and a sheath reservoir 108 containing a sheath fluid. The flow cytometer transports the cells in the fluid sample in the cell stream to the flow cell 104 , while also directing the sheath fluid to the flow cell 104 .
Within the flow cell 104 , the sheath fluid surrounds the cell stream, and the combined sheath fluid and cell stream exits the flow cell 104 via an opening 110 as a sample stream. The opening 110 can have a diameter of, for example, 50 μm, 70 μm, 100 μm, or any other suitable diameter. As illustrated, due to characteristics of the sheath fluid, such as surface tension and the like, the sample stream remains intact until breaking off into droplets at the droplet break-off point 112 , which is at a certain distance from opening 110 . The distance from opening 110 at which the droplet break-off point 112 occurs, and the frequency or rate at which the droplets are formed, are governed by the fluid pressure, as well as the amplitude and frequency of oscillation of oscillating device 114 which can be, for example, a piezoelectric element.
As shown in FIG. 2, the oscillating device 114 is connected to an alternating voltage source 116 whose output voltage amplitude, frequency and phase is controlled by a controller 118 which can include, for example, a microprocessor or any other suitable controlling device. Further details of the controller 118 are described below. The amplitude of the alternating voltage signal output by alternating voltage source 116 can be increased or decreased by controller 118 to in turn increase or decrease the distance from opening 110 at which the droplet break-off 112 occurs. Likewise, the frequency of the alternating voltage signal output by alternating voltage source 116 can be increased or decreased by controller 118 to increase or decrease the rate at which droplets of sample fluid are formed at the droplet break-off point 112 .
To view the droplet break-off point 112 , a light source 119 , such an LED array, can be positioned in the region of the sample fluid stream containing the droplet break-off point 112 . The controller 118 can control the light source 119 to strobe at a described frequency, so that the detector 120 , such as a camera or other special viewing device, can be used to view the region of the sample fluid stream containing the droplet break-off point 112 . The flow cytometer 100 further includes at least one laser 122 , such as a diode laser, which is controlled by controller 118 to emit laser light. The emitted laser light intersects the sample stream at a point of interest 124 commonly referred to as a the interrogation point.
The laser 122 can be, for example, a red laser that emits light having a wavelength of at or about 633 nm, which is in the red light spectrum. Alternatively, laser 122 can be a blue laser that emits light having a wavelength of at or about 488 nm, which is in the blue light spectrum. Laser 122 also can be an ultraviolet laser that emits light having a wavelength of at or about 325 nm, or within the range of at or about 351 nm to at or about 364 nm, all of which are within the ultraviolet spectrum. As discussed in more detail below, flow cytometer 100 can include multiple lasers 122 that each emit their respective laser light to a respective interrogation point along the fluid flow stream. Also, if desired, a lens or filter 126 can be positioned between the laser 122 and the interrogation point 124 to filter out light of unwanted wavelengths from the laser light prior to its reaching the interrogation point 124 .
As further illustrated, the flow cytometer includes at least one fiberoptic cable 130 that receives laser light that has intersected the sample stream at the interrogation point 124 and has been scattered by the sample stream fluid and, in particular, by any cells or particles of interest present in the sample stream. The input port 132 of the fiberoptic cable 130 in this example is located in the same plane as the laser light being emitted from laser 122 , and at a 90° angle or about a 90° angle with respect to the direction of propagation of the laser light being emitted from laser 122 . The laser light scattered by the fluid stream and any cells or particles of interest at the interrogation point 124 is commonly referred to as side-scatter laser light.
As further illustrated, a detector 134 and filter 136 arrangement can be used to detect a portion of the laser light that has passed through the interrogation point 124 along the direction of propagation of the laser light being emitted by laser 122 , which is commonly referred to as the forward-scatter laser light. Also, if desired, an obscuration bar 138 can be position in the path of the forward-scatter laser light, in the path of the side-scatter laser light, or in both paths, to reduce the amount of side-scatter laser light entering fiber optic cable 130 or to reduce the amount of forward-scatter laser light entering detector 134 . The side-scatter laser light entering the fiberoptic cable 130 is input to an emission block 140 as described in more detail below.
As further shown in FIGS. 1 and 2, the flow cytometer 100 can include deflection plates 1142 and 1144 which can be controlled by controller 118 to allow droplets to pass to droplet collection container 1146 , or to deflect droplets that have been charged by charging unit 147 towards droplet collection containers 1148 and 1150 , as appropriate. In additional, a laser and filter arrangement 1152 and 1154 , detector and filter arrangement 1156 and 1158 , and detector and filter arrangement 1160 and 1162 , can be employed to monitor the manner in which the droplets are being deflected. Further details of the charging, deflection, and monitoring of the droplets are described in copending U.S. patent application Ser. No. 09/346,692, referenced above.
Further details of the emission block 140 will now be discussed with reference to FIGS. 3-10. As illustrated, emission block 140 includes a support ring 142 which can be made from stainless steel or any other suitable material. As shown, in particular, in FIGS. 4-6, support ring 142 has inner groves 144 in its inner surface and outer groves 146 in its outer surface. A first flex circuit 148 is mountable in support ring 142 . Specifically, the first flex circuit 148 includes projections 150 that are received into inner groves 144 of support ring 142 to thus mount the first flex circuit 148 inside support ring 142 . As can be appreciated by one skilled in the art, first flex circuit 148 is an integrated circuit board arrangement that includes a plurality of integrated circuits (not shown) and contact pads 152 that have contacts 154 which are adapted to provide connections to the circuitry in the first flex circuit 148 .
As further illustrated, a second flex circuit 156 is mountable to the support ring 142 . That is, the second flex circuit 156 includes projections 158 that can be received in the outer groves 146 of the support ring 142 to thus mount the second flex circuit 156 to the exterior of support ring 142 . An adhesive can be used to secure the first flex circuit 148 and the second flex circuit 156 to the support ring 142 . Like first flex circuit 148 , second flex circuit 156 is also an integrated circuit arrangement that includes integrated circuits 160 that are capable of carrying out certain data processing operation as discussed in more detail below. The second flex circuit 156 further includes contact pads 162 that include contacts 164 which provide connections to the circuitry in the second flex circuit 156 .
As further illustrated, the emission block 140 , first flex circuit 148 and second flex circuit 156 are housed within an outer housing 166 and inner housing 168 . As illustrated, the combination of the support ring 142 , first flex circuit 148 , second 156 , outer housing 166 and inner housing 168 form openings 170 and 172 as illustrated in FIG. 7 . Each of the openings 170 is configured to receive a mirror assembly 174 which includes a dichroic mirror 176 , the purpose of which is described in more detail below. Furthermore, each opening 172 is configured to receive a filter assembly 180 , the purpose of which is described in more detail below. In this example, emission block 140 is capable of receiving six mirror assemblies 174 - 1 through 174 - 6 and seven filter assemblies 180 - 1 through 180 - 7 (see FIGS. 7 and 10 ). However, the emission block 140 can be configured to include any suitable number of mirror assemblies 174 and filter assemblies 180 .
An example of a mirror assembly 174 is shown in FIG. 8 . As stated above, each mirror assembly 174 includes a dichroic mirror 176 that is capable of passing light having a particular wavelength (e.g., blue light) while reflecting light of all other wavelengths. The diachronic mirror assembly 174 includes a memory, such as an electrically, erasable read-only memory (EEPROM), in which is stored information pertaining to the type of dichroic mirror 176 in the mirror assembly 174 , along with other information such as the company of manufacture, the date and place of manufacture and so on, for purposes described in more detail below. The mirror assembly 174 further includes contacts 178 that provide electrical connection with the memory embedded in the mirror assembly 174 . Accordingly, when the mirror assembly 174 is inserted into an opening 170 as shown, for example, in FIG. 7, the contacts 178 of mirror assembly 174 engage with the contact 154 on the contact pads 152 of the first flex circuit 148 . Accordingly, the circuitry in the first flex circuit 148 can thus access the information stored in the memory of the mirror assembly 174 for the purposes described in more detail below.
A filter assembly 180 is shown in more detail in FIG. 9 . Filter assembly 180 includes a filter 182 that is capable of passing light of a certain wavelength (e.g., blue light) while blocking light of all other wave lengths. Furthermore, like mirror assembly 174 , filter assembly 180 includes a memory, such as ROM, in which is stored information pertaining to the type of filter 182 in the filter assembly 180 , the date, place, and company of manufacture, and so on. Filter assembly 180 also includes contacts 184 which provide electrical contact to the memory embedded in the filter assembly 180 . Accordingly, when the filter assembly 180 is inserted into an opening 172 as shown, for example, in FIG. 7, the contacts 184 of the filter assembly 180 engage with the contacts 164 on a contact pad 162 of the second flex circuit 156 . Hence, the circuitry in the second flex circuit 156 can then access the information stored in the memory of the filter assembly 180 for reasons discussed below.
As further shown in FIG. 3, for example, emission block 140 include a plurality of detectors 186 which, in this example, are photomultiplier tubes (PMTs). Each photomultiplier tube detector 186 has an opening therein (not shown) which is aligned with a dichroic mirror 176 in its respective mirror assembly 174 , and with a filter 182 in its respective filter assembly 180 , so that the detector 186 will receive light passing through its respective dichroic mirror 176 and filter 182 . Each detector 186 further includes a circuit board assembly 188 that include circuitry for processing the light received by its respective PMT detector 186 , as well as power and control circuitry for the PMT, as discussed in more detail below.
As shown in FIG. 3, for example, and in more detail in FIG. 10, the mirror assemblies 174 are angled so that the side-scatter laser light entering the emission block 140 from fiber optic cable 130 is reflected to all of the mirror assemblies 174 and to all of the filter assemblies 180 . Specifically, when the laser light enters the emission block 140 from fiber optic cable 130 , the laser light propagates to mirror assembly 174 - 1 . The dichroic mirror of mirror assembly 174 - 1 allows light having a certain wavelength to pass to filter assembly 180 - 1 , which also allows light of that wavelength to be detected by its respective detector 186 - 1 . Detector 186 - 1 outputs a signal representative of the detected light, which is processed as described in more detail below.
As further illustrated, the portion of the laser light reflected by mirror assembly 174 - 1 propagates to mirror assembly 174 - 2 , which functions in a manner similar to mirror assembly 174 . That is, the dichroic mirror of mirror assembly 174 - 2 allows light of a certain wavelength (e.g., green light) to pass to filter assembly 180 - 2 while reflecting light of all other wavelengths. Accordingly, the light passing to filter assembly 180 - 2 will pass through the filter of filter assembly 180 - 2 and be received by detector 186 - 2 , while the reflected light will propagate to mirror assembly 174 - 3 . As can be appreciated from the above description, mirror assemblies 174 - 3 through 174 - 6 will each allow light within a certain respective wavelength range to pass through to the corresponding filter assemblies 180 - 3 through 180 - 6 , respectively, while reflecting light of all remaining wavelengths. It is noted that the light reflected by mirror assembly 174 - 6 will propagate directly into filter assembly 180 - 7 , because no further reflection is necessary. Filter assembly 180 - 7 will therefore allow light within a respective wavelength to pass to its corresponding detector 186 - 7 .
As discussed above, each laser 122 (see FIG. 1) of the flow cytometer 100 is associated with a respective fiber optic cable 130 and emission block 140 . Accordingly, as discussed in more detail below, if flow cytometer 100 includes, for example, four different lasers 122 , then the flow cytometer will also include four emission blocks 140 , with each emission block 140 being associated with a respective laser 122 to receive side-scatter laser light in the manner described above.
An example of the electronics included in the flow cytometer 100 is shown in block diagram format in FIG. 11 . As discussed above, the flow cytometer 100 includes a controller 118 which, in this example, includes a data acquisition unit 190 , a status and control unit 192 , a droplet control module 222 and a fluidics control module 224 . As indicated, the data acquisition unit 190 includes a processor 194 which, in this example, is a real-time or near real-time CPU, such as a Pentium III processor or any other suitable processor. The processor 194 is coupled to the screen LCD 196 of the flow cytometer 100 , as well as a sample loader 198 and sample output device 200 . The processor 194 is further coupled to a hub 202 which provides data to and from work station 204 and processor 194 as described in more detail below. It is noted that the processor 194 provides the data pertaining to the event readings to the work station 204 in packet format in real-time or near real-time. The hub 202 further provides data to and from processor 194 and a prepper unit 206 which can be, for example, any type of sample preparation unit such as that described in U.S. patent application Ser. No. 09/447,804, referenced above.
The data acquisition unit 190 further include a plurality of data acquisition modules 208 that are each capable of acquiring data from respective circuit board assemblies 188 of the detectors 186 discussed above as described in more detail below. The data acquisition unit 190 further includes a master data acquisition module 210 that gathers the data from all of the other data acquisition modules 208 via a plurality of link-ports 211 and provides the data to processor 194 as discussed in more detail below.
As further illustrated, the processor 194 of data acquisition unit 190 communicates with the controller 212 of status and control unit 192 to control, for example, the fluid flow, drop delay, PMT driving voltage, and so on as described in more detail below. The status and control unit 192 include PMT modules 214 which, under the control of controller 212 , control the driving voltage of the PMT detectors 186 as discussed in more detail below. The status and control unit 192 further include a laser control module 216 which, under control of controller 212 , controls operation of laser 122 . The status and control unit 192 also includes a power and temperature control module 218 that controls, for example, the power to components of the flow cytometer 100 , as well as the temperature of the sheath and sample fluid.
In addition, status and control unit 192 further includes an emission identification (ID) module 220 that receives information from the first flex circuit 148 and second flex circuit 156 indicative of the locations of the mirror assemblies 174 and filter assemblies 180 , in the emission block 140 . That is, as discussed above, each mirror assembly 174 and filter assembly 180 includes a memory in which is stored information pertaining to its respective mirror or filter. The circuitry in the first flex circuit 148 is capable of accessing the memory in the filter assemblies 180 , and providing the content of this memory to the emission ID module 220 . Likewise, the circuitry in the second flex circuit 156 is capable of accessing the memories in the filter assemblies 180 and providing that information to the emission ID module 220 . The emission ID module 220 then can determine whether each of the mirror assemblies 174 and filter assemblies 180 are in the appropriate positions based on information pertaining to a desired configuration stored in a memory that was provided, for example, by work station 204 . If the emission ID module 220 determines that a mirror assembly 174 or filter assembly 180 is missing or in an incorrect location in the emission block 140 , or if an erroneous or faulty mirror assembly 174 or filter assembly 180 has been installed in the emission block 140 , emission ID module 220 will provide the appropriate data to, for example, the controller 212 , which can then provide the data to the processor 194 . The processor 194 can then provide this data to, for example, work station 204 , which can display an appropriate error message. This error message can indicate the location of the incorrect mirror or filter assembly in the emission block 140 , and the work station 204 can also display the filter and mirror configuration, which therefore greatly simplifies troubleshooting.
As further shown in FIG. 11, the master data acquisition module 210 , which is described in more detail below, receives from the data acquisition modules 208 event data that has been provided to the data acquisition modules 208 from the PMT detectors 186 of the emission blocks 140 . Prior to running the flow cytometer 100 to detect events, the work station 204 can download data via the hub 202 and processor 194 to the master data acquisition module 210 . This downloaded data is stored in a memory in the master data acquisition module 210 and indicates to the master data acquisition module 210 the channel configuration of the data acquisition modules 208 , so that the master data acquisition module 210 can recognize which channels of the data acquisition modules 208 are active, and the type of data (e.g., representative of side scatter blue light, side scatter red light and so on) that the data from each channel represents, as discussed in more detail below.
The master data acquisition module 210 further provides and receives data to and from the droplet control module 222 and the fluidics control module 224 to control the operation of the flow cytometer 100 in the manner described above. For example, the master data acquisition module 210 can receive high-speed clock data from the droplet control module 222 that gives the master data acquisition module 210 a time reference as to the rate of drop formation (e.g., 50 thousand drops per second). Master data acquisition module 210 can use this time base to synchronize a direction command signal which can be, for example, a four bit binary code, that the master data acquisition module 210 sends to the droplet control module 222 so that the droplet control module 222 can control the charging unit 147 (see FIG. 2) as appropriate to achieve the desired charging of the appropriate droplets containing a cell or particle of interest. By charging the droplet with the appropriate charge, the droplet control module 222 thus controls the amount and direction of deflection that the deflection plates 1142 and 1144 (see FIG. 2) deflect the charged droplet. The deflection plates 1142 and 1144 are included among the sorting hardware 235 shown in FIG. 11 . The droplet can be deflected, for example, to be received in one of any suitable number (e.g., sixteen) collection vessels 1142 , 1146 and 1150 .
In addition, the master data acquisition module 210 can receive data from the processor 194 that has been acquired by, for example, detectors 120 , 1156 and 1160 that provide information concerning the status of the break-off point 112 (see FIG. 1) as well as information pertaining to the droplet sorting. Based on this data, the master data acquisition module 210 can provide control signal to the droplet control module 222 to control, for example, drop delay, droplet formation and so on as discussed above with regard to FIGS. 1 and 2, processor 194 can further control the droplet control module 222 to control, for example, a cooling module 234 and an aerosol management module 236 to control the temperature of the sorted sample, for example, as well as to control sorting and aerosol containment management and safety devices in the flow cytometer 100 . It is also noted that the fluidics control module 224 can control the valve and pump drivers 226 , the agitation module 228 , the temperature control module 230 and the multiport valve HPLC 232 to control the temperature of the fluid sample and sheath fluids, to agitate the sample in the sample reservoir 106 (see FIG. 1 ), and to control the flow of fluids in the flow cytometer 100 .
It is further noted that the flow cytometer 100 need not include all of the electronics shown in FIG. 11 . For example, if the flow cytometer 100 is not equipped to perform droplet sorting, certain components shown in FIG. 11 can be omitted. As shown in FIG. 12, the hardware of the data acquisition unit 190 and status and control unit 192 can consolidated into a data acquisition unit 190 - 1 . The components of the data acquisition unit 190 - 1 , such as the processor 194 , data acquisition modules 204 and master data acquisition module 210 operate in a manner similar to those described above with regard to FIG. 11 . However, the data acquisition module 190 - 1 includes an SCI controller 238 which performs the operations performed by status and control I/F unit 192 shown in FIG. 11, such as controlling the driving voltages of the lasers 122 and power and temperature sensor module 218 which operates as described above. The SCI controller 238 further controls operation of the driving voltage of detectors 186 in a manner described below, and receives and processes the mirror and filter assembly position information received from the emission block 140 in a manner similar to the emission ID module 220 described above.
The operation of the above components in relation to the operation of flow cytometer 100 will now be described. As discussed above, flow cytometer 100 will typically employ more than one laser 122 to sample more than one type of cell or particle of interest, or more than one characteristic of a cell or particle of interest. The following discussion will assume that the flow cytometer 100 includes four lasers 122 , each emitting light having a different wavelength.
As discussed above and as shown conceptually in FIGS. 13-16, if the flow cytometer 100 includes four lasers 122 - 1 through 122 - 4 , then the flow cytometer 100 will include four corresponding fiber optic cables 130 - 1 through 130 - 4 that feed the respective side-scatter laser lights to the respective emission blocks 1401 through 140 - 4 . As further shown, the laser light emitted from these respective lasers 122 - 1 through 122 - 4 strike respective interrogation points 124 - 1 through 124 - 4 on the fluid stream. In this example, the interrogation points are displaced by about 133 micrometers along the direction of flow of the fluid stream, which translates into a spacing of about 22 microseconds for a fluid stream flowing at a rate of 6 meters per second. As shown in FIG. 16, this spacing also permits inter-laser mixing to occur. For example, the side scatter laser light from interrogation point 124 - 3 can enter the fiber optic cable 130 - 4 dedicated to receive side scatter laser light from interrogation point 124 - 4 . The mirror assemblies 174 and filter assemblies 180 in the emission blocks 140 - 1 through 140 - 4 can be configured to eliminate any light of undesired wavelengths as discussed above, in the event that unwanted inter-laser mixing occurs.
Further details of the relationship between the detectors 186 , a data acquisition module 208 , master data acquisition module 210 , processor 194 (real time CPU) and the work station will now be described with regard to FIGS. 17-21. In this arrangement, each data acquisition module 208 can receive data from four detectors 186 from any of the emission blocks 140 . For purposes of this discussion, data acquisition module 208 is configured to receive side scatter laser light that has been generated by the four different wavelength lasers 122 - 1 through 122 - 4 .
As illustrated, the analog data signals from the detectors 186 are input to their respective data acquisition module 208 as 2 MHz bandwidth (BW) analog signals. Further details of the data acquisition module are shown in FIGS. 18 and 19. That is, the signal from each detector 186 is input to a respective analog-to-digital (A/D) converter 240 where the analog data is converted into digital data. As illustrated, each A/D converter 240 have differential inputs to maximize common mode rejection of the received analog signals. The frequency (e.g., 10 MHz) at which the A/D converters 240 are operating enable the A/D converters 240 to take multiple samples (e.g., 10 or 20, or more) of the waveform as shown in FIG. 21 in real-time or near real-time. As indicated, the intensity of the signal will typically increase to a maximum when the particle or cell of interest is at the center of the interrogation point, and then drop-off to a minimum as the cell passes out of the interrogation point 124 . Accordingly, each individual sample of the waveform will have a value representing the characteristic (e.g., height) of that sampled portion of the waveform. This sampling of the entire or substantially the entire waveform improves the details at which the waveforms can be analyzed and compared, for example, to other waveforms representative of other events. Accordingly, this sampling allows for a more detailed sampling of the characteristics of each event.
The digital data output by each A/D converter 240 is provided to a respective delay circuit 244 which imposes a respective delay on the digital data as described in more detail below. As shown, for example, in FIG. 19, the delay imposed by each delay circuit 244 is set to compensate for the delays between the interrogation points 124 - 1 and 124 - 4 as shown in FIG. 15 or, in other words, to compensate for the time delay that occurs between when the side scatter light representative of a particle or cell of interest at interrogation point 124 - 1 is received by a detector 186 in emission block 140 - 1 and when the side scatter light representative of that particle or cell of interest reaching interrogation points 124 - 2 through 124 - 4 are subsequently received by detectors 186 in their respective emission blocks 140 - 2 through 140 - 4 .
The digital data from each delay circuit 244 is provided to a respective channel field programmable gate array (FPGA) circuit 246 , which provide the data to a Super Harvard Architecture Computer (SHARC) unit 248 . It is noted that each channel FPGA circuit 246 can process the characteristics of the data samples to produce data representing a single characteristic of the analog waveform, such as the width or height of the waveform, if desired, instead of passing all of the samples (e.g., 20 samples per waveform as discussed above) to the SHARC unit 248 . Also, the channel FPGA circuits 246 will add a time stamp to their respective data prior to passing the data to the SHARC 248 . Under the control of a programmable logic device, versa-module Eurocard interface (PLD VME I/F) unit 250 and a trigger FPGA unit 252 , the SHARC unit 248 provides the digital data via a link port 211 to the master data acquisition module 210 as indicated.
Specifically, prior to running the flow cytometer 100 to detect the events, the workstation 204 can download channel data to the trigger FPGA unit 252 of each data acquisition module 208 via the hub 202 and processor 194 . This channel data indicates to the channel FPGA circuits 246 whether they should collect the data from their respective delay circuits 244 , that is, whether they are receiving data on an active channel. The channel data further indicates to the trigger FPGA unit 252 when the trigger FPGA unit 252 should trigger the SHARC 248 to transfer the event data received in parallel from the channel FPGAs 246 to the master data acquisition module 210 via the link port 211 .
Details of the master data acquisition data module 210 are shown FIG. 20 . That is, the master data acquisition module 210 includes a multi-SHARC unit 256 that includes a SHARC event classification unit 258 , a SHARC drop classification unit 260 and a SHARC event assembly unit 262 , the details of which are described below. The master data acquisition module 210 further include a gate FPGA 264 , a logarithmic look-up table 266 , and a data FIFO unit 268 . Furthermore, the master data acquisition data module 210 includes an FPGA module 270 that includes a drop control FPGA 272 and a trigger FPGA 274 . The master data acquisition module further include a PLD VME I/F 276 . The details of these components are described below.
Specifically, prior to running the flow cytometer 100 to detect the events, the workstation 204 can download channel data to the trigger FPGA unit 274 of master data acquisition module 210 via the hub 202 and processor 194 . This channel data indicates to the trigger FPGA units 252 of each data acquisition module 208 whether they should trigger their respective SHARC 248 to transfer the event data received in parallel from the channel FPGAs 246 to the master data acquisition module 210 via their respective link port 211 . That is, when the trigger FPGA units 252 provide their respective indications to the trigger FPGA unit 274 indicating that event data has been received on their appropriate respective channels, the trigger FPGA unit 274 will signal the trigger FPGA units 252 to trigger their respective SHARCs 248 to transfer the event data received in parallel from the channel FPGAs 246 to the master data acquisition module 210 via the link port 211 .
When the master data acquisition module 210 receives the event data via the linkports 211 , the event data is input to the SHARC event assembly 262 . The SHARC event assembly 262 assembles the data into lists, tables or buffers based on their time-stamp that has been added by the channel FPGAs 246 . That is, the SHARC event assembly 262 uses the time stamps to determine which data is associated with which event.
If no sorting of cells is to be performed, the SHARC event assembly 262 passes the lists, tables or buffers of data to the data FIFO unit 268 . The data FIFO unit 268 sends the lists, tables or buffers of the data via the VME bus 254 to the processor 194 . The processor 194 can then provide the data to the work station 204 for further display in, for example, a scatter plot diagram, a graphical representation, and so on.
However, if cell sorting is to be performed, data received by the SHARC event assembly unit 262 is processed by the SHARC event classification unit 258 and SHARC drop classification unit 260 . For example, the flow cytometer 100 can be run to sample a portion of the cell sample to therefore provide initial sample data to the work station 204 as discussed above. The work station 204 can display the detected events on, for example, a scatter plot which can be reviewed by the operator. The operator can select certain cells of interest to be sorted by selecting, for example, a region on an interactive display screen of the work station 204 . The work station 204 can then pass the desired cell sorting data to the master data acquisition module 210 via hub 202 and processor 194 . The master data acquisition module 210 stores this cell sorting data in, for example, the logarithmic lookup SRAM 266 .
When the operator reactivates the flow cytometer 100 to continue processing the sample, the SHARC event classification unit 258 and SHARC drop classification unit 260 can access the data in the logarithmic lookup SRAM 266 in real-time or near real-time to determine which data received by the SHARC event assembly unit 262 represents cells to be sorted. The SHARC event classification unit 258 and SHARC drop classification unit 260 can then provide signals to the Drop Control FPGA 272 which can provide the appropriate direction command signal to the droplet control module 222 so that the droplet control module 222 can control sorting as discussed above. The SHARC event assembly 262 can then pass the lists, tables or buffers of data to the data FIFO unit 268 , which sends the lists, tables or buffers of the data via the VME bus 254 to the processor 194 as discussed above. The processor 194 can then provide the data to the work station 204 in real-time or near real-time for further display in, for example, a scatter plot diagram, a graphical representation, and so on.
Additionally, the event data can be used to process the sample waveforms in various ways. For example, the above system, in particular, the controller 212 (FIG. 11) or SCI controller 238 (FIG. 12) can adjust system can adjust the voltages applied to the detector 186 (PMTs) to adjust the relative zero point of the PMT detector 186 . For example, as shown in FIG. 22, the PMT and circuit board 188 includes a DC high voltage power supply 280 that provide the driving voltage to the PMT socket 282 that drives the PMT. The current from the PMT generated upon, for example, detection of side scatter light as described above is converted by a current voltage converter 284 so that the voltage signal is provided to the respective channel data acquisition module 208 as described above. Voltage control and serial control signal are provided from the PMT controllers 214 in, for example, the respective channel data acquisition module 208 to adjust the base voltage of the PMT, to therefore adjust the relative zero point of the PMT. Accordingly, this adjustment can be used to perform the gain adjustment as shown, for example, in FIG. 23 to increase the height of the smaller waveform to be consistent with the heights of the red and blue waveforms.
In addition, as shown in FIGS. 24-27, the SHARC event assembly 262 the master data acquisition module 210 can compare the entire sample wave form of data obtained from different detectors 186 and can perform different types of processing functions on this data in a real time or near-real time basis. For example, the event data representative of the red side scatter light signal received at time T can be delayed so that it can be compared with the event data representative of the blue side scatter light signal received at time T+1 as shown in FIG. 24, so that the signals can be time correlated as shown in FIG. 25 . Furthermore, as shown in FIGS. 26 and 27, the data signals can be processed to remove crosstalk that can occur as discussed above. In this event, the blue data represented as the “blue+red crosstalk” can be processed to remove a percentage of the red signal that is affecting the magnitude of the blue data, so that the magnitudes of the blue and red data can be made similar for comparison as shown in FIG. 27 .
Although only a few exemplary embodiments of the present invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims.
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A system and method for use with a flow cytometer to improve event reading and data processing capabilities of the flow cytometer, while also providing efficient system configuration assessment capabilities. The system and method enables the flow cytometer to capture and sample an entire waveform representative of an event being read, and provides improved processing and analysis of the sampled data in a real time or near real-time basis. The system and method further enable the flow cytometer to assess its configuration and provide assessment results to an operator in an efficient and effective manner.
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[0001] This application claims priority from U.S. provisional application No. 60/867,382, filed Nov. 27, 2006, the disclosure of which is herewith incorporated by reference.
BACKGROUND
[0002] Lights for stage and production operations are often heavy and awkward. These lights are intended to be remotely controlled, and also to project a high intensity light. The lights often include special bulbs and ballasts. The lights are mountable on trusses, but often very difficult to handle. Many devices, for example, require two men to carry them.
[0003] The lights are often rented, and after the rental is completed, they must be tested to be readied for the next rental. This means testing the lights.
SUMMARY
[0004] The present application teaches a special moving table and system that allows the lights to be automatically handled, tested and cleaned.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIGS. 1A-1C show handling of the lights;
[0006] FIG. 2 shows an interface board; and
[0007] FIG. 3 illustrates the moving light table.
DETAILED DESCRIPTION
[0008] The general structure and techniques, and more specific embodiments which can be used to effect different ways of carrying out the more general goals, are described herein.
[0009] This application recognizes that multiple handling of lights after a rental or other hire is inefficient. According to the present system, a device is disclosed which allows manually handling the lights only a single time, after which the lights are automatically processed. In an embodiment, the lights are attached both mechanically and electrically to an interface board that allows the lights to be electronically handled and also tested.
[0010] The embodiment refers to handling and control of “moving lights”, which in an embodiment are devices that are remotely controllable to move in pan and tilt directions, based on controls from a remote console. Moving lights also have beam parameters, like hue, saturation, beam size, intensity, and pattern that are all remote controllable as well as the above referenced pan and tilt. The moving lights may be of a type that has a base connection, and a moving head that is connected to and controlled by electronics in the base connection.
[0011] In an embodiment, a crane or other comparable device can be used to handle the lights. For example, the crane can be maneuvered to turn the lights upside down, an otherwise difficult operation. The crane can also be used to raise and lower the lights in and out of road cases and on and off the table.
[0012] FIGS. 1A-1C illustrate an embodiment that shows the way that the lights are handled.
[0013] When the lights are first removed from the truck or other transportation device, they are usually placed “upside down”, with the light part facing up, as shown in FIG. 1A . The lights are formed of two parts: a base part such as 100 , and a light producing part 105 . The light producing part 105 is movable relative to the control part 100 . When the lights are hung on trusses, the base part is connected to the truss, while the moving part 105 is controlled by and moved relative to the truss. However, the base part is often much heavier than the moving part (since the control part forms the anchor and never really needs to move). Accordingly, the lights can be maneuvered to place the control part downward. However, this is not the position in which the lights will be used, and hence this may not be the optimum position to test those lights.
[0014] In the embodiment, the lights are attached to a special interface board which is shown in FIG. 2 . The interface board is referred to as a “boogie board”. The boogie board includes a light mounting surface 200 , and also includes a connection portion 205 which includes connections that can make a connection to portions of the light which normally interface to the clamps that are used to hang the light. The light is connected to the connection portions 205 , 210 . The connection is then tightened to be thereby held on the interface board. An electrical connector portion 215 includes a light interfacing connector part 220 , and a test interfacing connector part 225 . These two connectors may be configurable depending on the light which is used, for example. The light interfacing connector 220 connects to the light which is attached to the board 200 . This provides power and control signals on the light's normal connectors for power and data. The power and control may be a generic connector with pigtail connections that are intended for use with multiple different devices, or it may be specific connectors that are directly connected into connectors on the light.
[0015] There may be more than two connectors on the Plug box, e.g., an XLR 5 pin for DMX, AMP 19 pin connector for Vari-Lite S300 lights that need Low voltage power, communication, and bulb power. An L620 connector may be provided for 208 volt power, a stagepin connector for 110 volt non dim power, another stagepin connector for 110 volt dimming, and finally an RJ45 Ethernet connector. More generally, there may be multiple connectors for multiple types of power and data configurations.
[0016] For example, the connectors may provide XLR connections for the DMX connection, and may also provide standard kinds of power connections. Connector 225 may similarly be configured in this way.
[0017] Once the light is connected on the interface board 199 , it can be automatically handled using a crane or winch. FIG. 1B illustrates how the lights can be placed on a table which allows the lights to be moved and tilted. The light 130 is placed on the table in a position where it can be moved along the table. The table also includes tiltable support parts, each controllable by a hydraulic arm 131 , which more generally may be, pneumatic, vacuum, or electromagnetic. When the arm 131 is extended, the table is tilted as shown in 133 , causing the light to be tilted under power. The light can then be tested in the tilted position. This position is closer to the light's normal operating position, and hence this may be a more realistic way of testing the light's operation. This also puts the maximum amount of physical strain on the light as well. If desired, the lights on the boards can also be handled by a crane and hung from trusses for testing. 140 shows a group of lights being hung from trusses so that the lights can be tested in their normal position.
[0018] In this embodiment, the connectors are fully modular connectors, that can be configured in any desired way for any desired light. For example, the connectors may have configurable shapes, pins and other features.
[0019] FIG. 3 illustrates the table and its test areas. The lights, on the interface boards, can be placed along the conveyor portion 300 of the table. The conveyor portion may move in an endless loop, moving the lights from one end to the other. Another embodiment may just form the conveyor as rollers along which the boards can be conveyed. In the embodiments, the conveyor portion is formed of slats 301 which allow open areas 302 in between adjacent slats. It may use rollers that are automated by rubber bands around the rollers and connected to a central line shaft with a single driving motor.
[0020] One or more testing stations such as 310 are provided. In the embodiment, the testing stations are hydraulically, pneumatically, vacuum, or electromagnetically controlled between a stowed position shown as 132 in FIG. 1B , and a tilted position shown as 133 in FIG. 1A . Each of the test stations have a provision for an interface board to be located, shown as 315 . The provision for the interface board includes an electrical connection 320 which plugs into the test interfacing connector part 325 . The board hence plugs into the connector 320 and allows powering up and testing the device in various ways. For example, a computer, shown as 325 , may provide a test program for each light, either automatically or under operator control. A power source 330 also is connected to the connectors 320 , and enables providing AC and/or DC power of various types to power the operations of the light.
[0021] In one embodiment, various sections along the conveyor include suction portions 340 . The suction portions create a downdraft through the open areas 302 in the slats. There may also be blowers such as 341 which blow on the lights to further remove debris whenever possible. This forms an area which is a downdraft section. Other portions of the workstation may carry out other functions. For example, a barcode scanner 355 may scan a barcode or other identifying indicia on the light to determine information about the light such as its model number or any identifying characteristics.
[0022] Once the identifying information has been read, the identifying indicia can indicate specific information about the light. That information can be used to determine information about the light, e.g., directly, or by looking up the information from a database. The looked-up information can include, for example, format and/or type of power to the light, and format of control signals.
[0023] The output of the scanner 355 is connected into the computer, to assist the computer in this determination. Moreover, while the scanner is shown separated from the detection stations, it should be understood that the scanner can be located at the detection stations, such that each detection station has its own scanner to facilitate testing of individual lights. As an alternative to a scan, a machine vision device can be used.
[0024] In the embodiment, any crane can be used to move the devices, for example a hydraulic crane from Spanco.
[0025] Although only a few embodiments have been disclosed in detail above, other embodiments are possible and the inventors intend these to be encompassed within this specification. The specification describes specific examples to accomplish a more general goal that may be accomplished in another way. This disclosure is intended to be exemplary, and the claims are intended to cover any modification or alternative which might be predictable to a person having ordinary skill in the art. For example, other resistance sizes can be used, and other devices can be tested in this way.
[0026] Also, the inventors intend that only those claims which use the words “means for” are intended to be interpreted under 35 USC 112, sixth paragraph. Moreover, no limitations from the specification are intended to be read into any claims, unless those limitations are expressly included in the claims. The computers described herein may be any kind of computer, either general purpose, or some specific purpose computer such as a workstation. The computer may be a Pentium class computer, running Windows XP or Linux, or may be a Macintosh computer. The computer may also be a handheld computer, such as a PDA, cellphone, or laptop.
[0027] The programs may be written in C, or Java, Brew or any other programming language. The programs may be resident on a storage medium, e.g., magnetic or optical, e.g. the computer hard drive, a removable disk or media such as a memory stick or SD media, or other removable medium. The programs may also be run over a network, for example, with a server or other machine sending signals to the local machine, which allows the local machine to carry out the operations described herein.
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A moving light test system allows connecting moving lights to an interface board and conveying the lights and orienting and testing the lights while they are attached to the board. The lights can be mechanically and electrically connected to the board, and once connected, can be tested in multiple ways without reconfiguring or removing the lights. The board has a connector that can be plugged in at various locations, and the board can also be handled by mechanical devices. In this way, once the light is connected to the board, it does not need to be re-handled. In addition, lights can be tested in different orientations.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is based upon and claims the benefit of priority of the prior Japanese Patent Application No. 2013-069154, filed on Mar. 28, 2013, and the Japanese Patent Application No. 2014-033156, filed on Feb. 24, 2014, the entire contents of which are incorporated herein by reference.
FIELD
The present invention relates to a cell culture device, a cell culture system and a cell culture method.
BACKGROUND
Cell culture devices are known in which cells are cultured while culture fluid is being delivered and circulated by a pump (fluid delivery device). Moreover Japanese Patent No. 4330436 describes a cell culture device provided with a gas chamber (air damper), and in which pulsations of a pump (fluid delivery device) are absorbed.
SUMMARY
Cell culture devices that deliver a culture fluid during cell culture need to deliver the culture fluid over a long period of time. As result, a high capacity syringe pump is required in cases in which a constant capacity pump such as a syringe pump is used to deliver fluid. Due to their bulkiness, such high capacity syringe pumps cannot be placed on a microscope stage, making it difficult to perform regular observation of the cell culture state. Moreover, large devices are less portable, so compact tubing pumps or the like are suited to culture fluid delivery.
An issue arises in that, due to their structure, pulsations in tubing pumps are unavoidable, so the flow rate of the culture fluid cannot be made constant. The present inventor has confirmed through repeated experimentation that cell death can be avoided by suppressing pulsations and maintaining the culture fluid flow rate within a constant range.
Even when a gas chamber is provided, sometimes pulsations of the pump (fluid delivery device) cannot be sufficiently absorbed, and the pressure of the culture fluid fluctuates and variation in the flow rate cannot be suppressed. Namely, if the volume of the gas chamber fluctuates due to a temperature change, its resilience as an air damper fluctuates and it becomes difficult to maintain a constant pulsation suppression function. Moreover, air inside the gas chamber expands if the temperature increases and there is a risk of gas bubbles becoming mixed in with the culture fluid. If the capacity of the gas chamber is increased in order to avoid the above issue, then the device becomes bulky. A compact cell culture device capable of suppressing pump pulsations is therefore desired.
Due to reasons such as pH regulation and cytotoxicity, culture fluid used in cell culture generally includes a carbonate component buffering system. The occurrence of gas bubbles, such as carbon dioxide gas bubbles, in the culture fluid due to factors such as temperature change becomes more likely as a result. Since these gas bubbles are a cause of cell death, the occurrence of gas bubbles needs to be suppressed. The present inventor performed the above investigation and identified the need for a cell culture device that is capable of suppressing pump pulsations and is capable of reducing gas bubble occurrence, and has arrived at the present invention.
In consideration of the above circumstances, an object of one aspect of the present invention is to provide a cell culture device, a cell culture system and a cell culture method that are capable of suppressing fluctuations in pressure in culture fluid and also capable of suppressing influx of gas bubbles into a cell culture section.
Solution to Problem
A cell culture device according to a first aspect of the present invention includes: a cell culture section that cultures cells; a storage section that stores a culture fluid; a flow path that connects the cell culture section and the storage section; a fluid delivery device that is provided at the flow path and that delivers the culture fluid from the storage section to the cell culture section; a pressure equalizing unit that is provided at the flow path and that suppresses fluctuations in pressure imparted to the culture fluid delivered to the cell culture section; and a pressurization unit that is provided at the flow path at a flow outlet side of the cell culture section and that applies a specific pressure to the culture fluid.
In the above aspect of invention, the culture fluid is delivered from the storage section to the cell culture section through the flow path by the fluid delivery device. The pressure equalizing unit provided at the flow path suppresses fluctuations in pressure imparted to the culture fluid delivered to the cell culture section. This thereby enables pulsations in the culture fluid to be to be constrained, and variations in the flow rate to be suppressed.
Moreover, the pressurization unit is provided at the flow path at the flow outlet side of the cell culture section. Gas within the culture fluid is suppressed from forming gas bubbles by the pressurization unit applying a specific pressure to the culture fluid, enabling death of cells caused by air bubbles to be avoided. As a result, for example, occurrence of gas bubbles can be suppressed even if the temperature of the culture fluid changes. Moreover, applying pressure to the culture fluid enables gas bubbles to be dissolved in the culture fluid. Furthermore, the pulsation can be further reduced when pressure is applied to the culture fluid, compared to cases disposed only with the pressure equalizing unit, without the pressurization unit.
Moreover, even when the flow rate of the culture fluid delivered by the fluid delivery device is changed, pulsations are suppressed by the pressure equalizing unit and the pressurizing unit, thereby enabling minor adjustments to the culture fluid flow rate to be made without sudden fluctuations in the culture fluid flow rate. This thereby enables delivery of the culture fluid at a flow rate that is appropriate for culture of the cells. As described above, providing a pressure equalizing unit, and further disposing a pressurizing unit to the flow path at the flow outlet side of the cell culture section, enables a practical cell culture device to be obtained.
A cell culture device according to a second aspect of the present invention is the first aspect, in which the pressure equalizing unit includes: a fluid chamber charged with the culture fluid; a flow inlet and a flow outlet that are formed to the fluid chamber and are connected to the flow path; and a flexible membrane that configures a portion of an inner wall of the fluid chamber, and that flexes according to pressure fluctuations in the fluid chamber.
In the above aspect of invention, the flow chamber volume increases and decreases due to flexing of the flexible membrane to match pulsations, enabling fluctuations in flow chamber pressure to be reduced. Moreover, in cases in which a gas chamber is employed to suppress pressure fluctuations, the volume of the gas chamber fluctuates corresponding to temperature changes, and the culture fluid flow rate is unstable. However, in the pressure equalizing unit of the present invention, due to employing the flexible membrane, the flow chamber volume does not increase or decrease even when the temperature changes, enabling the culture fluid flow rate to be stabilized.
A cell culture device according to a third aspect of the present invention is the second aspect, in which: the flow inlet and the flow outlet are formed at opposing end portions of the fluid chamber; and the fluid chamber is formed so as to gradually widen on progression from the end portions toward a center portion.
In the above aspect of invention, incorporation of gas bubbles when the flow chamber is being charged with the culture fluid is suppressed, enabling death of cells caused by gas bubbles to be avoided.
A cell culture device according to a fourth aspect of the present invention is the cell culture device according to the third aspect, in which the fluid chamber has a rhombus shape with rounded corners in plan view.
The above aspect of invention enables suppression of gas bubbles entering and residing in the corner portions of the rhombus shape.
A cell culture device according to a fifth aspect of the present invention is the cell culture device according to the first aspect, in which the pressurization unit includes a pressurization portion that is connected to the flow path, and that has a smaller cross-sectional area than the flow path; and a resilient membrane that configures a portion of a wall face of the pressurization portion, and that undergoes resilient deformation due to pressure of the culture fluid that has flowed into the pressurization portion.
The above aspect of invention enables pressure to be applied to the culture fluid merely by making the culture fluid flow into the pressurizing portion. When the culture fluid reaches a specific pressure or greater at this time, gas bubbles are dissolved in the culture fluid, enabling death of cells to be avoided. Moreover, for example, in cases in which a narrow width tube body is connected and pressure is applied, there is a possibility that cells become stuck in the tube body and the flow path pressure fluctuates. In contrast thereto, by configuring the portion of the pressurization portion wall face with the flexible membrane, the resilient membrane is capable of undergoing resilient deformation to widen the flow path width, thereby enabling suppression of cells becoming stuck.
A cell culture device according to a sixth aspect of the present invention is the invention according to the first aspect, in which a gas bubble removal part that removes gas bubbles is provided at the flow path at flow inlet side of the cell culture section.
The above aspect of invention enables gas bubbles in the culture fluid to be removed by the gas bubble removal part prior to the culture fluid flowing into the cell culture section, thereby enabling avoidance of gas bubbles flowing into the cell culture section and killing the cells therein.
A cell culture device according to a seventh aspect of the present invention according to the first aspect, in which plural pressure equalizing unit are provided.
The above aspect of invention enables greater suppression of fluctuations in pressure in culture fluid compared to a case in which only one pressure equalizing unit is provided. Moreover, the culture fluid flow rate can be more finely set.
A cell culture system according to a eighth aspect of the present invention includes the cell culture device of the first aspect, and a thermostatic container that houses the cell culture device.
The above aspect of invention enables cells to be cultured at a temperature appropriate for culture of the cells by housing the entire cell culture device in the thermostatic container. Moreover, occurrence of gas bubbles due to changes in ambient temperature can be suppressed. Note that an observation means, such as a microscope, may be included to the cell culture system in order to observe the cells grafted to the cell culture section.
A cell culture method according to a ninth aspect employs the cell culture device of the first aspect to culture cells, and the cell culture method includes: a process of adding cells to at least one of the cell culture section, the storage section, or the pressure equalizing unit; and a process of circulating the culture fluid within the flow path using the fluid delivery device while pressurizing the culture fluid within the flow path using the pressurization unit.
In the above aspect of invention, cells are added in the cell addition process to at least one of the cell culture section, the storage section, or the pressure equalizing unit. There is no particular constraint to the added cells, and they may be, for example, pluripotent cells. By adding the cells, secretions secreted by the cells flow into the culture fluid and flow into the cell culture section, enabling promotion of cell culture therein. Moreover, the culture fluid is circulated by the circulation process, enabling the culture fluid containing the secretions to be repeatedly delivered to the cell culture portion.
Advantageous Effects of Invention
Due to the configuration described above, the aspects of present invention enables provision of a cell culture device, a cell culture system and a cell culture method capable of suppressing fluctuations in pressure in culture fluid, and suppressing flow of gas bubbles into a cell culture section.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a plan view illustrating an overall configuration of a cell culture device according to a first exemplary embodiment.
FIG. 2A is a cross-section view viewed from a front face and illustrating a pressure equalizing mechanism according to the first exemplary embodiment, and FIG. 2B is a cross-section view taken along line 2 B- 2 B in FIG. 2A .
FIG. 3 is cross-section view viewed from a front face illustrating the pressure equalizing mechanism according to the first exemplary embodiment when a culture fluid is pulsating.
FIG. 4 is enlarged view viewed from a front face illustrating an air trap according to the first exemplary embodiment.
FIG. 5 is an exploded perspective view of a cell culture section according to the first exemplary embodiment.
FIG. 6 is a cross-section view of the cell culture section according to the first exemplary embodiment.
FIG. 7 is an enlarged cross-section view viewed from a front face illustrating a state prior to the culture fluid flowing in a pressurizing mechanism according to the first exemplary embodiment.
FIG. 8 is an enlarged cross-section view of relevant parts viewed from the front face illustrating a state in which the culture fluid is flowing in the pressurizing mechanism according to the first exemplary embodiment.
FIG. 9 is a graph illustrating a relationship between elapsed time and culture fluid flow rate in a cell culture device of a comparative example, to which neither a pressure equalizing mechanism, nor a pressurizing mechanism, are provided.
FIG. 10 is a graph illustrating a relationship between elapsed time and culture fluid flow rate in the cell culture device according to the first exemplary embodiment.
FIG. 11 is a plan view illustrating an overall configuration of a cell culture device according to a second exemplary embodiment.
FIG. 12 is a plan view illustrating a first modified example of a cell culture device.
FIG. 13 is a plan view illustrating a second modified example of a cell culture device.
DESCRIPTION OF EMBODIMENTS
First Exemplary Embodiment
Explanation follows regarding a cell culture system 100 provided with a cell culture device 10 according to a first exemplary embodiment of the present invention, with reference to the drawings. The cell culture system 100 according to the present exemplary embodiment is mainly employed in the culture of pluripotent cells, but is not limited thereto, and may also be employed as a device for culture of other cells. Herein, pluripotent cells refers to cells that are capable of differentiating into plural types of cells. For example, pluripotent cells include but are not limited to: embryonic stem cells (ES cells), germline stem cells (GS cells), embryonic germ cells (EG cells), induced pluripotent stem cells (iPS cells), pluripotent cells (Muse cells) derived from cultured fibroblasts or bone marrow stem cells and adult stem cells. Moreover, pluripotent cells may be derived from various kinds of organisms. Pluripotent cells derived from a mammal, including a human, are preferable, and pluripotent cells derived from a mouse or pluripotent cells derived from a primate are more preferable. Pluripotent cells derived from a human are particularly preferable.
Of the types of pluripotent cell, embryonic stem cells (ES cells) and induced pluripotent stem cells (iPS cells) in particular are expected to be employed in regenerative medicine in the near future. Embryonic stem cells (ES cells) used here refers to stem cells that are established from an inner cell mass of an early stage embryo (such as a blastocyst) of a mammal such as a human or a mouse, and that are pluripotent and capable of propagating by self-replication. Induced pluripotent stem cells (iPS cells) used here refers to stem cells that can be generated by introducing specified reprogramming factors into body cells in the form of DNA or a protein. In particular, induced pluripotent stem cells are artificial stem cells deriving from somatic cells that have substantially the same characteristics as ES cells, such as pluripotency and propagation by self-replication.
As illustrated in FIG. 1 , the cell culture system 100 according to the present exemplary embodiment is provided with an incubator 102 as a thermostatic container, and the cell culture device 10 is housed inside the incubator 102 . The incubator 102 , with inside temperature maintained at a specific temperature, needs to be of a size that can house the cell culture device 10 . Note that in the present exemplary embodiment, the temperature inside the incubator 102 is maintained at 37 degrees C. in order to perform cell culture at a temperature close to human body temperature, however the temperature is not limited thereto, and a suitable temperature for culture of the cells may be maintained. Moreover, use of a CO 2 incubator 102 as the incubator 102 is preferable.
The cell culture device 10 is principally provided with a cell culture section 12 , a reservoir (storage section) 14 , circulation pumps (fluid delivery device) 16 , pressure equalizing mechanisms (pressure equalizing unit) 18 , air traps (gas bubble removal part) 20 and pressurization mechanisms (pressurization unit) 22 . Tubes 24 A to 24 F are connected to each section, configuring circulation flow paths 26 . Note that in the present exemplary embodiment, of six channels formed to the cell culture section 12 , two of the channels are employed for performing culture. As a result, two each are provided of the circulation pumps 16 , the pressure equalizing mechanisms 18 , the air traps 20 and the pressurization mechanisms 22 , however configuration is not limited thereto, and more of the circulation flow paths 26 may be provided corresponding to the number of channels employed. Moreover, plural tubes 24 may be connected to a single circulation pump 16 .
Explanation follows regarding each section configuring the cell culture device 10 according to the present exemplary embodiment. The reservoir 14 is provided at the lower side in FIG. 1 , and culture fluid is stored inside the reservoir 14 . In the present exemplary embodiment, two circulation pumps 16 are connected to a single reservoir 14 , however configuration is not limited thereto, and an independent reservoir 14 may be provided for each of the circulation pumps 16 .
An appropriate culture fluid corresponding to the cells for culture may be selected for the culture fluid stored in the reservoir 14 . For example, a DMEM/F-12 culture fluid supplemented with 0.1 mM of 2-mercaptoethanol, 0.1 mM of non-essential amino acid, 2 mM of L-glutamic acid, 20% KSR and 4 ng/ml of bFGF is used as a culture fluid in order to culture ES cells. DMEM, DMEM/F12, or a DME culture fluid containing 10% to 15% FBS is used as a culture fluid for iPS cell induction. Moreover, commercially available culture fluids (such as culture fluid for mouse ES cell culture, culture fluid for primate ES cell culture, serum-free media and the like) may also be employed.
The circulation pumps 16 serving as the fluid delivery device are connected to the reservoir 14 through the tubes 24 A. Various fluid delivery pumps may be used as the circulation pumps 16 , but a compact pump with a low flow rate is preferred. In the present exemplary embodiment, peristaltic tubing pumps are used, as an example, however configuration is not limited thereto, and other pumps may also be used. Moreover, in the present exemplary embodiment, the culture fluid is delivered at an average flow rate of 0.75 μl/min or less.
The circulation pumps 16 suck up culture fluid from the reservoir 14 through the tubes 24 A and deliver the culture fluid to the tubes 24 B. Culture fluid inside the pressure equalizing mechanisms 18 , connected to the tubes 24 B, is thereby pushed out, and is delivered to the air traps 20 through the tubes 24 C. Culture fluid is delivered to the cell culture section 12 through the tubes 24 D in a similar way, and delivered onward to the reservoir 14 through the tubes 24 E. The culture fluid accordingly circulates around the cell culture device 10 with laminar flow. Note that laminar flow used here refers to flow in which lines of flow in a fluid are parallel to a wall face, and refers to a non-turbulent flow field. It is preferable to have laminar flow, with a flow field in which the flow speed is lower closer to the walls, with the flow speed becoming uniform at a certain distance or more from the wall face.
The pressure equalizing mechanisms 18 serving as pressuring equalizing unit are connected to the circulation pumps 16 through the tubes 24 B. As illustrated in FIG. 2A , each pressure equalizing mechanism 18 is principally provided with an upper block 40 , a lower block 42 and a flexible membrane 44 , the flexible membrane 44 being formed sandwiched between the upper block 40 and the lower block 42 . The upper block 40 and lower block 42 are resin blocks. A fluid chamber 46 is formed as a recess in a lower face of the upper block 40 .
The fluid chamber 46 is a space charged with the culture fluid, with a flow inlet 40 A that passes through an upper face of the upper block 40 formed to one length direction end portion of the fluid chamber 46 . The tube 24 B is connected to the flow inlet 40 A. A flow outlet 40 B that passes through the upper face of the upper block 40 is formed to a length direction other end portion of the fluid chamber 46 , and is connected to the tube 24 C.
As illustrated in FIG. 2B , the fluid chamber 46 is formed in a rhombus shape with rounded corners in plan view. This thereby enables suppression of air (gas bubbles) remaining within the fluid chamber 46 when culture fluid flows from the flow inlet 40 A to the flow outlet 40 B to charge the fluid chamber 46 . Moreover, in the present exemplary embodiment, by forming the flow inlet 40 A and the flow outlet 40 B at positions where the rhombus shape forms acute angles, the width of the fluid chamber 46 gradually widens from the flow inlet 40 A toward a center portion of the fluid chamber 46 , making gas bubbles less liable to be incorporated when the fluid chamber 46 is charged with the culture fluid. An acute angle θ is preferably from 5 degrees to 90 degrees, more preferably from 8 degrees to 60 degrees, and particularly preferably from 10 degrees to 30 degrees. Note that the corners of the fluid chamber 46 are not necessarily rounded, and the shape does not have to be a rhombus.
As illustrated in FIG. 2A , the flexible membrane 44 is adhered to the lower face of the upper block 40 , configuring a portion of an inner wall of the fluid chamber 46 . There are no particular limitations to the material for the flexible membrane 44 providing the material is capable of flexing enough to sufficiently change the volume of the fluid chamber 46 , and for example a resilient body such as a flexible resin or rubber, or a flexible metal, may be used. Obviously the flexible membrane 44 is formed of a material that does not react with the culture fluid.
When the fluid chamber 46 pressure increases due to, for example, pulsations of the circulation pump 16 , the flexible membrane 44 flexes downward and the fluid chamber 46 volume is increased, as illustrated in FIG. 3 . The fluid chamber 46 pressure is accordingly lowered, enabling fluctuations in the circulation flow path 26 pressure to be suppressed. Conversely, the flexible membrane 44 flexes upward when the fluid chamber 46 pressure decreases, and the fluid chamber 46 volume decreases. The fluid chamber 46 pressure is accordingly raised, enabling fluctuations in the circulation flow path 26 pressure to be suppressed. In this manner, the pressure can accordingly be equalized by flexing of the flexible membrane 44 corresponding to fluctuations in the fluid chamber 46 pressure.
Note that in the present exemplary embodiment, the flow inlet 40 A and the flow outlet 40 B are formed at the upper face of the upper block 40 and the culture fluid flows into the fluid chamber 46 from the vertical direction, however configuration is not limited thereto, and the flow inlet 40 A and flow outlet 40 B may be formed at two side faces of the upper block 40 , with the culture fluid flowing into the fluid chamber 46 from the horizontal direction.
As illustrated in FIG. 1 , the air traps 20 serving as the gas bubble removal part are connected to the pressure equalizing mechanisms 18 through the tubes 24 C. As illustrated in FIG. 4 , a trap main body 48 is provided to the air trap 20 , and the tube 24 C and the tube 24 D are connected to an upper face of the trap main body 48 . Moreover, a flow path 48 A linking together the tube 24 C and the tube 24 D is formed inside the trap main body 48 .
A trap portion 48 B that broadens the width of flow path 48 A is formed at a center portion of the flow path 48 A. The size of the trap portion 48 B is formed with appropriate dimensions corresponding to the culture fluid flow rate and the degree of gas bubble occurrence. As a result, when a gas bubble O occurs in the culture fluid flowing through the flow path 48 A, the gas bubble O floats upward while passing through trap portion 48 B, and is blocked by a wall face and trapped. The trapped gas bubble O may be vented by opening a vent pipe (omitted from the drawings) formed in the trap main body 48 , or may be removed by pressurization with the pressurization mechanism 22 .
As illustrated in FIG. 1 , the cell culture section 12 is connected to the air traps 20 through the tubes 24 D. The cell culture section 12 is a member in which cell culture is performed and is substantially rectangular shaped in plan view. As illustrated in FIG. 5 , the cell culture section 12 is provided with a resin plate 30 , a polydimethylsiloxane (PDMS) layer 32 and a glass plate 34 formed stacked in that order from the top downward. In a state in which a lower clamp 38 is disposed beneath the glass plate 34 , an upper clamp 36 is brought down from above the resin plate 30 , and the resin plate 30 , the PDMS layer 32 , and the glass plate 34 are sandwiched between the upper clamp 36 and the lower clamp 38 . In this state, bolts 41 are inserted through and fasten together with bolt holes 36 A formed to the upper clamp 36 and bolt holes 38 A formed to the lower clamp 38 , thereby forming the cell culture section 12 .
Six independent slit shaped grooves 32 A that form channels are formed to the PDMS layer 32 . In the present exemplary embodiment, the grooves 32 A are formed, as an example, with width of 0.5 mm, length of 20 mm, and depth of 0.5 mm, but the dimensions are not limited thereto, and the grooves 32 A may be formed with other dimensions. A flow inlet 32 B and a flow outlet 32 C are formed to each of the grooves 32 A. Note that in the present exemplary embodiment, the grooves 32 A are formed to the PDMS layer 32 , however a member made of a different material may be used. For example, a plastic, silicone resin, polymethylmethacrylate, polyurethane, polystyrene or glass may be used.
As illustrated in FIG. 6 , the tubes 24 D are connected to the flow inlets 32 B, and when culture fluid is delivered from the tubes 24 D into the cell culture section 12 , the culture fluid arrives at one end portion of a culture chamber 12 B formed at a lower portion of the cell culture section 12 . Cells are grafted inside the culture chamber 12 B, and are cultured by the culture fluid flowing as a laminar flow. The culture fluid that has passed through the culture chamber 12 B moves upward from the other end portion of the culture chamber 12 B, and flows out from tubes 24 E connected to the flow outlets 32 C.
As illustrated in FIG. 1 , the pressurization mechanisms 22 serving as the pressurization unit are connected to the cell culture section 12 through the tubes 24 E. The pressurization mechanisms 22 are mechanisms for pressurizing the culture fluid flowing in the circulation flow paths 26 to a specific pressure. As illustrated in FIG. 7 , each pressurization mechanism 22 is principally provided with an upper block 50 , a diaphragm base 54 , a diaphragm 56 serving as a resilient membrane, and a lower block 52 .
The upper block 50 and the lower block 52 are resin blocks. Two through holes 50 A, 50 B are provided to the upper block 50 , and the tubes 24 E, 24 F are inserted through each of the through holes 50 A, 50 B respectively. Moreover, inner tubes 58 , 60 are respectively inserted inside the tubes 24 E, 24 F, and the tubes 24 E, 24 F are respectively interposed between the inner tubes 58 , 60 and hole walls of the through holes 50 A, 50 B.
The lower block 52 is provided beneath the upper block 50 with a separation between lower block 52 and the upper block 50 . A through hole 52 A is formed at a center portion of the lower block 52 . As a result, the diaphragm 56 , explained later, does not contact with the lower block 52 when the diaphragm 56 undergoes downward resilient deformation. Note that a recessed portion may also be formed by hollowing out an upper face of the lower block 52 .
The diaphragm base 54 is provided between the upper block 50 and the lower block 52 . The diaphragm base 54 is a plate shaped resin member formed with a flow path 54 A that passes through the diaphragm base 54 at positions corresponding to the through holes 50 A, 50 B of the upper block 50 . The height of a center portion of the diaphragm base 54 is lower than that of a peripheral edge portion.
The diaphragm 56 is attached to a lower face of the diaphragm base 54 . The diaphragm 56 is a membrane shaped member capable of resilient deformation. In the present exemplary embodiment, the diaphragm 56 is formed with the same size to that of the diaphragm base 54 , however the size is not limited thereto, and the size may be different to that of the diaphragm base 54 , providing the size is sufficient to cover the flow path 54 A. Furthermore, the diaphragm 56 is adhered to the peripheral edge portion of the diaphragm base 54 , and a narrow portion 54 B that is narrower in width than the circulation flow paths 26 is formed between the diaphragm 56 and the center portion of the diaphragm base 54 .
When the culture fluid is delivered from the tube 24 E to the pressurization mechanism 22 , the culture fluid flows from the flow path 54 A of the diaphragm base 54 to the narrow portion 54 B. As illustrated in FIG. 8 , when this occurs the culture fluid is pressurized by the narrow portion 54 B and the diaphragm 56 undergoes downward resilient deformation, pushing the narrow portion 54 B outward. Restoring force accordingly acts on the resiliently deformed diaphragm 56 , applying force in a direction contracting the flow path 54 A, thereby pressurizing the culture fluid at the specific pressure. Note that in the present exemplary embodiment, the thickness of the diaphragm 56 and so on are adjusted so as to enable pressurization at 10 kPa, as an example, however the pressure is not limited thereto, and pressurization may be at a pressure of 10 kPa or more.
As illustrated in FIG. 1 , the reservoir 14 is connected to the pressurization mechanisms 22 through the tubes 24 F. The culture fluid delivered to the reservoir 14 is stored in the reservoir 14 , then sucked up by the circulation pumps 16 and circulated around the circulation flow paths 26 until the circulation pumps 16 stop.
Note that in the present exemplary embodiment, the cells are only grafted in the cell culture section 12 , however configuration is not limited thereto, and cells may be added to the reservoir 14 or the pressurization mechanisms 22 . Sometimes in such cases, secretions secreted by the cells are mixed in with the culture fluid circulated by the circulation pumps 16 , enabling promotion of culture of the cells in the cell culture section 12 .
Explanation follows regarding the operation of cell culture device 10 according to the present exemplary embodiment. The cell culture device 10 according to the present exemplary embodiment is provided with the pressure equalizing mechanisms 18 , thus enabling suppression of fluctuations in the culture fluid pressure due to pulsations of the circulation pumps 16 . As a result, the cells do not sustain damage resulting from pressure fluctuations in the culture fluid flowing in the cell culture section 12 .
Moreover, the pressurization mechanisms 22 , provided to the circulation flow paths 26 on the flow outlets 32 C side of the cell culture section 12 , pressurize the culture fluid delivered to the cell culture section 12 , thus enabling occurrence of gas bubbles in the culture fluid to be suppressed. Furthermore, applying the specific pressure, or greater, enables gas bubbles caught up in the circulation flow path 26 can be dissolved in the culture fluid. Suppressing gas bubbles from flowing into the cell culture section 12 in this way enables death of cells caused by gas bubbles to be avoided.
Moreover, the pressurization mechanisms 22 are formed using the diaphragm 56 that is capable of resilient deformation, enabling steady circulation of the culture fluid without cells in the culture fluid becoming stuck, even when the flow path 54 A is narrowed
Furthermore, in the cell culture device 10 according to the present exemplary embodiment, providing both the pressure equalizing mechanisms 18 and the pressurization mechanisms 22 enables a synergistic effect to be obtained. Namely, even when pressure fluctuations cannot be sufficiently suppressed by the pressure equalizing mechanisms 18 alone, pressurization of the culture fluid by the pressurization mechanisms 22 enables pressure fluctuations to be suppressed, and also enables occurrence of gas bubbles in the culture fluid to be suppressed.
Moreover, the culture fluid flow rate required in the cell culture device 10 according to the present exemplary embodiment is a low flow rate of 0.75 μl/min or less, enabling the overall size of the device to be made more compact. This thereby, for example, enables the whole device to be taken out from the incubator 102 and carried to a microscope to observe the culture chamber 12 B of the cell culture section 12 .
Moreover, just changing the flow rate settings of the circulation pumps 16 greatly affects pulsations when the culture fluid is delivered at a low flow rate, which might have potentially prevented fine adjustments from being performed to the flow rate. However, fluctuations in the flow rate are suppressed by providing the pressurization mechanisms 22 , enabling fine adjustments to the flow rate. By enabling fine adjustments to be made, culture conditions can be reproduced.
Test Example
The following tests were performed in order to confirm the advantageous effects of the cell culture device 10 according to the present exemplary embodiment.
Test 1: Using the cell culture device 10 according to the present exemplary embodiment, the flow rate of culture fluid delivered to the cell culture section 12 was measured using a micro flow meter, as illustrated in FIG. 10 . Moreover, for a cell culture device of a Comparative Example in which the pressure equalizing mechanisms 18 and the pressurization mechanisms 22 have been removed from the cell culture device 10 , the flow rate of culture fluid delivered to the cell culture section 12 was measured using a micro flow meter, as illustrated in FIG. 9 .
Test 2: Using the cell culture device 10 according to the present exemplary embodiment, the flow rate of culture fluid delivered to the cell culture section 12 was set at 0.3 μl/min, 0.5 μl/min and 0.7 μl/min, and for each case the number of iPS cells grafted to the culture chamber 12 B was counted using a microscope and entered into Table 1 on the first day and the third day after starting cell culture. Moreover, the same test was performed using the cell culture device of the Comparative Example described above. Note that the average flow rate of the culture fluid in the cell culture device of the Comparative Example was set at 0.5 μl/min. In all the tests, culture was performed inside a CO 2 incubator, and a 1.0×10 5 cells/ml culture fluid was employed.
It can be seen from the test results, as illustrated in FIG. 9 , that in the cell culture device of the Comparative Example, the pulsations of circulation pumps 16 are reflected unmodified in the flow rate, and the flow rate periodically fluctuated in a range of from −0.2 μl/min to 1.3 μl/min. Cells can sustain damage when such large fluctuations are present in the flow rate. As illustrated in Table 1, in the cell culture device of the Comparative Example that is not provided with the pressure equalizing mechanism 18 and the pressurization mechanism 22 , all the cells were dead by the third day.
In contrast, as illustrated in FIG. 10 , in the cell culture device 10 according to the present exemplary embodiment in which the pressure equalizing mechanisms 18 and the pressurization mechanisms 22 are connected, the pulsations are suppressed, and it can be confirmed that the culture fluid flow rate was stable at around 0.5 μl/min, demonstrating that the cell culture device 10 enables cell culture to be performed in a stable environment.
As illustrated in Table 1, in the cell culture device 10 according to the present exemplary embodiment, there was no occurrence of all the cells dying up to at least the third day. Moreover, in the cell culture device 10 according to the present exemplary embodiment, for all the flow rates set, the flow rate (measured values) fluctuation range was small, at 20% or less of the set values. Namely, the cell culture device 10 according to the present exemplary embodiment can be said to have a high resolution capability with regards to flow rate control, and setting values can be finely controlled by changing the set flow rate. For example, when seeking an appropriate flow rate for culture of the cells, the flow rate can be finely set and the determination precision of the most appropriate value can be increased by using the cell culture device 10 according to the present exemplary embodiment. Using the example illustrated in Table 1, at the set flow rates of 0.3 μl/min, 0.5 μl/min and 0.75 μl/min, there is no duplication of measured values, thereby enabling the effect at each rate set to be precisely compared and evaluated. Note that in the present example, it can be seen that a high cell survival rate can be achieved when the culture fluid flow rate is 0.5 μl/min. Note that the quantity ratio exceeds 100% owing to the fact that the cells have divided. When culturing cells, for example, finer adjustment is possible with respect to the set flow rate for cell cultivation, enabling culture under the most appropriate laminar flow conditions.
The one aspect of the present invention enables the flow rate (measured values) fluctuation range to be suppressed to within a range of from 0% to 50% of a set value. For example, the cell culture device 10 according to the present exemplary embodiment enables the flow rate (measured values) fluctuation range to be suppressed to within 3% to 30% of a set value.
TABLE 1
Pressure equalizing
mechanism and
Cell No. ratio
Flow rate
pressurizing
First day
Third day
(%) of third day
(μl/min)
mechanism present?
(Cell No.)
(Cell No.)
to first day
0.5
No
13.5
0
0
0.3
Yes
328
101
31
0.5
Yes
335
397
119
0.75
Yes
40
1
3
Second Exemplary Embodiment
Explanation follows regarding a cell culture device 70 according to a second exemplary embodiment of the present invention. Note that the same reference numerals are applied for configurations that are the same as in the first exemplary embodiment, and explanation thereof is omitted.
As illustrated in FIG. 11 , the cell culture device 70 according to the present exemplary embodiment is housed in an incubator 102 and maintained at 37 degrees C., similarly to the first exemplary embodiment. Moreover, the cell culture device 70 is provided with a cell culture section 12 , a reservoir 14 , circulation pumps 16 , pressure equalizing mechanisms 18 , air traps 20 and pressurization mechanisms 22 . Furthermore, second pressure equalizing mechanisms 72 are disposed between the air traps 20 and a culture chamber 12 B. The second pressure equalizing mechanisms 72 are connected to the cell culture section 12 by tubes 24 G.
The second pressure equalizing mechanisms 72 have a similar construction to the first pressure equalizing mechanisms 18 , and are configured so as to be capable of suppressing pressure fluctuations. Note that in the present exemplary embodiment, the second pressure equalizing mechanisms 72 are, as an example, provided between the air traps 20 and the cell culture section 12 , however configuration is not limited thereto, and the second pressure equalizing mechanisms 72 may be connected to other sections, for example between the pressure equalizing mechanisms 18 and the air traps 20 .
In the cell culture device 70 according to the present exemplary embodiment, culture fluid flows through the pressure equalizing mechanisms 18 and the second pressure equalizing mechanisms 72 , thereby enabling greater suppression of pulsations compared to in the first exemplary embodiment, in which only the pressure equalizing mechanisms 18 are provided.
The first exemplary embodiment and the second exemplary embodiment of the present invention have been explained above, however the present invention is not limited by these exemplary embodiments; a combination of the embodiments may be employed, and it goes without saying that various other embodiments may be implemented within a range not departing from the spirit of the present invention. For example, as illustrated in FIG. 12 , a cell culture device 80 without an air trap may also be employed.
Moreover, as illustrated in FIG. 13 , a cell culture device 90 in which culture fluid is delivered from reservoirs 14 in one direction without circulating in a flow path may also be employed. In this case, culture fluid delivered from reservoirs 14 to a cell culture section 12 is discharged into a waste fluid tank 92 through pressurization mechanisms 22 .
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To provide a cell culture device, a cell culture system and a cell culture method capable of suppressing fluctuations in pressure in a culture fluid, and suppressing gas bubbles from flowing into a cell culture section. A cell culture device including: a cell culture section that cultures cells; a storage section that stores a culture fluid; flow paths that connect the cell culture section and the storage section; a fluid delivery device that is provided at the flow paths and that delivers the culture fluid from the storage section to the cell culture section; a pressure equalizing unit that is provided at the flow paths and that suppresses fluctuations in pressure imparted to the culture fluid delivered to the cell culture section; and a pressurization unit that is provided at the flow path at a flow outlet side of the cell culture section and that applies a specific pressure to the culture fluid.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to a padlock in particular to a padlock for securing and monitoring a switch of an industrial plant. The invention further relates to a set of padlocks, to a padlock housing and to a method of retrofitting a padlock.
[0002] A particular area of application of a padlock is in the field of occupational safety. There is the risk in connection with the servicing of industrial plants, for example, of a production machine, that the industrial plant deactivated for the purpose of service work is activated again by accident while the servicing work is still continuing. A substantial danger for the service engineer can result from this. It is therefore customary that the service engineer moves a switch associated with the industrial plant to an OFF position for the duration of the service work and secures it in this position, i.e. the switch is directly blocked or access to the switch is blocked. The named switch is typically an energy supply switch, for example a main electrical switch of a control device or of an energy supply device of the industrial plant (e.g. power switchbox). Alternatively to this, the named switch can, for example, be a valve of a liquid line or of a gas line.
[0003] In order to effectively avoid an accidental activation of the industrial plant by another person, each service engineer hangs a padlock on the named switch or on a blocking device associated with the switch before starting his work and locks said padlock. The switch is hereby secured in its OFF position, i.e. the switch cannot be moved accidentally back into an ON position by another person. When the service engineer has ended his work, he unlocks his padlock again and releases it from the switch. Each service engineer usually has his own individual padlock (or a plurality of his own individual padlocks) associated with him.
[0004] This procedure is also called locking out. The padlock used is accordingly called a lockout lock. The document U.S. Pat. No. 5,449,867 shows such a securing of an electric rocker switch by means of a padlock. It is known from the document U.S. Pat. No. 3,171,908 to secure the position of a rotary switch by means of a padlock.
[0005] So that a plurality of service engineers can block and release the switch again independently of one another, a plurality of receivers (e.g. eyelets) can be provided at the switch for hanging a plurality of lockout locks. This is known from the document U.S. Pat. No. 6,388,213, for example. If only a single receiver for a lockout lock is provided, a securing claw can be used which is hung into the respective eyelet of the switch or of the associated blocking device and which in turn has a plurality of hang-in eyelets for a respective padlock. Only when the last padlock has been removed from the securing claw, the securing claw can be removed from the switch so that it can again be brought into the ON position. Such a securing claw for use at an electric switchbox is known, for example, from documents U.S. Pat. No. 6,396,008, U.S. Pat. No. 5,365,757 and U.S. Pat. No. 3,667,259.
[0006] It is known in connection with such a securing of a switch of an industrial plant to equip the lockout lock having a lock body used with a housing of plastic, with a shackle being displaceably held at the lock body and with a lock cylinder being arranged in the lock body. The lock cylinder can selectively be brought from an open position into a locked position to lock the shackle to the lock body after the shackle has, for example, been hung into an eyelet of the switch. By forming the lock housing from plastic, a particularly light padlock results which is of advantage in the use as a lockout lock since the service engineers occasionally carry a plurality of lockout locks simultaneously. A housing of plastic can also contribute to a desired electrical insulation. By the use of a plastic housing, there is furthermore a particularly simple possibility of color marking the padlock. Such a lockout lock having a housing of plastic is known, for example, from documents U.S. Pat. No. 7,278,283 and U.S. Pat. No. 5,755,121.
[0007] Depending on the specific application or use, a customer may desire different designs of the lockout lock. It may for example be necessary to have a relatively long lock housing so that identity pictures or photos can be applied to the lock housing and/or warning messages can be printed on the lock housing in multiple languages. Such a modification of the exterior of the lockout lock should, however, not necessarily affect its interior (i.e. the lock body, particularly the locking mechanism including for example a lock cylinder, an associated key and displaceable locking members). It is also desirable that such a change of the design may be carried out fast and easily by a locksmith or a service unit. The known padlocks, however, require an enormous investment in inventory to meet the market's expectations for fast delivery of special versions, due to the numerous possibly required versions (e.g. color, size, shackle engagement length, cylinder configuration).
SUMMARY OF THE INVENTION
[0008] It is an object of the invention to provide a padlock which enables a reliable securing of a switch of an industrial plant with a simple design, and which allows for an easy and fast change of the exterior of the padlock.
[0009] Particularly, it is an object of the invention to provide a padlock which has a relatively long housing and which can be produced by retrofitting a standard size padlock. It is another object of the invention to provide a padlock which minimizes the necessary inventory investment.
[0010] This object is satisfied by a padlock having the features of claim 1 and in particular by a padlock comprising
a lock body defining first and second passages therein; a shackle having first and second shanks linearly displaceable in the first and second passages between a locked position and a released position, the first shank being withdrawn from the first passage and the second shank being retained in the second passage in the released position; a housing having a lock body reception space and a head space;
the housing comprising a reception groove at an outside thereof extending along the head space adjoining the first passage;
and the first shank at least partly overlapping the housing and being pivotable into and out of the reception groove about the second shank in the released position.
[0014] Such a padlock has a modular design which allows not only to exchange the lock body (including the locking mechanism) if necessary, but also the housing. Particularly, instead of a standard size housing of relatively short length a long housing may be used which for example has bilingual warning messages printed on its exterior. The padlock can be easily and quickly assembled from an existing padlock having a standard size housing and shackle by exchanging the housing and shackle, while optionally keeping the lock body if desired. As such, if a customer requires a padlock (particularly a lockout lock) having a relatively long housing, a locksmith or a service unit may simply provide an off-the-shelf or existing standard lock body with the housing according to the invention and an associated shackle. The padlock according to the invention and particularly its housing therefore in conjunction with standard size padlocks create a modular padlock system which allows an easy and fast modification of the padlock exterior design.
[0015] The housing including the reception groove can be manufactured very cheaply, particularly when the housing is made of plastic. For example, the housing can be made in an injection molding process. The associated shackle must be of corresponding length but can be of simple design. If an electrical insulation is desired for the use as a lockout lock, the shackle can be made of plastic, or the shackle can be made of a metal or a metal alloy having a plastic cover on the parts protruding from the housing during use.
[0016] As such, the invention minimizes the inventory investment and at the same time facilitates faster delivery of desired padlock configurations.
[0017] Moreover, by providing the housing with said reception groove a padlock is created which can only be opened by pivoting the padlock about the second shank in one direction. This also prevents the padlock from unnecessarily engaging plant parts when the lock is opened, since it cannot open about a full angle of 360° as is the case for prior art padlocks.
[0018] The padlock in accordance with the invention will be explained in the following only by way of example with reference to the drawings and by means of the dependent claims.
[0019] The invention further relates to a set of padlocks which comprise a first padlock, which is of prior art design, i.e. having a relatively short housing without a reception groove, and a second padlock having the herein described features.
[0020] The invention further relates to a padlock housing comprising:
a lock body reception space for receiving a lock body and a head space; and a reception groove at an outside of the housing extending along the head space for receiving a shank of a shackle of the padlock.
[0023] The invention further relates to a method of retrofitting a padlock, the padlock comprising a lock body defining first and second passages therein, a first shackle having first and second shanks linearly displaceable in the first and second passages between a locked position and a released position, and a first housing having a lock body reception space. The method comprises the steps of:
removing the first housing and the first shackle from the lock body; and mounting a second shackle and a second housing to the lock body;
wherein the second shackle is longer than the first shackle along an axis of the first passage; and wherein the second housing is longer than the first housing along the axis of the first passage, the second housing comprising a lock body reception space for receiving the lock body and a head space, and further comprising a reception groove at an outside of the second housing, wherein the reception groove extends along the head space and adjoins the first passage of the lock body.
[0026] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0027] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0028] FIG. 1 is a cross-sectional view through the center of a padlock from the front in accordance with the invention;
[0029] FIG. 2 is a perspective rear view of the padlock; and
[0030] FIG. 3 shows a set of padlocks comprising a padlock in accordance with FIG. 1 and a padlock having an identical interior and the same shackle engagement length (clearance) but a smaller sized standard housing.
DETAILED DESCRIPTION
[0031] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
[0032] Referring now to FIG. 1 , where a section through a padlock 10 is illustrated. The padlock comprises a lock body 12 , a U-shaped shackle 14 and a lock actuator 18 that are secured within the lock body 12 . The lock body 12 is incorporated in a housing 20 and terminated at an end (bottom side) by a plastic bumper 22 of the housing 20 . The lock body 12 further defines first and second passages 28 , 30 , within which respective first and second shanks 32 , 34 of the shackle 14 are slidably disposed.
[0033] The first and second shanks 32 , 34 include respective notches, which are selectively engaged by respective locking members 40 , 42 or bolt drivers of the lock actuator 18 to inhibit axial movement of the shackle 14 in the direction A when the lock is locked. The first shank 32 is shorter than the second shank 34 and may be withdrawn from the first passage 28 . The second shank 34 is slidably disposed within the second passage 30 but can not be withdrawn therefrom. More specifically, a shackle retaining pin 44 of the lock body 12 extends into a blocking notch 46 defined within the second shank 34 . The blocking notch 46 defines the range of slidable movement of the second shank 34 within the second passage 30 . The shackle retaining pin 44 inhibits a removal of the second shank 34 from the second passage 30 .
[0034] A rotatable plug 60 secured with a plug retaining pin 62 is operably engaged with the lock actuator 18 . The plug retaining pin 62 also serves as a rotational abutment for the plug 60 , i.e. a so-called stop pin. A key 48 is insertable into a keyhole of the plug 60 to enable rotation of the plug 60 between a first position and a second position. In the first position, which is shown in FIG. 1 , the plug 60 holds the lock actuator 18 in a locked condition. In the locked condition, the locking members 40 , 42 of the lock actuator 18 engage the notches of the first and second shanks 32 , 34 of the shackle 14 , thereby inhibiting axial movement of the shackle 14 in the direction A. In the second position, the plug 60 holds the lock actuator 18 in an unlocked condition (not shown). In the unlocked condition, the locking members 40 , 42 of the lock actuator 18 retreat from the notches of the first and second shanks 32 , 34 , enabling the shackle 14 to move in the direction A (and vice versa) by a distance X defined by the shackle retaining pin 44 and the blocking notch 46 of the second shank 34 . During the assembly of the padlock 10 the retaining pin 44 is only introduced into the lock body 12 in a loose manner as will be discussed in the following.
[0035] When the key 48 is turned to open the lock (not shown) it actuates the lock actuator 18 . A series of cylindrical pins 52 respectively biased with respect to a pin hole cover 84 via pin springs 54 permit the movement of the plug 60 via the key 48 only if bottom pins 56 align the cylindrical pins 52 at a shear line permitting movement of the plug 60 and hence of the lock actuator 18 .
[0036] As can be seen from FIG. 1 the housing 20 is of generally rectangular shape and is preferably made of plastic, as this is an electrically insulating and light weight durable material, which can be provided in a multitude of colors in a simple injection molding process. The different colors enable a color coding between different locks 10 and machine parts or operating/servicing personal (not shown).
[0037] In addition to housing the lock body 12 in a lock body reception space 64 , the housing 20 further comprises a head space 66 at its end 68 housing the second shank 34 of the shackle 14 . This means that a volume of the housing 20 between the lock body 12 and the end 68 (i.e. the top side) of the housing 20 is referred to herein as the head space 66 . For this purpose second shank 34 is guided within the head space 66 between the second passage 30 and the end 68 . The first shank 32 is guided in a reception groove 72 ( FIG. 2 ) arranged at an outside of the housing 20 in the region of the head space 66 adjoining the first passage 28 . In particular, the reception groove 72 is arranged at a corner of the housing 20 . The reception groove 72 extends coaxially with the first passage 28 and is parallel to the second passage 30 of the lock body 12 .
[0038] In the unlocked state of the padlock 10 , i.e. when the locking members 40 , 42 are retracted from the notches, the shackle 14 is slid upwardly (with respect to the drawing, it can naturally also slide in any direction A in which the padlock 10 is pointing in use) whilst the second shank 34 is retained in the housing 20 by means of the shackle retaining pin 44 . The distance X the shackle 14 is displaced in the direction A would actually be too small for allowing the pivoting of the first shank 32 about the second shank 34 since the first shank 32 still partly overlaps the housing 20 and the first shank 32 would thus still be stuck within the housing 20 . Accordingly, if the reception groove 72 were not provided, the padlock 10 would not function.
[0039] The shackle 14 and the lock body 12 are generally of metal or a metal alloy. For example, the lock body 12 can be formed by aluminum or an aluminum alloy to save weight. As can be seen from FIG. 1 the shackle 14 is at least partly covered with a plastic casing 76 at least in an external region of the padlock 10 , i.e. those parts of the shackle which in the locked state of the padlock are visible. The plastic casing 76 is provided to additionally electrically insulate the shackle 14 .
[0040] The housing 20 has a length which is at least substantially defined by the sum of a length of the lock body reception space 64 and a length of the reception groove 72 . In practice one would normally select the length of the reception groove 72 to correspond to at least 20% of a length of the housing 20 and to at most 80% of a length of the housing 20 . Other lengths are naturally possible, provided at least a part of the first shank 32 is still received by the reception groove 72 in the released state. In the example of FIG. 1 length of the reception groove 72 corresponds at least substantially to the length of the lock body reception space 64 .
[0041] A shank 32 , 34 is herein defined as a limb of the shackle 14 , the length of the shank 32 , 34 being defined as the dimension extending from a free end of the shank to the start of the curvature of the shackle 14 .
[0042] FIG. 2 shows a perspective rear view of the padlock 10 with an installed shackle 14 in the locked position. One can clearly see the reception groove 72 into and out of which the first shank 32 of the shackle 14 is pivoted in use in the released state of the padlock 10 , and which also allows a rectilinear movement of the first shank 32 of the shackle 14 along the direction A for inserting the first shank 32 into the first passage 28 of the lock body or for withdrawing the first shank 32 of the shackle 14 from the first passage 28 .
[0043] It also becomes clear from FIG. 2 that the front side of the housing 20 (hidden in FIG. 2 ) has a large surface not affected by the reception groove 72 . The large surface of the front side of the housing 20 offers enough space, for example, to print warning messages on the padlock 10 in multiple languages or to apply an identity photograph.
[0044] The invention also relates to a set of padlocks ( FIG. 3 ) comprising at least: a first padlock 110 and a second padlock 10 as herein described, the first padlock 110 including the same lock body as the second padlock 10 , but a smaller sized regular housing 120 and also a shorter shackle 114 (having first and second shanks 132 , 134 ). In general, the set can include multiple padlocks having a variety of housing lengths and associated reception groove lengths and shackle lengths. Since the plastic housing 20 can be manufactured very cheaply and since also the manufacture of the shackle 14 does not require great expense, the set of padlocks according to FIG. 3 can be provided based on the same type of internal lock body at low additional costs. As shown in FIG. 3 , the padlocks 10 , 110 can have the same engagement length (clearance) of the respective shackle 14 , 114 when the padlock 10 , 110 is locked.
[0045] If a customer requires a lockout lock having a long housing 20 (for example having warning messages in multiple languages printed on the housing 20 ), it is possible to retroactively convert a standard size first padlock 110 according to FIG. 3 to a so-called “long-body” type second padlock 10 by simply exchanging only the housings 120 , 20 and shackles 114 , 14 . Such a method of retrofitting a padlock includes the steps of: removing the housing 120 and the shackle 114 of the first padlock 110 from its lock body; and mounting instead the second shackle 14 and the second housing 20 to the lock body.
[0046] More particularly, the step of mounting the shackle 14 and the housing 20 to the lock body may generally comprise: inserting the second shank 34 of the shackle 14 into the second passage 30 of the lock body 12 (see FIG. 1 ); retaining the second shank 34 in the second passage 30 ; and subsequently encasing the lock body 12 by means of the housing 20 .
[0047] For example, the second shank 34 is introduced into the lock body 12 of the padlock 10 via the second passage 30 until the second shank 34 of the shackle 14 abuts at an end of the second passage 30 (see FIG. 1 ). Once the second shank 34 abuts the end of the second passage 30 the retaining pin 44 is introduced substantially perpendicular to the second shank 34 into a bore 45 , i.e. the shackle retaining pin 44 and the bore 45 are oriented in a transverse direction with respect to an axis of the second shank 34 of the shackle 14 . In this way the shackle 14 is retained in the second passage 30 and can only move in the direction A by the distance X. The retaining pin 44 is only introduced into the bore 45 in a loose manner, such that the retaining pin 44 can be removed again if necessary and the housing 20 and/or the shackle 14 can be exchanged without the need of a tool. During the assembly the housing 20 can already be positioned partly over the lock body 12 such that the bore 45 is still accessible and the second shank 34 can be introduced into the lock body 12 . Once the retaining pin 44 has been introduced into the lock body 12 , the housing 20 is slid further over the lock body 12 and the plastic bumper 22 is placed over the end of the housing 20 (for example forming a snap-fit) in order to secure the housing 20 to the padlock 10 .
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The invention relates to a padlock in particular to a padlock for securing and monitoring a switch of an industrial plant. The invention further relates to a set of padlocks, to a padlock housing and to a method of retrofitting a padlock.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a Continuation of U.S. application Ser. No. 11/635,485 filed Dec. 8, 2006, which is a Continuation of U.S. application Ser. No. 11/450,440 filed on Jun. 12, 2006, now issued U.S. Pat. No. 7,156,492, which is a Continuation of U.S. application Ser. No. 11/250,450 filed on Oct. 17, 2005, now U.S. Pat. No. 7,066,573, which is a Continuation of U.S. application Ser. No. 10/728,922 filed Dec. 8, 2003, now issued U.S. Pat. No. 6,997,545, which is a Continuation of U.S. application Ser. No. 10/102,700 filed on Mar. 22, 2002, now issued U.S. Pat. No. 6,692,113, all of which is herein incorporated by reference.
CO-PENDING APPLICATIONS
[0002] Various methods, systems and apparatus relating to the present invention are disclosed in the following co-pending applications filed by the applicant or assignee of the present invention:
[0000]
6,428,133
6,526,658
6,795,215
7,154,638
BACKGROUND OF THE INVENTION
[0003] The following invention relates to a printhead module assembly for a printer.
[0004] More particularly, though not exclusively, the invention relates to a printhead module assembly for an A4 pagewidth drop on demand printer capable of printing up to 1600 dpi photographic quality at up to 160 pages per minute.
[0005] The overall design of a printer in which the printhead module assembly can be utilized revolves around the use of replaceable printhead modules in an array approximately 8½ inches (21 cm) long. An advantage of such a system is the ability to easily remove and replace any defective modules in a printhead array. This would eliminate having to scrap an entire printhead if only one chip is defective.
[0006] A printhead module in such a printer can be comprised of a “Memjet” chip, being a chip having mounted thereon a vast number of thermo-actuators in micro-mechanics and micro-electromechanical systems (MEMS). Such actuators might be those as disclosed in U.S. Pat. No. 6,044,646 to the present applicant, however, might be other MEMS print chips.
[0007] In a typical embodiment, eleven “Memjet” tiles can butt together in a metal channel to form a complete 8/2 inch printhead assembly.
[0008] The printhead, being the environment within which the printhead module assemblies of the present invention are to be situated, might typically have six ink chambers and be capable of printing four color process (CMYK) as well as infrared ink and fixative. An air pump would supply filtered air through a seventh chamber to the printhead, which could be used to keep foreign particles away from its ink nozzles.
[0009] Each printhead module receives ink via an elastomeric extrusion that transfers the ink. Typically, the printhead assembly is suitable for printing A4 paper without the need for scanning movement of the printhead across the paper width.
[0010] The printheads themselves are modular, so printhead arrays can be configured to form printheads of arbitrary width.
[0011] Additionally, a second printhead assembly can be mounted on the opposite side of a paper feed path to enable double-sided high-speed printing.
SUMMARY OF THE INVENTION
[0012] According to an aspect of the invention, a printhead assembly comprises an elongate channel member of a metal alloy, a flexible elongate fluid carrier, and a series of printhead modules mounted to an external surface of the fluid carrier. The flexible elongate fluid carrier is positioned on a floor of the channel member, and defines a plurality of passages longitudinally extending along a length of the fluid carrier. The fluid carrier further defines a repeated pattern of holes on the external surface. The holes provide fluid communication from outside the fluid carrier to respective passages of the fluid carrier. Each printhead module includes an upper micro-molding and a lower micro-molding. The lower micro-molding has an air inlet slot in fluid communication with one of the plurality of passages via a hole of the repeated pattern of holes. The upper micro-molding has an exhaust hole aligned with the air inlet slot and through which air carried in one of the passages is expelled. Each repeated pattern of holes diagonally spans a width of the fluid carrier, and the repeated pattern of holes together span a length of the fluid carrier. The air expelled through the exhaust hole facilitates repulsion of a print media from the printhead.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings wherein:
[0014] FIG. 1 is a schematic overall view of a printhead;
[0015] FIG. 2 is a schematic exploded view of the printhead of FIG. 1 ;
[0016] FIG. 3 is a schematic exploded view of an ink jet module;
[0017] FIG. 3 a is a schematic exploded inverted illustration of the inkjet module of FIG. 3 ;
[0018] FIG. 4 is a schematic illustration of an assembled ink jet module;
[0019] FIG. 5 is a schematic inverted illustration of the module of FIG. 4 ;
[0020] FIG. 6 is a schematic close-up illustration of the module of FIG. 4 ;
[0021] FIG. 7 is a schematic illustration of a chip sub-assembly;
[0022] FIG. 8 a is a schematic side elevational view of the printhead of FIG. 1 ;
[0023] FIG. 8 b is a schematic plan view of the printhead of FIG. 8 a;
[0024] FIG. 8 c is a schematic side view (other side) of the printhead of FIG. 8 a;
[0025] FIG. 8 d is a schematic inverted plan view of the printhead of FIG. 8 b;
[0026] FIG. 9 is a schematic cross-sectional end elevational view of the printhead of FIG. 1 ;
[0027] FIG. 10 is a schematic illustration of the printhead of FIG. 1 in an uncapped configuration;
[0028] FIG. 11 is a schematic illustration of the printhead of FIG. 10 in a capped configuration;
[0029] FIG. 12 a is a schematic illustration of a capping device;
[0030] FIG. 12 b is a schematic illustration of the capping device of FIG. 12 a , viewed from a different angle;
[0031] FIG. 13 is a schematic illustration showing the loading of an ink jet module into a printhead;
[0032] FIG. 14 is a schematic end elevational view of the printhead illustrating the printhead module loading method;
[0033] FIG. 15 is a schematic cut-away illustration of the printhead assembly of FIG. 1 ;
[0034] FIG. 16 is a schematic close-up illustration of a portion of the printhead of FIG. 15 showing greater detail in the area of the “Memjet” chip;
[0035] FIG. 17 is a schematic illustration of the end portion of a metal channel and a printhead location molding;
[0036] FIG. 18 a is a schematic illustration of an end portion of an elastomeric ink delivery extrusion and a molded end cap; and
[0037] FIG. 18 b is a schematic illustration of the end cap of FIG. 18 a in an out-folded configuration.
DETAILED DESCRIPTION OF THE INVENTION
[0038] In FIG. 1 of the accompanying drawings there is schematically depicted an overall view of a printhead assembly. FIG. 2 shows the core components of the assembly in an exploded configuration. The printhead assembly 10 of the preferred embodiment comprises eleven printhead modules 11 situated along a metal “Invar” channel 16 . At the heart of each printhead module 11 is a “Memjet” chip 23 ( FIG. 3 ). The particular chip chosen in the preferred embodiment being a six-color configuration.
[0039] The “Memjet” printhead modules 11 are comprised of the “Memjet” chip 23 , a fine pitch flex PCB 26 and two micro-moldings 28 and 34 sandwiching a mid-package film 35 . Each module 11 forms a sealed unit with independent ink chambers 63 ( FIG. 9 ) which feed the chip 23 . The modules 11 plug directly onto a flexible elastomeric extrusion 15 which carries air, ink and fixitive (see channels 49 - 55 in FIG. 15 ). The upper surface of the extrusion 15 has repeated patterns of holes 21 which align with ink inlets 32 ( FIG. 3 a ) on the underside of each module 11 . The extrusion 15 is bonded onto a flex PCB (flexible printed circuit board).
[0040] The fine pitch flex PCB 26 wraps down the side of each printhead module 11 and makes contact with the flex PCB 17 ( FIG. 9 ). The flex PCB 17 carries two busbars 19 (positive) and 20 (negative) for powering each module 11 , as well as all data connections. The flex PCB 17 is bonded onto the continuous metal “Invar” channel 16 . The metal channel 16 serves to hold the modules 11 in place and is designed to have a similar coefficient of thermal expansion to that of silicon used in the modules.
[0041] A capping device 12 is used to cover the “Memjet” chips 23 when not in use. The capping device is typically made of spring steel with an onsert molded elastomeric pad 47 ( FIG. 12 a ). The pad 47 serves to duct air into the “Memjet” chip 23 when uncapped and cut off air and cover a nozzle guard 24 ( FIG. 9 ) when capped. The capping device 12 is actuated by a camshaft 13 that typically rotates throughout 180°.
[0042] The overall thickness of the “Memjet” chip is typically 0.6 mm which includes a 150-micron inlet backing layer 27 and a nozzle guard 24 of 150-micron thickness. These elements are assembled at the wafer scale.
[0043] The nozzle guard 24 allows filtered air into an 80-micron cavity 64 ( FIG. 16 ) above the “Memjet” ink nozzles 62 . The pressurized air flows through microdroplet holes 45 in the nozzle guard 24 (with the ink during a printing operation) and serves to protect the delicate “Memjet” nozzles 62 by repelling foreign particles.
[0044] A silicon chip backing layer 27 ducts ink from the printhead module packaging directly into the rows of “Memjet” nozzles 62 . The “Memjet” chip 23 is wire bonded 25 from bond pads on the chip at 116 positions to the fine pitch flex PCB 26 . The wire bonds are on a 120-micron pitch and are cut as they are bonded onto the fine pitch flex PCB pads ( FIG. 3 ). The fine pitch flex PCB 26 carries data and power from the flex PCB 17 via a series of gold contact pads 69 along the edge of the flex PCB.
[0045] The wire bonding operation between chip and fine pitch flex PCB 26 may be done remotely, before transporting, placing and adhering the chip assembly into the printhead module assembly. Alternatively, the “Memjet” chips 23 can be adhered into the upper micro-molding 28 first and then the fine pitch flex PCB 26 can be adhered into place. The wire bonding operation could then take place in situ, with no danger of distorting the moldings 28 and 34 . The upper micro-molding 28 can be made of a Liquid Crystal Polymer (LCP) blend. Since the crystal structure of the upper micro-molding 28 is minute, the heat distortion temperature (180° C.-260° C.), the continuous usage temperature (200° C.-240° C.) and soldering heat durability (260° C. for 10 seconds to 310° C. for 10 seconds) are high, regardless of the relatively low melting point.
[0046] Each printhead module 11 includes an upper micro-molding 28 and a lower micro-molding 34 separated by a mid-package film layer 35 shown in FIG. 3 .
[0047] The mid-package film layer 35 can be an inert polymer such as polyimide, which has good chemical resistance and dimensional stability. The mid-package film layer 35 can have laser ablated holes 65 and can comprise a double-sided adhesive (ie. an adhesive layer on both faces) providing adhesion between the upper micro-molding, the mid-package film layer and the lower micro-molding.
[0048] The upper micro-molding 28 has a pair of alignment pins 29 passing through corresponding apertures in the mid-package film layer 35 to be received within corresponding recesses 66 in the lower micro-molding 34 . This serves to align the components when they are bonded together. Once bonded together, the upper and lower micro-moldings form a tortuous ink and air path in the complete “Memjet” printhead module 11 . In addition, an upper surface of the upper micro-molding 28 has a pair of opposed recesses 39 which serve as robot pick-up points for picking and placing the micro-molding.
[0049] There are annular ink inlets 32 in the underside of the lower micro-molding 34 . In a preferred embodiment, there are six such inlets 32 for various inks (black, yellow, magenta, cyan, fixitive and infrared). There is also provided an air inlet slot 67 . The air inlet slot 67 extends across the lower micro-molding 34 to a secondary inlet which expels air through an exhaust hole 33 , through an aligned hole 68 in fine pitch flex PCB 26 . This serves to repel the print media from the printhead during printing. The ink inlets 32 continue in the undersurface of the upper micro-molding 28 as does a path from the air inlet slot 67 . The ink inlets lead to 200 micron exit holes also indicated at 32 in FIG. 3 . These holes correspond to the inlets on the silicon backing layer 27 of the “Memjet” chip 23 .
[0050] There is a pair of elastomeric pads 36 on an edge of the lower micro-molding 34 . These serve to take up tolerance and positively located the printhead modules 11 into the metal channel 16 when the modules are micro-placed during assembly.
[0051] A preferred material for the “Memjet” micro-moldings is a LCP. This has suitable flow characteristics for the fine detail in the moldings and has a relatively low coefficient of thermal expansion.
[0052] Robot picker details are included in the upper micro-molding 28 to enable accurate placement of the printhead modules 11 during assembly.
[0053] The upper surface of the upper micro-molding 28 as shown in FIG. 3 has a series of alternating air inlets and outlets 31 . These act in conjunction with the capping device 12 and are either sealed off or grouped into air inlet/outlet chambers, depending upon the position of the capping device 12 . They connect air diverted from the inlet slot 67 to the chip 23 depending upon whether the unit is capped or uncapped.
[0054] A capper cam detail 40 including a ramp for the capping device is shown at two locations in the upper surface of the upper micro-molding 28 . This facilitates a desirable movement of the capping device 12 to cap or uncap the chip and the air chambers. That is, as the capping device is caused to move laterally across the print chip during a capping or uncapping operation, the ramp of the capper cam detail 40 serves to elastically distort and capping device as it is moved by operation of the camshaft 13 so as to prevent scraping of the device against the nozzle guard 24 .
[0055] The “Memjet” chip assembly 23 is picked and bonded into the upper micro-molding 28 on the printhead module 11 . The fine pitch flex PCB 26 is bonded and wrapped around the side of the assembled printhead module 11 as shown in FIG. 4 . After this initial bonding operation, the chip 23 has more sealant or adhesive 46 applied to its long edges. This serves to “pot” the bond wires 25 ( FIG. 6 ), seal the “Memjet” chip 23 to the molding 28 and form a sealed gallery into which filtered air can flow and exhaust through the nozzle guard 24 .
[0056] The flex PCB 17 carries all data and power connections from the main PCB (not shown) to each “Memjet” printhead module 11 . The flex PCB 17 has a series of gold plated, domed contacts 69 ( FIG. 2 ) which interface with contact pads 41 , 42 and 43 that are located, together with section 44 , on the fine pitch flex PCB 26 of each “Memjet” printhead module 11 .
[0057] Two copper busbar strips 19 and 20 , typically of 200 micron thickness, are jigged and soldered into place on the flex PCB 17 . The busbars 19 and 20 connect to a flex termination which also carries data.
[0058] The flex PCB 17 is approximately 340 mm in length and is formed from a 14 mm wide strip. It is bonded into the metal channel 16 during assembly and exits from one end of the printhead assembly only.
[0059] The metal U-channel 16 into which the main components are place is of a special alloy called “Invar 36”. It is a 36% nickel iron alloy possessing a coefficient of thermal expansion of 1/10 th that of carbon steel at temperatures up to 400° F. The Invar is annealed for optimal dimensional stability.
[0060] Additionally, the Invar is nickel plated to a 0.056% thickness of the wall section. This helps to further match it to the coefficient of thermal expansion of silicon which is 2×10 −6 per ° C.
[0061] The Invar channel 16 functions to capture the “Memjet” printhead modules 11 in a precise alignment relative to each other and to impart enough force on the modules 11 so as to form a seal between the ink inlets 32 on each printhead module and the outlet holes 21 that are laser ablated into the elastomeric ink delivery extrusion 15 .
[0062] The similar coefficient of thermal expansion of the Invar channel to the silicon chips allows similar relative movement during temperature changes. The elastomeric pads 36 on one side of each printhead module 11 serve to “lubricate” them within the channel 16 to take up any further lateral coefficient of thermal expansion tolerances without losing alignment. The Invar channel is a cold rolled, annealed and nickel plated strip. Apart from two bends that are required in its formation, the channel has two square cut-outs 80 at each end. These mate with snap fittings 81 on the printhead location moldings 14 ( FIG. 17 ).
[0063] The elastomeric ink delivery extrusion 15 is a non-hydrophobic, precision component. Its function is to transport ink and air to the “Memjet” printhead modules 11 . The extrusion is bonded onto the top of the flex PCB 17 during assembly and it has two types of molded end caps. One of these end caps is shown at 70 in FIG. 18 a.
[0064] A series of patterned holes 21 are present on the upper surface of the extrusion 15 . These are laser ablated into the upper surface. To this end, a mask is made and placed on the surface of the extrusion, which then has focused laser light applied to it. The holes 21 are evaporated from the upper surface, but the laser does not cut into the lower surface of extrusion 15 due to the focal length of the laser light.
[0065] Eleven repeated patterns of the laser ablated holes 21 form the ink and air outlets 21 of the extrusion 15 . These interface with the annular ring inlets 32 on the underside of the “Memjet” printhead module lower micro-molding 34 . A different pattern of larger holes (not shown but concealed beneath the upper plate 71 of end cap 70 in FIG. 18 a ) is ablated into one end of the extrusion 15 . These mate with apertures 75 having annular ribs formed in the same way as those on the underside of each lower micro-molding 34 described earlier. Ink and air delivery hoses 78 are connected to respective connectors 76 that extend from the upper plate 71 . Due to the inherent flexibility of the extrusion 15 , it can contort into many ink connection mounting configurations without restricting ink and air flow. The molded end cap 70 has a spine 73 from which the upper and lower plates are integrally hinged. The spine 73 includes a row of plugs 74 that are received within the ends of the respective flow passages of the extrusion 15 .
[0066] The other end of the extrusion 15 is capped with simple plugs 18 which block the channels in a similar way as the plugs 74 on spine 17 .
[0067] The end cap 70 clamps onto the ink extrusion 15 by way of snap engagement tabs 77 . Once assembled with the delivery hoses 78 , ink and air can be received from ink reservoirs and an air pump, possibly with filtration means. The end cap 70 can be connected to either end of the extrusion, ie. at either end of the printhead.
[0068] The plugs 74 are pushed into the channels of the extrusion 15 and the plates 71 and 72 are folded over. The snap engagement tabs 77 clamp the molding and prevent it from slipping off the extrusion. As the plates are snapped together, they form a sealed collar arrangement around the end of the extrusion. Instead of providing individual hoses 78 pushed onto the connectors 76 , the molding 70 might interface directly with an ink cartridge. A sealing pin arrangement can also be applied to this molding 70 . For example, a perforated, hollow metal pin with an elastomeric collar can be fitted to the top of the inlet connectors 76 . This would allow the inlets to automatically seal with an ink cartridge when the cartridge is inserted. The air inlet and hose might be smaller than the other inlets in order to avoid accidental charging of the airways with ink.
[0069] The capping device 12 for the “Memjet” printhead would typically be formed of stainless spring steel. An elastomeric seal or onsert molding 47 is attached to the capping device as shown in FIGS. 12 a and 12 b . The metal part from which the capping device is made is punched as a blank and then inserted into an injection molding tool ready for the elastomeric onsert to be shot onto its underside. Small holes 79 ( FIG. 13 b ) are present on the upper surface of the metal capping device 12 and can be formed as burst holes. They serve to key the onsert molding 47 to the metal. After the molding 47 is applied, the blank is inserted into a press tool, where additional bending operations and forming of integral springs 48 takes place.
[0070] The elastomeric onsert molding 47 has a series of rectangular recesses or air chambers 56 . These create chambers when uncapped. The chambers 56 are positioned over the air inlet and exhaust holes 30 of the upper micro-molding 28 in the “Memjet” printhead module 11 . These allow the air to flow from one inlet to the next outlet. When the capping device 12 is moved forward to the “home” capped position as depicted in FIG. 11 , these airways 32 are sealed off with a blank section of the onsert molding 47 cutting off airflow to the “Memjet” chip 23 . This prevents the filtered air from drying out and therefore blocking the delicate “Memjet” nozzles.
[0071] Another function of the onsert molding 47 is to cover and clamp against the nozzle guard 24 on the “Memjet” chip 23 . This protects against drying out, but primarily keeps foreign particles such as paper dust from entering the chip and damaging the nozzles. The chip is only exposed during a printing operation, when filtered air is also exiting along with the ink drops through the nozzle guard 24 . This positive air pressure repels foreign particles during the printing process and the capping device protects the chip in times of inactivity.
[0072] The integral springs 48 bias the capping device 12 away from the side of the metal channel 16 . The capping device 12 applies a compressive force to the top of the printhead module 11 and the underside of the metal channel 16 . The lateral capping motion of the capping device 12 is governed by an eccentric camshaft 13 mounted against the side of the capping device. It pushes the device 12 against the metal channel 16 . During this movement, the bosses 57 beneath the upper surface of the capping device 12 ride over the respective ramps 40 formed in the upper micro-molding 28 . This action flexes the capping device and raises its top surface to raise the onsert molding 47 as it is moved laterally into position onto the top of the nozzle guard 24 .
[0073] The camshaft 13 , which is reversible, is held in position by two printhead location moldings 14 . The camshaft 11 can have a flat surface built in one end or be otherwise provided with a spline or keyway to accept gear 22 or another type of motion controller.
[0074] The “Memjet” chip and printhead module are assembled as follows:
1. The “Memjet” chip 23 is dry tested in flight by a pick and place robot, which also dices the wafer and transports individual chips to a fine pitch flex PCB bonding area. 2. When accepted, the “Memjet” chip 23 is placed 530 microns apart from the fine pitch flex PCB 26 and has wire bonds 25 applied between the bond pads on the chip and the conductive pads on the fine pitch flex PCB. This constitutes the “Memjet” chip assembly. 3. An alternative to step 2 is to apply adhesive to the internal walls of the chip cavity in the upper micro-molding 28 of the printhead module and bond the chip into place first. The fine pitch flex PCB 26 can then be applied to the upper surface of the micro-molding and wrapped over the side. Wire bonds 25 are then applied between the bond pads on the chip and the fine pitch flex PCB. 4. The “Memjet” chip assembly is vacuum transported to a bonding area where the printhead modules are stored. 5. Adhesive is applied to the lower internal walls of the chip cavity and to the area where the fine pitch flex PCB is going to be located in the upper micro-molding of the printhead module. 6. The chip assembly (and fine pitch flex PCB) are bonded into place. The fine pitch flex PCB is carefully wrapped around the side of the upper micro-molding so as not to strain the wire bonds. This may be considered as a two step gluing operation if it is deemed that the fine pitch flex PCB might stress the wire bonds. A line of adhesive running parallel to the chip can be applied at the same time as the internal chip cavity walls are coated. This allows the chip assembly and fine pitch flex PCB to be seated into the chip cavity and the fine pitch flex PCB allowed to bond to the micro-molding without additional stress. After curing, a secondary gluing operation could apply adhesive to the short side wall of the upper micro-molding in the fine pitch flex PCB area. This allows the fine pitch flex PCB to be wrapped around the micro-molding and secured, while still being firmly bonded in place along on the top edge under the wire bonds. 7. In the final bonding operation, the upper part of the nozzle guard is adhered to the upper micro-molding, forming a sealed air chamber. Adhesive is also applied to the opposite long edge of the “Memjet” chip, where the bond wires become ‘potted’ during the process. 8. The modules are ‘wet’ tested with pure water to ensure reliable performance and then dried out. 9. The modules are transported to a clean storage area, prior to inclusion into a printhead assembly, or packaged as individual units. This completes the assembly of the “Memjet” printhead module assembly. 10. The metal Invar channel 16 is picked and placed in a jig. 11. The flex PCB 17 is picked and primed with adhesive on the busbar side, positioned and bonded into place on the floor and one side of the metal channel. 12. The flexible ink extrusion 15 is picked and has adhesive applied to the underside. It is then positioned and bonded into place on top of the flex PCB 17 . One of the printhead location end caps is also fitted to the extrusion exit end. This constitutes the channel assembly.
[0087] The laser ablation process is as follows:
13. The channel assembly is transported to an eximir laser ablation area. 14. The assembly is put into a jig, the extrusion positioned, masked and laser ablated. This forms the ink holes in the upper surface. 15. The ink extrusion 15 has the ink and air connector molding 70 applied. Pressurized air or pure water is flushed through the extrusion to clear any debris. 16. The end cap molding 70 is applied to the extrusion 15 . It is then dried with hot air. 17. The channel assembly is transported to the printhead module area for immediate module assembly. Alternatively, a thin film can be applied over the ablated holes and the channel assembly can be stored until required.
[0093] The printhead module to channel is assembled as follows:
18. The channel assembly is picked, placed and clamped into place in a transverse stage in the printhead assembly area. 19. As shown in FIG. 14 , a robot tool 58 grips the sides of the metal channel and pivots at pivot point against the underside face to effectively flex the channel apart by 200 to 300 microns. The forces applied are shown generally as force vectors F in FIG. 14 . This allows the first “Memjet” printhead module to be robot picked and placed (relative to the first contact pads on the flex PCB 17 and ink extrusion holes) into the channel assembly. This is further facilitated by a recess 59 formed in the body of each module 11 . 20. The tool 58 is relaxed, the printhead module captured by the resilience of the Invar channel and the transverse stage moves the assembly forward by 19.81 mm. 21. The tool 58 grips the sides of the channel again and flexes it apart ready for the next printhead module. 22. A second printhead module 11 is picked and placed into the channel 50 microns from the previous module. 23. An adjustment actuator arm locates the end of the second printhead module. The arm is guided by the optical alignment of fiducials on each strip. As the adjustment arm pushes the printhead module over, the gap between the fiducials is closed until they reach an exact pitch of 19.812 mm. 24. The tool 58 is relaxed and the adjustment arm is removed, securing the second printhead module in place. 25. This process is repeated until the channel assembly has been fully loaded with printhead modules. The unit is removed from the transverse stage and transported to the capping assembly area. Alternatively, a thin film can be applied over the nozzle guards of the printhead modules to act as a cap and the unit can be stored as required.
[0102] The capping device is assembled as follows:
26. The printhead assembly is transported to a capping area. The capping device 12 is picked, flexed apart slightly and pushed over the first module 11 and the metal channel 16 in the printhead assembly. It automatically seats itself into the assembly by virtue of the bosses 57 in the steel locating in the recesses 83 in the upper micro-molding in which a respective ramp 40 is located. 27. Subsequent capping devices are applied to all the printhead modules. 28. When completed, the camshaft 13 is seated into the printhead location molding 14 of the assembly. It has the second printhead location molding seated onto the free end and this molding is snapped over the end of the metal channel, holding the camshaft and capping devices captive. 29. A molded gear 22 or other motion control device can be added to either end of the camshaft 13 at this point. 30. The capping assembly is mechanically tested.
[0108] Print charging is as follows:
31. The printhead assembly 10 is moved to the testing area. Inks are applied through the “Memjet” modular printhead under pressure. Air is expelled through the “Memjet” nozzles during priming. When charged, the printhead can be electrically connected and tested. 32. Electrical connections are made and tested as follows: 33. Power and data connections are made to the PCB. Final testing can commence, and when passed, the “Memjet” modular printhead is capped and has a plastic sealing film applied over the underside that protects the printhead until product installation.
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A printhead assembly comprises an elongate channel member of a metal alloy, a flexible elongate fluid carrier, and a series of printhead modules mounted to an external surface of the fluid carrier. The flexible elongate fluid carrier is positioned on a floor of the channel member, and defines a plurality of passages longitudinally extending along a length of the fluid carrier. The fluid carrier further defines a repeated pattern of holes on the external surface. The holes provide fluid communication from outside the fluid carrier to respective passages of the fluid carrier. Each printhead module includes an upper micro-molding and a lower micro-molding. The lower micro-molding has an air inlet slot in fluid communication with one of the plurality of passages via a hole of the repeated pattern of holes. The upper micro-molding has an exhaust hole aligned with the air inlet slot and through which air carried in one of the passages is expelled. Each repeated pattern of holes diagonally spans a width of the fluid carrier, and the repeated pattern of holes together span a length of the fluid carrier. The air expelled through the exhaust hole facilitates repulsion of a print media from the printhead.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a probe card for connecting a wafer to be measured with a measuring device in a semiconductor wafer testing device.
[0003] 2. Description of the Related Art
[0004] Marked progress has been seen in the recent semiconductor manufacturing technology, including the progress of fine processing technology required for high density integration. For high density implementation as well as for suppression of heat generation and downsizing each elements, the current and voltage required for operation in the semiconductor devices are reduced year by year. Thus, the importance of microcurrent measurement has been recognized, and higher accuracies in microcurrent measurement are required in probe cards for connecting measuring devices and wafers.
[0005] Such a requirement is also present in the wafer process control testing. As a conventional testing method for process control, measurement chips referred to as TEG (Test Element Group) are formed at the same time as ordinary chips are formed on wafers for characteristic measurements. In such measurement, a probe card is used as an interface card between a measuring device and a wafer prober for moving and positioning a wafer to be measured, and is provided around its circular hole with a plurality of wafer contact needles also referred to as contact blades so as establish contacts with measuring terminals of the wafer.
[0006] In FIG. 10, a probe card is generally a circular disk 100 having a diameter from about 20 to 30 cm, with its central portion provided with an opening 102 through which contact needles or blades (not shown) can extend to contact with measuring terminals on a semiconductor wafer placed to be measured just under the probe card. Each wire 103 extends from each needle or blade located at the inner periphery toward the outer periphery where it is connected to a measuring device or the like. That is, a signal picked up from each terminal of a semiconductor wafer to be measured is introduced into the outer periphery of the probe card via each needle or blade, and is then sent to a measurement device from an external connection terminal 104 located on the outer periphery of the probe card. At that time, wires for connecting the semiconductor wafer to be measured with the measuring device are several tens in number and placed adjacent to one another. Guard patterns 105 formed with a conductor are located around the corresponding external connection terminals 104 . In the example shown in the drawing, the number of external connection terminals or pins is forty eight (48). Such a probe card is also known as a personality board or interface card. See Japanese Utility Model Provisional Publication (JP-A) No. Showa 64-47042, and Japanese Patent Provisional Publication (JP-A) No. Heisei 8-330369.
[0007] In general, such a probe card has external contact terminals 104 at its outer periphery for connection with a measuring device. Each contact terminal 104 is composed of a planar conductor provided on a substrate surface of the probe card, on which, for example, a conductor contact needle, such as a contact pin member which comprises a conductive rod with a circular cross-section provided with a spring at its base and surrounded by a cylindrical member such that on application of appropriate force the rod is retracted and biased by a reaction force so as to establish electrical contact by pushing the tip of the rod against a conductor surface, with a mechanism to provide secured electric contact is pushed against the planar conductor surface of the probe card, thereby to connect with an external apparatus such as a measuring device. Further, each external contact terminal 104 has a pattern extension portion 106 near its inner periphery, and a corresponding planar conductor on the surface of the probe card extends inwardly. To the pattern extension portion one end of a coaxial cable 103 is connected, and the other end of the coaxial cable is connected with a base end of a contact needle which has the shape of the needle or blade as described above. Namely, the coaxial cable 103 extends in the air between the pattern extension portion and the contact needle. The needle or blade is attached to the inner periphery of the probe card and extends inwardly therefrom. Further, the tip of the needle or blade extending inwardly is connected to a predetermined terminal on a semiconductor wafer to be tested.
[0008] As mentioned above, in the field of testing semiconductor elements, testing appliances which can measure microcurrents smaller than the currently used level are required. Also, the measuring accuracy of femtoampere order is required for interface cards used for wafer probers. Major problems on developing testing devices with such high performance include leakage current between adjoining electric wires for connecting a testing device and a semiconductor to be measured and dielectric absorption occurring between such wires and dielectrics in a probe card substrate.
[0009] For example, the problem of dielectric absorption occurs due to dielectric absorption properties (absorption current) of the dielectric used as the probe card substrate. Generally, insulating materials show dielectric polarization when a voltage applied across two electrodes changes, and absorb a current gradually until the polarization process is completed. Therefore, even if a predetermined voltage is applied to a semiconductor wafer for current measurement, the current measurement can not be performed correctly for a certain time period and a waiting time is necessary until the current flow becomes stabilized. A waiting time is also necessary when the voltage supply is terminated because a discharge current flows out gradually. For conventional interface cards for wafer probers, it is not unusual that such a waiting time for measurement may be several tens of seconds until the dielectric absorption current is reduced to a femtoampere order. This is one of important problems in case of reducing the time required for the microcurrent measurement.
[0010] As the measuring accuracy of a femtoampere order is now required, the leakage current flowing through a dielectric material between adjoining wires has also become important.
[0011] Among the components on the probe card as mentioned above, portions of the external contact terminal and the pattern extension portion tend to be affected by the dielectric absorption and current leakage. The coaxial cable extending from each pattern extension portion runs in the air so that it is little influenced by the dielectric absorption or current leakage. As the needle portion, for example, a coaxial highly insulating needle can be used, and a shield wire surrounding the core wire of this needle can be connected with a guard. In addition, insulation between adjoining needles having a portion of the needle wire not covered with the shield wire is good because it is achieved by air which has the same dielectric constant approximately as that of vacuum. Also, the response time of the dielectric polarization is not an issue.
[0012] To address these problems caused by the external contact terminal, conventionally, a plurality of through-holes are formed from electrodes on the surface through the probe card substrate such that the periphery of the electrodes can be defined. One example of such technologies is described in Japanese Patent Provisional Publication No. Heisei 8-335754.
[0013] One problem in such a method is that a distortion tends to occur in the probe card as the number of through-holes is increases, and that the physical strength of the card degrades in or near the region of the through-holes. Even if the number of the through-holes is increased regardless of manufacturing difficulties and cost elevation, some leakage current through the dielectric between these through-holes still remains as a problem, and a dielectric loss can not be reduced to a desired level as a higher level of measuring accuracy is required.
[0014] It has been noted that there are variations in the dielectric and leakage current properties of each wire for each probe card. Therefore, even if the manufacturing process control is improved sufficiently, such variations in the dielectric and current leakage properties of each wire for each probe card would limit the accuracy of current measurements. For example, in case of a currently used probe card with 48 pins after application of a voltage of about 10 volts, the leakage current 10 seconds after that voltage application of most pins is about 0.3×10 −13 A. However, such a leakage current of other specific pins becomes about 1 to 2×10 −13 A.
SUMMARY OF THE INVENTION
[0015] It is an object of the present invention to reduce a measuring waiting time resulted from dielectric absorption and decrease a steady-state leakage current so as to enhance accuracy of measuring microcurrents or fluctuations of them. It is another object of the present invention to reduce variations of properties of each pin or each probe card.
[0016] In light of the problems described above of the prior art, the present invention relates to a structure in which an external connection terminal for use in a probe card is surrounded by conductors.
[0017] The present invention provides a probe card which comprises a substrate and an external connection terminal disposed on the substrate, wherein the external terminal is separated from a substrate body via conductors attached to the substrate.
[0018] The conductors surrounding the external connection terminal in the present invention is preferably connected to a guard terminal, more preferably to an active guard terminal.
[0019] The conductor attached to the substrate surrounds the external connection terminal in the substrate. Assuming that the conductor has a box-like configuration, the bottom face of the conductor is located below the external terminal in the substrate, and the four side faces are located in the substrate and surround the external connection terminal from all quarters. The term “in the substrate” does not necessarily mean that the conductor is embedded in the substrate. That is, at least a portion of each conductor should appear from the substrate surface and may protrude therefrom. Further, when the substrate surface is recessed or notched, the conductor may be exposed in the recessed or notched portions of the substrate or protrude in the air.
[0020] In such a construction of the present invention, the microcurrent properties of femtoampere order can be enhanced so that the measuring accuracy can be improved. The waiting time resulted from the instability of the current due to the dielectric absorption can also be reduced. In addition, the substrate can include other electrical networks which could not be included in the substrate so far because of their possibility of degrading the microcurrent properties. Because the probe card of the present invention can be made in general in a planar structure (although it can have three-dimensional structures), it can be handled easily and reduce the cost for storage or transportation. Moreover, the present invention is compatible with currently available probe cards.
[0021] The substrate may have a mono-layered structure, but preferably it has a multi-layered structure. In a preferred embodiment, for example, conductive wires can be provided among layers, and via-holes or through-holes can be formed in a multi-layered substrate by one of commonly known technologies for manufacturing multi-layered substrates.
[0022] The probe card of the present invention can be manufactured in accordance with the following procedure, while it is not limited by any manufacturing processes. The external connection terminal surrounded by conductor can be produced, for example, by forming a recess in a substrate, providing a box-like external connection terminal portion in which an external connection terminal is formed on the top surface, and a conductor material is disposed on the side surfaces by plating or the like, and fitting the box-like external connection terminal portion in the recess. Alternatively, the external connection terminal can be produced by forming a recess in a substrate, disposing a conductor material in the recessed portion by plating or the like, and fitting or adhering in that recess a member composed of a box-like dielectric and an external connection terminal provided thereon. Otherwise, in case of a multi-layered substrate, the external connection terminal surrounded by conductors can be produced by placing a conductor pattern on an inner layer located below the external connection terminal, cutting a pattern surrounding the terminal and reaching the inner layer after lamination, and applying a conductor material into the cut pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 is a perspective view of a fundamental embodiment of the present invention with substrate portions around side and bottom conductors being eliminated.
[0024] [0024]FIG. 2 is a cross-section taken along line A-A of FIG. 1.
[0025] [0025]FIG. 3 is a cross-section corresponding to FIG. 2 showing another embodiment of the present invention.
[0026] [0026]FIG. 4 is a schematic diagram for approximately determining capacitance between an external connection terminal and each side surfaces of an embodiment of the present invention.
[0027] [0027]FIG. 5 is a perspective view of another embodiment of the present invention with substrate portions around side and bottom conductors being eliminated as shown in FIG. 1.
[0028] [0028]FIG. 6 is a perspective view corresponding to FIG. 5 showing yet another embodiment of the present invention.
[0029] [0029]FIG. 7 is a perspective view showing yet another embodiment of the present invention.
[0030] [0030]FIG. 8 is a cross-section of an embodiment in which gaps are provided within a substrate of the present invention.
[0031] [0031]FIG. 9 is a cross-section of another embodiment in which gaps are provided within a substrate of the present invention.
[0032] [0032]FIG. 10 is a top view of a probe card showing its entire construction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Several embodiments of the present invention will be described with reference to FIGS. 1 to 9 . FIG. 1 shows a fundamental embodiment of the present invention. In the same drawing surrounding substrate portions are eliminated to show external connection terminal 1 and a conductor material 2 , 3 , 4 placed around it. The conductor material 2 , 3 , 4 is electrically connected and equipotential to one another. On the substrate, the external connection terminal 1 and the upper guard pattern 2 surrounding the terminal 1 can be seen, both of which are composed of conductor. Over the external connection terminal 1 and the upper guard pattern 2 , three contact pin members 20 , 21 , 22 projecting from a test head of a semiconductor measuring device are positioned so as to contact with their corresponding targets. In this embodiment, the contact pin member 20 is a so-called “force” terminal for applying a voltage and measuring a current, the contact pin member 21 is a “sense” terminal for picking up a voltage to be measured. These force and sense terminals provide a Kelvin connection. The contact pin member 22 is a guard terminal for applying a voltage to the upper guard pattern 2 . The contact pin member 22 functions as a guard terminal in an active guard mechanism in which it is held equipotential to the force and sense terminals to block external influences on the external connection terminal or in a passive guard mechanism in which it is connected to a fixed voltage. The present invention is applicable to both active and passive guard mechanisms. In FIG. 1, these force and sense terminals are placed over the same external connection terminal 1 . However, two external connection terminals may be provided separately for the sense and force terminals, and each external connection terminal may be connected to a probe needle using a separate coaxial cable.
[0034] [0034]FIG. 1 shows external connection terminal 1 surrounded by the side conductors 3 and the bottom conductor 4 . The side conductors 3 and the bottom conductor 4 are connected electrically to each other, and also connected to upper guard pattern 2 . Ideally, the external connection terminal 1 is separated electromagnetically from a dielectric constituting the outer substrate via the side conductors 3 and bottom conductor 4 . However, as will be described below, complete electromagnetic separation is not required for some specific embodiments of the present invention. A core wire of coaxial cable 8 for connection with a probe needle is connected to the external connection terminal 1 , and the other external conductor of coaxial cable 8 is connected to the conductor 2 .
[0035] FIG. 2 shows a cross-section taken along line A-A showing a cross-sectional view of the substrate 10 . As shown in FIG. 2, the substrate is composed of two layers. The surface of the first layer 5 defines the surface of the substrate 10 , and the bottom conductor 4 is provided between the first layer 5 and the second layer 6 . This structure can be made by providing the conductor 4 using plating or the like on the bottom of the first layer 5 or the top of the second layer 6 . The side conductor 3 can be formed using plating or the like on faces created by cutting away a portion of the first layer 5 . Alternatively, the conductor can be formed by plating or the like on the side and bottom faces of the dielectric 7 to be fitted in the cut-away area in the first layer 5 .
[0036] Examples of materials which can be used for making the substrate 10 include synthetic resins commonly used for substrates of electric circuits, for example, glass-fiber-reinforced polycarbonates, polyimides, glass-epoxy resins, and other stocks, such as ceramics. Examples of materials used for the dielectric to be fitted in the substrate 10 for carrying the external connection terminal 1 thereon include synthetic resins similar to those used for the substrate 10 as well as materials with excellent insulating and dielectric properties, such as PTFE. It is also possible to make fine structures using materials other than those described above by application of the manufacturing technologies for producing integrated circuits and the micromachining technologies.
[0037] [0037]FIG. 3 shows another embodiment having a different cross-section from that of FIG. 2. In this embodiment, air gaps 9 are provided between the first layer 5 and the dielectric 7 carrying the external connection terminal 1 thereon. These gaps can greatly reduce capacitance between the external connection terminal 1 and the conductor 3 , 4 . In the configuration of FIG. 2, assuming that capacitance values C1 and C3 as shown in FIG. 4(A) between the external connection terminal 1 and the conductor 3 on its right and left sides are 10 pF, respectively, and assuming that capacitance C2 between the terminal 1 and the bottom conductor 4 is 10 pF, the total capacitance becomes 30 pF as the sum of them. In case of providing air gaps 9 as shown in FIG. 4(B), capacitance values C12 and C32 corresponding to these gaps 9 can be considered to be about 1 pF, respectively. Thus, for example, capacitance C1′ between the left side conductor 3 and the external connection terminal 1 is 0.9 pF as obtained by the following equation:
C1′=C12*C1/(C12+C1)=0.9 pF
[0038] Accordingly, the total capacitance is about 11.8 pF as obtained by C1′+C2+C3′ (C3′ is the capacitance between the right side conductor 3 and the external connection terminal 1 ), thereby significantly reducing the total capacitance.
[0039] In the structures shown in FIGS. 1 to 3 , each side conductor 3 may protrude from the surface of the substrate(not specifically shown). In such a structure, when the contact pin members 20 , 21 , 22 contact with the substrate surface, these pin members can not be seen from the outside, and an electromagnetic shield can be provided among these contact pin members.
[0040] [0040]FIG. 5 shows another embodiment in which the external connection terminals 31 , 32 can be seen only in areas where the contact pin members 20 , 21 for connection with an external measurement device will be in contact with them. Connection between these terminals 31 , 32 is provided by a conducting pathway 35 formed within the substrate. The terminal 33 can provide connection to a probe needle via a coaxial cable. In this embodiment, higher shielding properties can be obtained by forming a conductive pattern 34 which serves as an upper guard just near the periphery of external connection terminals 31 , 32 , 33 . Thus, the contact pin member 22 for measuring a guard potential can contact with an upper shield 34 . Further, the connection to a probe needle via a coaxial cable 8 can be replaced by a shielded conductive pathway formed in the substrate.
[0041] A partly or entirely meshed portion 40 , cut portions 41 , and notched portions 42 in the side conductor 3 are shown in FIG. 6(A) to FIG. 6(C), respectively. The conducting pathway 35 inside the substrate as shown in FIG. 5 can be disposed through cut portions 41 or notched portions 42 from the outside of the support structure of the external connection terminal 1 . In another embodiment of the present invention, one of the side surfaces corresponding to the side conductors 3 of the dielectric carrying the external connection terminal 1 thereon may be opened in place of covering all the surfaces including the bottom face with conductor. Such a structure is preferred for ease of manufacturing and flexibility of designing.
[0042] In FIGS. 1 to 3 , substrates 10 with a two-layered structure are shown as an example. Substrates having three or more layered structures, however, can be also applied to the present invention, and it is possible to use more complex structures utilizing substrates with a number of layers. In one example of such cases, it is possible to provide a structure in which the external connection terminal 1 is positioned lower than the surface of the substrate 10 as shown in FIG. 7. In FIG. 7, four side faces of the substrate 10 are trimmed leaving the guard pattern 2 . The level of the external connection terminal 1 is lowered, while the side conductor 3 on the wall surfaces of the substrate 10 around the external connection terminal 1 protrude therefrom. Thus, when the contact pin members 20 , 21 touch the terminal 1 , the side conductors 3 serve as an electromagnetic shield for the contact pin members 20 , 21 to prevent dielectric absorption due to potential differences between components of adjoing external connection terminals and the pin members.
[0043] As described with reference to FIGS. 3 and 4, by providing air gaps around the dielectric carrying the external connection terminal thereon, the capacitance between the external connection terminal and the surrounding conductor can be reduced significantly. Effects of dirt attachment to the surfaces constituting the gaps and humidity and the like may cause the degradation of insulating resistance and dielectric absorption properties. To prevent such undesired effects, the gaps can be sealed. FIGS. 8 and 9 show cross-sections of such structures, respectively. In the structures of FIGS. 8 and 9, an external connection terminal 51 extends up to the inside of the substrate 10 . The external connection terminal 51 is supported by a support dielectric 52 embedded in the substrate 10 . Gaps 54 are sealed by dielectric layers 53 , respectively. In the sealed gaps 54 , dry air or inert gas is filled. The external connection terminal 51 is exposed on the substrate surface, and upper guard conductor patterns 55 are formed surrounding the exposed portion. In FIG. 8, support dielectric 52 is in contact with the side and bottom conductor 56 , 57 . In FIG. 9, support dielectric 52 is in contact with the bottom conductor 57 , but is not in contact with the side conductor 56 . The structure as shown in FIGS. 8 and 9 is generally similar to the structure or principle of shield wires. Therefore, utilizing such a structure in place of the connection via coaxial cables or shield cables also makes it possible to connect the external connection terminal 51 with a probe needle.
[0044] The present invention has been described with reference to the above several embodiments. It is also possible, in specific applications, to substitute the coaxial cable for a single core cable with a high insulating coat typically represented by PTFE (Teflon®) or the like to be used for connection with a probe needle.
[0045] The probe card of the present invention as described above can reduce the waiting time due to the dielectric absorption occurring between different electric potentials, and reduce the steady-state leakage current to a negligible level. Moreover, since the insulating body located between different potentials card be shielded by conductors, variations in the microcurrent properties for each probe card or each contact pin member due to the inherent nature of the insulating body or unever manufacturing processes can be prevented.
[0046] The entire disclosure of Japanese Patent Application NO. 2000-36626 filed on Feb. 15, 2000 including the specification, claims, drawings and summary are incorporated herein by reference in its entirety.
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The present invention provides a probe card comprising a substrate and an external connection terminal located on substrate, wherein external connection terminal 1 is separated from a body of substrate by conductors attached to the substrate, whereby the waiting time due to dielectric absorption can be constantly shortened, and the steady-state leakage current can be stably reduced, thereby enhancing the accuracy of measuring microcurrents and determining microcurrent fluctuations for semiconductor wafer testing devices.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to power tools and, more particularly, to a system adapted to reposition a protective hood of a power tool and method of manufacturing the same.
2. Prior Art
U.S. Pat. No. 3,382,578 to Dobbertin discloses a power driven cutter tool with a safety shield. The tool has a knob on a clamp to adjust the shield. U.S. Pat. No. 3,969,856 to Zerrer discloses an adjustable protective hood with an arresting device comprising a handle and having an arresting element with a clamping surface. U.S. Pat. No. 4,060,940 to DeWitt discloses a tool with an adjustable guard. A knob is used to friction hold the guard in place. U.S. Pat. No. 4,402,241 to Moores, Jr. discloses a spindle lock with a spring biased pin. U.S. Pat. No. 3,177,909 Laube et al. discloses a spring biased pin used to lock a guard in position. Olympyk Corporation sells cut-off saws with a detent plate spot welded to its wheel guard. A pivotally mounted panel on an arm is used to lock and unlock the hood and arm.
A problem exists in the prior art in that prior art mechanisms for respositionally mounting a guard or hood have a relatively large number of parts or, the parts are relatively large and thus heavy. This increases the weight and size of the tool. For a tool such as a hand carried demolition saw, a heavy tool exhausts a worker more rapidly than a lighter tool.
Another problem exists in the prior art in that clamp or friction type fixing systems, although allowing repositioning of a guard or hood, do not provide a good assured fixation at all times and, are susceptible to wear and fatigue over prolonged use and time.
It is therefore an objective of the present invention to provide a new and improved system for repositioning a protective hood of a power tool and a method of manufacturing the same.
SUMMARY OF THE INVENTION
The foregoing problems are overcome and other advantages are provided by a new and improved system for repositioning a protective hood of a power tool and a method of manufacturing the same.
In accordance with one embodiment of the present invention, a power tool is provided comprising a frame, a motor, a circular cutting member, a hood, and means for repositionably fixing the position of the hood relative to the frame. The motor is connected to the frame. The circular cutting member is operably connected to the motor. The hood is rotatably connected to the frame and, at least partially, covers the cutting member. The means for repositionably fixing includes the hood having a plurality of lock member receiving areas and the frame having a lock member movably connected thereto. The lock member is adapted to be removably positioned into the receiving areas such that, when the lock member is located in one of the receiving areas, the hood is prevented from rotating relative to the frame and, the lock member can be removed from a receiving area to allow the hood to be repositioned relative to the frame.
In accordance with another embodiment of the present invention, a system for repositionably fixing a movable protective hood relative to a frame of a power tool is provided. The system comprises a locking member, means for biasing the locking member in a locked position, and means for moving the locking member from the locked position to an unlocked position. The means for biasing can bias the locking member in a locked position to lock the position of the hood relative to the frame. The means for moving includes a cam surface adapted to at least partially move the locking member.
In accordance with another embodiment of the present invention, a system for repositionably fixing a movable protective hood relative to a frame of a power tool is provided. The system comprises a detent plate, and a movement control. The detent plate is connected to the hood and has a plurality of notches. The movement control is connected to the frame and comprises a locking pin, a control knob connected to the locking pin, and means for longitudinally moving the locking pin into and out of the detent plate notches upon rotation of the control knob.
In accordance with one method of the present invention, a method of manufacturing a power tool is provided comprising steps of connecting a protective hood to a frame of the power tool, the hood having detent locking holes on one side thereof and the frame having means for rotating the hood relative to the frame about a first axis of rotation; and connecting a locking pin to the frame, the locking pin being axially longitudinally movable relative to the frame and having a front end adapted to be positioned in the detent locking holes at an offset from the first axis of rotation to prevent the hood from rotating relative to the frame.
DETAILED DESCRIPTION OF THE DRAWINGS
The foregoing aspects and other features of the invention are explained in the following description, taken in connection with the accompanying drawings, wherein:
FIG. 1 is a side view of a demolition saw incorporating features of the present invention.
FIG. 2 is a cross sectional view of the front wheel portion of the demolition saw shown in FIG. 1.
FIG. 3 is an exploded perspective view of portions of the front wheel portion of the demolition saw shown in FIG. 1.
FIG. 4 is a perspective view of an alternate form of cam sleeve for use in the embodiment shown in FIGS. 1-3.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, there is shown a side view of a demolition saw 10 incorporating features of the present invention. Although the present invention will be described with reference to the single embodiment shown in the drawings, it should be understood that the present invention can be used in various different types of power tools and is not limited to use in demolition saws. In addition, it should also be understood that the present invention is not limited to hand-held power tools but may also be used with other types of power tools or other types of machines having rotating or cutting members that may require a repositional guard or protective hood. The present invention may also be incorporated into various different types of embodiments. In addition, any suitable size, shape or type of elements or materials may be used to practice the present invention as further described below.
The demolition saw 10 shown in FIG. 1 generally comprises a frame 12, a motor 14, a front handle 16, and a front wheel portion 18. The motor 14, in the embodiment shown, is an internal combustion engine with a fuel tank 20 and an air filter 21. The frame 12, in the embodiment shown, is comprised of multiple members that are connected to each other and generally house the motor 14. The front handle 16 is fixedly mounted to the frame 12 and forms a rear handle 22.
Referring also to FIGS. 2 and 3, the front wheel portion 18 generally comprises a front wheel arm 24 that forms part of the frame 12, a cover plate 26, a drive system 28, a cutting wheel 30, a protective hood or guard 32, and a hood positive repositioning system 34.
The front wheel arm 24 has a rear end 36 and a front end 38. The rear end 36 has a channel 40 such that fasteners (not shown) can be passed therethrough to fixedly, but repositionably mount the arm 24 to the remainder of the frame 12. The repositionable feature of the arm 24 allows the arm 24 to be moved to provide appropriate tension to drive belt 42. The front end 38 also has a channel 44 for receiving a front driven shaft 46 and its bearings 47. The arm 24 is adapted to allow the drive belt 42 to move proximate its top and bottom sides 48 and 49. The arm 24 also has a guide 50 for leaf spring 52 and a cam channel 54 for receiving cam sleeve 56.
The cover plate 26 is adapted to be fixedly connected to the front arm 24 in order to cover the drive belt 42 and driven pulley 58 of the front drive system 28. In the embodiment shown, the cover plate 26 has a depression 60 having a general shape of a pie piece with a hole 62 therethrough. The depression 60 and hole 62 are intended to movably receive a lock control 64. The front drive system 28 generally comprises front driven shaft 46, bearings 47, driven pulley 58 and drive belt 42. The drive belt 42 is connected to a drive pulley (not shown) that is connected to the motor 14. The driven pulley 58 has the belt 42 thereon and is connected to the driven shaft 46. Thus, the motor 14 can rotate the drive pulley (not shown) which, in turn, causes the drive belt 42 to rotate between the drive pulley and the driven pulley 58, thus rotating the driven shaft 46 connected thereto. The bearings 47 allow the driven shaft 46 to rotate in the arm channel 44. The cutting wheel 30 is fixedly, but removably mounted to the driven shaft 46 by nut 66. The cutting wheel or blade 30 is a circular disk adapted to cut material such as concrete, stone, asphalt, steel, etc. As the driven shaft 46 rotates, it rotates the cutting wheel 30. However, any suitable drive system can be provided.
The protective hood 32 is generally semi-circular shaped with an interior chamber 68. The hood 32 to rotatably mounted to the arm 24 with the same axis of rotation as the driven shaft 46. In the embodiment show, the hood 32 has a first wall 70 proximate the arm 24 and a second wall 72 with the chamber 68 therebetween. The first wall 70 has an adjuster pad 74 and adjuster detent 76 connected thereto. Located inside the chamber 68 against the first wall 70 are a plastic washer 79, a rubber washer 78 and a spring washer or plate 80. The spring washer 80 is fixedly connected to the arm 24 by screws 82. The rubber washer 78 is biased by the spring washer 80 to hold the first wall 70 against the arm 24, but nonetheless allow the hood 32 to be rotatable. The plastic washer 79 provides a suitable surface to allow plate 80 to axially rotate relative to rubber washer 78. The hood 32 shrouds or covers a portion of the cutting wheel 30 inside the chamber 68, but allows a portion of the wheel 30 to extend therefrom such that the exposed area of the wheel 30 can be used for cutting. However, any suitable type of protective hood or mounting of the hood to the frame could be provided.
The first wall 70, in the embodiment shown, has a plurality of studs 83. The adjuster pad 74, in the embodiment shown, has a plurality of notches 84. The adjuster detent 76 has a plurality of lateral protrusions 86 that are located in every other notch 84. The studs 83 are also located in every other notch 84, at an offset to the protrusions 86, such that the notches 84 are alternatingly filled, at least partially, with protrusions 86 and studs 83. The interlocking nature of the studs 83 and protrusions 86 with the adjuster pad 74 provide the means for axially rotating the adjuster detent 76 with the hood 32. In the embodiment shown, the hood 32, pad 74, and detent 76 are merely retained together by the sandwiching effect between the plate 80 and arm 24. However, any suitable connection and/or interconnection means could be provided. When the hood 32 and adjuster pad 74 are rotated, the adjuster detent 76 rotates with them. The adjuster detent 76, in the embodiment shown, comprises a generally semi-circular array of notches or grooves 98. These notches 98 are suitably sized and shaped to receive a front end 92 of the locking pin 88 as further described below. However, any suitable type of adjuster detent could be provided or, the detent notches could be integrally formed with the hood 32.
The hood positive repositioning system 34 generally comprises the lock control 64 and the adjuster detent 76. The lock control 64 generally comprises locking pin 88, control knob 90, leaf spring 52, cam sleeve 56, and cam pin 96. The control knob 90 is fixedly connected to one end of the locking pin 88 and is adapted to be grasped by a user to axially rotate the locking pin 88. The control knob 90 sits partially recessed in the depression 60 of the cover 26. The locking pin 88 has a front end 92 and a cam pin channel 94. The front end 92 is adapted to be positioned in locking notches or grooves 98 of the adjuster detent 76 as will further be described below. The cam pin channel 94 is adapted to fixedly receive the cam pin 96 therein. The locking pin 88 is located in a center channel 100 of the cam sleeve 56 with the cam pin 96 positioned against the cam surface 102 of the cam sleeve 56. The cam surface 102, in the embodiment shown, has two types of areas, high areas and low areas. The cam surface 102, as best seen in FIG. 3, has two opposing high areas and two opposing low areas. In the position shown in FIG. 2, the ends of the cam pin 96 are located adjacent the low areas. The cam sleeve 56 is fixedly located in the cam channel 54 of the arm 24 such that the sleeve 56 is not able to axially rotate. The leaf spring 52 has a first end 104 that is fixedly connected to the arm 24 and a second end 106. The second end 106 has a pin hole or notch 108 to allow the locking pin 88 to pass therethrough. The second end 106, in the embodiment shown, is positioned between the control knob 90 and pin 96. A spacer 110 is sandwiched between the leaf spring 52 and cam pin 96 with the spring 52 biasing the spacer 110 and cam pin 96 towards the hood 32 which, in turn, biases the front end 92 of the locking pin 88 towards the hood 32. In an alternate embodiment, any suitable type of cam system or biasing system could be provided and any suitable type of control could be provided. One type of alternate form of cam sleeve is shown in FIG. 4. In the cam sleeve 56a shown, the cam surface 102a has low areas 150, high areas 152, and a sloped surface 154 therebetween. Located at the high areas 152, in the embodiment shown, are notches 156. These notches 156 are adapted to receive the ends of the cam pin 96 therein to temporarily stationarily lock the lock control 64 in an unlocked position. This allows the user free use of both hands to rotate the hood 32 on the arm 24. Rotation of the lock control 64 by the user can relatively easily move the ends of the cam pins 96 back out of the notches 156 and into the low areas 150.
For the cutting saw 10 shown in FIG. 1, it may be desirable to adjust the protective hood 32 relative to the rest of the saw 10 in order to provide a more comfortable cutting angle and manipulation for the user. For example, if the user intended to cut an article directly in front of him, he might desire to reposition the hood 32 as shown by dotted lines in FIG. 1, thus leaving the cutting wheel 30 exposed directly in front of the rest of the saw 10. However, it is obviously very desirable not to have the hood 32 rotating once its position has been selected. The positioning system of the present invention allows relatively fast locking and unlocking of movement between the hood 32 and arm 24, but nonetheless provides an extremely good relative motion lock that does not significantly degrade with use, such as with friction locks.
In the position shown in FIG. 2, the hood 32 is locked relative to the arm 24 such that it is not able to rotate. This locked situation is accomplished do to the fact that the locking pin 88 is offset from the axis of rotation of the hood 32 and, it front end 92 is located in one of the detent grooves 98. As noted above, the adjuster detent 76 is substantially locked with the hood 32. The locking pin 88 is restrained from movement in all directions except axial movement because it is located in cam sleeve channel 100 and cam channel 54. Therefore, the hood 32 is prevented from rotating because the detent adjuster 76 is prevented from rotating due to its engagement by pin 88.
In order to reposition the hood 32, the user need only rotate the control knob 90 from its locked position shown in FIG. 2 to an unlocked position. In the embodiment shown, the angular rotation between the locked and unlocked position is about 90°. However, any suitable rotation angle could be provided. As the knob 90 is turned, the locking pin 88 is axially rotated. This causes the cam pin 96 to rotate in a direction transverse to its longitudinal axis. Because the cam sleeve 56 is fixed in the cam channel 54 such that it cannot axially rotate and, the cam pin 96 is biased against the cam surface 102, as the cam pin 96 moves it is displaced along the cam surface 102 from the low areas to the high areas of the cam surface 102. This causes the locking pin 88 to be longitudinally axially moved away from the hood 32 and adjuster detent 76. The leaf spring 52 merely deflects during this movement. Due to the longitudinal movement of the locking pin 88, the front end 92 of the pin 88 is moved out of the adjuster detent groove 98 that it was formerly located in. With the locking pin 88 no longer engaging the adjuster detent 76, the user can now reposition the hood 32 to a desired new position. The adjuster detent 76 moves with the hood 32 as it is rotated and, the wall 70 of the hood merely slides relatively to the spring washer 80.
Once the user has repositioned the hood 32 to its desired new position, the user then merely rotates the control knob 90 back towards its original position. As the locking pin 88 is axially rotated, the cam pin 96 is turned such that its ends move from the cam sleeve surface high areas back to the cam sleeve surface low areas. The leaf spring 52 is thus able to bias the cam pin 96 and locking pin 88 back towards the hood 32. The front end 92 of the locking pin 88 moves back into one of the adjuster detent grooves 98 to once again lock the hood 32 relative to the arm 24 such that it is prevented from rotating. The front end 92 of the locking pin 88 has beveled surfaces to help guide the front end 92 into the grooves 98. In the event that the front end 92 is positioned on top of a portion of the adjuster detent 76 between two grooves 98, this occurrence will be noticeable to the user due to the extended nature of the control knob 90. The user can then merely slightly rotate the hood 32 at which point the locking pin 88 will snap forward, being pushed by the leaf spring 52, when a groove 98 comes into registry with the front end 92 of the locking pin 88.
One of the advantages of the present invention is that the weight and size of the hood locking and repositioning system is substantially reduced. Unlike the prior art that used various assortments of handles, knobs and brackets, the present invention is relatively simple and easy to manufacture and use as well as reducing the weight of the tool. This can have significant advantage for a hand held tool. The weight of the hood can also be reduced by making the hood with thinner dimensions or different lighter material because the hood, by use of the system described above, is restrained on the arm between the pads 74 and 78 and, therefore, need not be as strong as in the prior art devices. Therefore, the hood can be provided lighter than in prior art devices. As noted above, although the present invention has been described with use in a demolition saw, it can also be used in various other tools as well as tools or machines that are not hand held.
Let it be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the spirit of the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.
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A hood for a power tool, such as a grinding wheel on a saw, in which the hood is rotatable relative to the frame of the tool. The tool has a system for repositionably fixing the hood at selected locations. The system includes a detent connected to the hood with a plurality of lock notches and a longitudinally movable lock pin connected to the frame. The lock pin can be positioned into one of the detent notches to prevent the hood from moving and, can be longitudinally moved to disconnect the lock pin from the detent thus allowing the hood to be repositioned. The system includes a knob to axially rotate the lock pin, a cam member to longitudinally move the lock pin upon axial rotation, and a leaf spring to bias the lock pin in an engaged lock position with the hood detent.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to temperature controls for electric irons, and more particularly to electronic temperature control means for cordless electric irons.
2. Description of the Prior Art
One of the most common of present day household appliances is the electric iron. While the modern electric iron, with variable temperature control, steam and spray features has much to recommend it over the old sadirons resting on a pot belly stove to be heated, there is one disadvantage of today's iron over the sadiron--the cord. No matter how one tries to work around it, it seems the iron's cord is always in the way. Recognizing this disadvantage, manufacturers have recently begun producing cordless electric irons, providing all of the conveniences of other modern irons without the inconvenience of the cord. Examples of these irons include U.S. Pat. No. 3,760,149 to Harsanyi, patented Sept. 18, 1973, and U.S. Pat. No. 4,528,429 to Dobson et al, patented July 9, 1985, and assigned to the same assignee as this invention.
In both of these prior art devices, the temperature of the sole plate is controlled by a mechanical adjustable thermostat mounted on the iron. While this manner of temperature control may be adequate for most uses, it is far from current state-of-the-art electronic temperature control means currently in use in a variety of consumer products.
SUMMARY OF THE INVENTION
This invention provides an accurate electronic temperature control means for cordless electric irons, with the temperature sensor being embedded in the sole plate of the iron, and the control means mounted in the base member, with the temperature sensor and the control means communicating by light wave communications whenever the iron is placed in operative connection with the base member.
Eliminating the control means from the iron member allows it to be more compact and lighter, and also allows the use of accurate, electronic temperature control circuitry mounted in the base to provide improved control and ease of operation of the cordless iron.
Other advantages include push button selection of the desired temperature, visual indications of the current status of the iron and its programmed temperature, audible indications of its operative functions, and automatic shut-off in case of various undesirable operating conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of a cordless iron incorporating the electronic temperature control of the subject invention.
FIG. 2 is a sectional view of the iron mounted in operational connection with the base member of the subject invention.
FIG. 3 is a schematic representation of the temperature sensing circuitry contained within the iron of the subject invention.
FIG. 4 is a schematic representation of the base-mounted electronic control circuitry.
FIG. 5 is a plan view of the key switch assembly and indicator lamps of the electronic temperature control means of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A pictorial view of the end product of this invention is illustrated in FIG. 1. Shown is a cordless electric iron 1 resting upon its base member 2. The base member 2 is connected by cord 3 to a source of alternating current (not shown), and houses the electronic control means for controlling and maintaining the temperature of the sole plate of iron 1. This control means is accessed through key switch assembly 11 for choosing a desired operating temperature for iron 1.
FIG. 2 shows the operative interconnection between the iron 1 and base member 2. Included are the male connector pins 4 on the iron and corresponding female connector 5 on the base for providing alternating current to the heating element of iron 1 whenever it is placed in base member 2. Also shown are the infrared light emitting diode 13 and associated base-mounted phototransistor PT1 of the communication system between the iron temperature sensor and the electronic control means in the base 2.
The schematic drawing of FIG. 3 is representative of the temperature sensing circuitry contained within iron 1. Terminals 7 are connected through the iron heating element (not shown) to male connector pins 4, which in turn are connected through the electronic control means to be described later to a source of alternating line current. This 120 volt line current is processed by capacitive reactance voltage divider C21, R26 and R21 to supply a reduced voltage to rectifier diode D21 and filter C22 such that an unregulated DC voltage of 12 to 16 volts appears at node 8.
This unregulated voltage is applied to integrated circuit voltage regulator VR2 and associated bypass capacitor C23 to provide a 5 volt DC regulated source at node 9, which source is used to power the temperature sensing circuitry mounted in the iron 1.
The temperature sensing circuitry consists of integrated circuit oscillator IC2, which performs as an astable multivibrator when connected as shown in FIG. 3. The sole plate temperature sensor is thermistor THM1, which, in combination with resistors R23 and R25 trimming potentiometer R24 and capacitor C25, provides the frequency determining network for astable multivibrator IC2. IC2 produces a nonlinear output pulse frequency which is inversely proportional to the resistance of thermistor THM1, and therefore proportional to the temperature of the sole plate of the iron. This pulse output drives infrared light-emitting diode 13 through current limiting resistor R22 such that the signal representing the temperature of the sole plate can be transmitted to the base-mounted electronic temperature control means.
The base circuitry will now be described with reference to FIG. 4. The base member is connected to a source of alternating line current through a power cord (not shown) connected to terminals 10. The alternating current is also connected directly to female connector terminals 5, to which the iron 1 is connected whenever it is placed on the base 2. This applied line current is reduced in voltage by transformer T1 and passed through full wave rectifier D1, D2, D3, D4. The resulting unregulated DC voltage of approximately nine volts is filtered by capacitor C1 and applied to the input of integrated circuit voltage regulator VR1, which provides a regulated output of 5 volts DC, which is used to power microprocessor IC1 and the remainder of the base circuitry.
Also connected to the secondary winding of transformer T1 is timing network R2, C2, Q2 which provides a 60 Hz. pulse signal for use as a time base for microprocessor IC1 for measuring of the frequency of the signal received from the iron-mounted temperature sensing circuitry.
Switch matrix 11 provides user input to microprocessor IC1 for selection of the desired temperature programming function. Diodes D5 and D6 serve to isolate the switching function from the light-emitting diode drives.
Resistors R4 through R11, transistors Q3 and Q4, and light-emitting diodes LED 1 through LED 10 provide visual indications of temperature selection and circuit status in accordance with the functions selected through microprocessor IC1 through switch matrix 11.
The resistance-capacitance network formed by R13 and C4 is the frequency-determining circuit for the instruction cycle oscillator of microprocessor IC1.
Resistor R12, diode D7 and capcitor C5 provide a power-up signal to microprocessor IC1 to reset it to its first instruction after a predetermined delay from turn-on. Diode D7 prevents low voltage reset during operation.
An audible indication is provided to the user upon execution of certain functions by microprocessor IC1, such as automatic turn-off, through application of a frequency pulse to piezoelectric buzzer PB1.
Iron in-base switch 12 is included to signal microprocessor IC1 whether or not the iron is in operational connection with the base. Switching current is provided by resistor R16.
The iron temperature frequency signal emitted by infrared LED 13 is received in the base by phototransistor PT1. The received signal is amplified and squared by the network of transistor Q1 and resistors R1 and R3 to provide a suitable signal to microprocessor IC1. The microprocessor measures the frequency of the received signal, which is proportional to the temperature of the sole plate, and makes control decisions based upon its programming and key switch inputs provided by the user. Resistor R17 prevents destruction of transistor Q1 if phototransistor PT1 should saturate.
Microprocessor IC1 outputs its control decisions through the network of resistors R14 and R15 and transistors Q5 and Q6, which drive power relay RLY1 for providing line current through female connector 5 to the iron heating element. Diode D8 protects the winding of relay RLY1 from negative spikes. Capacitor C6 provides current capacity during relay pull-in, and C3 provides bypassing.
FIG. 5 shows the display panel which is applied over key switch assembly 11. Illustrated are labels for the various temperatures which may be selected: DELICATE, PERM. PRESS, WOOL, COTTON and LINEN; intermediate temperatures LOW and HIGH for each standard setting; the ON/OFF switch; and indicator LED's for the selected temperature and the status of the iron electronic control circuitry (WAIT, READY).
The general operation of the microprocessor-controlled cordless electric iron wil be described next, followed by a more detailed description of the functional operational of the various operative states of the control circuitry.
First, the base member 2 is plugged into a source of line current and the iron 1 is placed in operative connection with the base. Pressing the ON button generates a single beep and the SELECT FABRIC indicator will begin to flash. No power is applied to the iron until a fabric temperature setting has been selected. If no fabric setting is chosen within ten minutes after pressing the ON button, the control means will go into an automatic shut-off mode.
A temperature may be selected by pressing one of the five fabric settings and optional HIGH or LOW buttons for intermediate temperatures. As these settings are selected, the associated LED indicators will light, and a beep will be generated for each switch pressed. Once a fabric setting is selected, the SELECT FABRIC indicator will go out, and the WAIT indicator will come on continuously until the temperature of the iron as measured by thermistor THM1 and its associated circuitry reaches the selected setting, at which point the WAIT indicator will be extinguished, and the READY indicator will light, accompanied by two beeps. When the iron is removed from the base, the fabric (temperature) indicators will remain lit, but both the WAIT and READY indicators will extinguish until the iron is replaced on the base.
If the iron is replaced on the base, and the temperature of the iron is outside the selected range, the WAIT indicator will come on, accompanied by a single beep. Power is applied to the iron only after the presence of the iron is sensed in the base, and the temperature control circuitry determines that the present iron temperature is out of range.
If the iron is left on the base for more than ten minutes without being removed, and the temperature setting is not changed, ten beeps will sound. If nothing is done within another two minutes, the iron will go into automatic shutdown. When this happens, the power to the iron is disconnected and the temperature display is turned off. The WAIT indicator will come on until the iron has cooled enough to be stored, at which time the WAIT light is extinguished and a single beep is generated. The temperature control and display can be re-activated using normal start-up procedures.
Turning off the iron using the ON/OFF switch causes the WAIT indicator to come on until the iron has cooled enough to be stored, at which time the WAIT indicator goes out, and a single beep is generated.
The following paragraphs describe the functional operation of the various operative states of the electronic cordless iron in detail.
OFF STATE:
When the iron is in the off state, the power relay is off, all LED's are off, and all switches are disabled except for the ON/OFF switch. If the iron is not in the base, the "off base" state is entered. If the ON/OFF switch is pressed while in the off state, and the iron is in the base, a beep is generated and the SELECT FABRIC mode is entered. If the ON/OFF switch is pressed while in the off state, and the iron is not in the base, a beep is sounded, but the SELECT FABRIC mode is not entered.
SELECT FABRIC STATE:
When the iron control means is in the SELECT FABRIC state, the power relay is off, all LED's are off, except for the SELECT FABRIC LED which is flashing, and the keybaord switches are enabled if the iron is in the base. If the iron is not in the base, the "off base" state is entered. If the ON/OFF switch is pressed, a beep is heard, and the "off" state is entered. If one of the fabric select switches is pressed, and the iron is in the base, a beep is generated, the LED associated with the switch pressed is turned on, and the "wait" state is entered. If no switches are pressed for ten minutes, the "automatic shuf-off" state is entered. If no infrared signal indicative of the temperature being measured at the sole plate is received, or the infrared signal is not increasing in frequency, the iron shuts off immediately.
WAIT STATE:
When the iron control is in the "wait" state, the power relay can be on or off, depending upon the requirements of the heating element, the selected fabric LED is on, the WAIT LED is on, all other LED's are off, and all eight keyboard switches are enabled. If the iron is removed from the base, the "off base" state is entered. In the "wait" state, the control means is monitoring the heating or cooling of the iron to determine when the selected temperature range has been reached. When the selected temperature is reached, two beeps are generated, and the "ready" state is entered. While waiting for the iron to reach the selected temperature, the control is monitoring the keyboard. If the ON/OFF switch is pressed, a beep is heard, and the "off" state is entered. If the HIGH or LOW switch is pushed, a beep is generated, and the associated LED is turned on if it was previously off (indicating that a new temperature range has been selected), or if it was on, it is left on. If the currently selected fabric switch is pressed (LED is already on), a beep is generated, the HIGH or LOW LED's are turned off, and if either the HIGH or LOW LED was on, a new temperature range is set as the selected temperature. If a new fabric switch is pushed, a beep is generated, the HIGH and LOW LED's are turned off, the newly selected fabric LED is turned on, and a new temperature range is set as the selected temperature. If a new temperature is selected, a two-second timeout is set. The iron cannot reach the "ready" state until this two-second timeout has expired, even if the selected temperature is achieved beforehand.
READY STATE:
When the control is in the "ready" state, the power relay may be on or off as needed to maintain the selected temperature, the selected fabric LED is on, the HIGH or LOW LED may be on, the READY LED is on, all other LED's are off, and all eight keyboard switches are in enabled. If the iron is removed from the base, the "off base" state is entered. If the "ready" state, the control is monitoring the heating or cooling of the iron to determine if the temperature is outside the selected temperature range. When the temperature is outside of the selected temperature range, the power relay is on to maintain the selected temperature setting. The READY LED strays on during this maintenance cycle. If, during an "off base" state, the iron cools too far to be functional when the iron is replaced on the base, the "wait" state is entered, and a single beep is generated. While waiting for the iron to be removed from the base, the control is monitoring keyboard. If no keys are pressed, or the iron is not removed for ten minutes, the "automatic shut-off" state is entered. If the ON/OFF switch is pressed, a beep is heard, and the "off" state is entered. If the HIGH or LOW switch is pressed, a beep is heard, and the associated LED is turned on if it was turned off, indicating that a new temperature range has been selected, and if it was on, it is left on. If the currently selected fabric switch is pressed, a beep is heard, the HIGH or LOW LED's are turned off, and if either the HIGH or LOW LED was on, a new temperature range is set as the selected temperature, and the "wait" state is entered. If a new fabric switch is pushed, a beep is heard, the HIGH and LOW LED's are turned off, the newly selected fabric LED is turned on, a new temperature range is set as the selected temperature, and the "wait" state is entered. If a new temperature is selected, a two-second timeout is set before entering the "ready" state.
OFF BASE STATE:
When the control is in the "off base" state, the power relay is off, the selected fabric LED is on, the HIGH or LOW LED may be on, all other LED's are off, and all keyboard switches are disabled except the ON/OFF switch. The control remains in the "off base" state until the iron is returned to the base. When the iron is replaced in the base, the state that the module was in just before the iron was removed from the base is reentered. If the iron is not replaced in the base, and the ON/OFF switch is not pressed for ten minutes, the "automatic shut-off" state is entered. If the ON/OFF switch is pressed, a beep is heard, and the "off" state is entered.
AUTOMATIC SHUT-OFF STATE:
When the control enters the "automatic shut-off" state, ten beeps are generated, and a two-minute timeout is started. If no keys are pressed or the iron is not removed from the base within the two-minute timeout, then the "off" state is entered. If the current fabric key is pressed, or the iron is removed and replaced during this two-minute timeout, then the state that the module was in just before the automatic shut-off state was entered is reentered. If a different fabric key is pressed, the control enters the "wait" state. If the iron is removed and not replaced during this two-minute timeout, the "off base" state is entered. If the ON/OFF key is pressed, the control enters the "off" state. Temperature is maintained during this two-minute period.
Operation of the preferred embodiment of the electronic temperature control means of the invention will now be described with reference to FIGS. 3 and 4. Once the iron has been turned on and a temperature has been selected, power is supplied through power relay RLY1, through connector terminal pairs 5 and 4 to the heating element of the iron, and to terminals 8 of the electronic temperature sensing circuitry.
The resistance of thermistor THM1 varies inversely proportionally in accordance with the temperature of the iron sole plate in which it is embedded. That resistance, in combination with resistors R23, R24 and R25, and capacitor C25, forms a frequency determining network for astable multivibrator IC2. The output frequency thus generated by multivibrator IC2 is also proportional to the temperature of the sole plate, and this frequency drives infrared LED 13 through current-limiting resistor R22.
This circuit functions only when the iron is operatively connected to the base, since the iron contains no source of power once it is removed from the base. As can be seen in FIG. 2, whenever the iron is placed in the base, LED 13 is positioned directly above phototransistor PT1. Thus, the variable frequency signals representing sole plate temperature being transmitted by LED 13 are received directly by phototransistor PT1, processed by amplifying and squaring network R1, Q1, R3 and applied to the microprocessor control means IC1. The microprocessor is programmed to translate the received frequency into a control signal by measuring the frequency against the 60 Hz. time base generated by R1, C2 and Q2. The microprocessor IC1 then compares the measured temperature of the sole plate with the selected temperature from key switch assembly 11, and controls relay driver R15, Q6, R14 and Q5 and power relay RLY1 to establish and maintain the selected temperature for as long as the iron is in operation.
While this preferred embodiment of the invention has been described utilizing a radiant energy communication link between the iron and the base, it is to be understood that other means for transmitting the variable frequency of the temperature sensing circuitry to the control means can be employed within the scope of the invention. Such other means might include audio transmission with piezoelectric transducers, inductive transmission using eelctromagnetic coils, or capacitive transducers.
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An electronic temperature control for a cordless ironing apparatus. The temperature of the sole plate of the iron is sensed by a thermistor embedded therein; the thermistor is part of an astable multivibrator circuit, and any change in temperature of the sole plate causes a change in resistance of the thermistor, and a corresponding change in frequency at the output of the multivibrator. This output drives an infrared LED, and the light emitted by the LED in the iron is sensed by a phototransistor in the base, which relays the sensed temperature information to a microprocessor therein which controls the current applied to the heating element accordingly, to maintain the desired temperature of the sole plate.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims foreign priority benefits under 35 U.S.C. §119 from European patent application Ser. No. 05 025 228.7 filed Nov. 18, 2005.
TECHNICAL FIELD
[0002] The present invention refers to a container, in particular for receiving moisture-sensitive goods, and a capsule to be received in the container characterized in that a transponder is received in said capsule body.
BACKGROUND OF THE INVENTION
[0003] Containers for receiving goods are widely used. Usually, the containers which may be vials are opaque such that the goods received in the container are not visible. To identify the good, there are inscriptions and/or pictures which are useful for selling and for the customer in order to select the goods which meet his desire.
[0004] To facilitate identification and tracking, such a container may have a bar-code which may be an EAN-code. A more sophisticated and advanced technique uses a transponder comprising a RFID chip. Such a transponder has to use an antenna which is formed on a flat disc with electric conductors being printed thereon. To allow an identification, electromagnetic waves are used. Thus, a minimum extension of the antenna is required and the antenna efficiency relies on having a specific form, such as the form of a flat spiral.
[0005] Although the use of RFID tags in a cover of such a container has already been proposed, there are several problems. With small containers, the area which may be used for receiving the tag is limited. This leads to a small antenna with a limited range of operation. On the other hand, such a transponder is subject to errors by external influences. A piece of metal arranged close to the container may influence the electromagnetic fields and the frequency selected for the transponder such that the transponder does not react properly.
[0006] To improve the independence from external influences, it has been proposed in DE GM 201 05 605 to receive the RFID chips in a mass made from polyurethane. However, during long term, the transponder of such a construction is not stable, and thus it is not reliable.
[0007] Also, it has been proposed in to incorporate a transponder directly into the plastic material of a container cover and to use a ring-shaped antenna which also acts as a capacitor and is operational as long as the container is closed. However, this structure is rather complicated to produce and requires a specific arrangement of the RFID chip. The thickness of the cover must be increased in order to safely receive the chip, and it is difficult to have the antenna in a flat arrangement, if it is not produced as a sheet covering the cover or lid from the outside. In the latter case, however, the container is not tamper-proof.
OBJECTS AND SUMMARY OF THE INVENTION
[0008] Therefor, it is an object of the invention to provide a container for receiving moisture sensitive goods, and a capsule to be received in the container characterized in that a transponder is received in said capsule body in a tamper-proof arrangement, which capsule has an improved handling and is inexpensive and easy to manufacture.
[0009] According to the invention, the transponder is arranged in the container cover but not within the plastic material thereof. Contrary thereto, it is preferably received in a hollow portion thereof and fully covered by desiccant material. Thus, it is close to the upper surface or wall of the cover but the cover plastic material has not to have an increased thickness. Advantageously, a generic and widely used cover may be selected for the present invention, and also the desiccant material may be of conventional type such that it is quite cheap and that there is no need to create specific packagings to receive the transponder.
[0010] Additionally, the protector covers the desiccant material at its lower part such that the transponder chip is safely received and double protected.
[0011] A specific advantage revises from the use of desiccant material in connection with the transponder: the transponder is closely adjacent to the desiccant material, and both sides of the antenna of the transponder are subject to the desiccating effect of the desiccant material. Thus, there will be no moisture and small water drops which could influence the electrical characteristics of the antenna. Thus, the inventive transponder is very stable even in a long-term view as the resonance frequency does not change even if the environment moisture increases. Thus, a small antenna may be used which on the other hand allows to receive a small transponder in the inner part of the container cover which receives the desiccant material.
[0012] Advantageously, the container with the transponder according to the invention is protected against moisture and any other damage. Advantageously, there will be no negative influence on the electrical characteristics of the antenna of the transponder as the desiccant material safely keeps the antenna dry.
[0013] Another important advantage is that the inventive container may be manufactured with the same tools as used for a conventional container; there is no amendment to the plastic material required.
[0014] On the other hand, according to the invention, the transponder is temper-proof protected in the container. By this, the drugs or any other goods which are received in the container may be protected against infringement and counterfeiting. Also, the RFID chip is well protected against shock and moisture such that even cheap RFID chips work reliably with the inventive container.
[0015] In this regard, it is an advantage if the transponder is supported by a protrusion and/or depression protruding from container cover. By this arrangement, a small gap is generated which on the other hand allows a drying action on both sides of the transponder.
[0016] Alternatively, if the chip of the transponder protrudes from said disc, the same effect is ensured even if the container cover has a flat inner surface.
[0017] According to another advantageous embodiment the transponder is received within a desiccant receiving space of the container cover which is filled with desiccant material, preferably at the top of said space.
[0018] According to another advantageous embodiment the transponder is adjacent to the top portion of the container cover and preferably separates the top container cover from the desiccant material.
[0019] According to another advantageous embodiment the transponder is received in a recess formed in the desiccant material, and preferably is surrounded by a portion of said desiccant material.
[0020] According to another advantageous embodiment the transponder is formed as a printed circuit board and may have any suitable form, such as a flat disc which substantially extends over the diameter of the space receiving the desiccant material.
[0021] According to another advantageous embodiment a flat cylindrical hollow space is left between the desiccant material and the container cover, and the transponder is received in said space.
[0022] According to another advantageous embodiment the desiccant material is in the form of powder or granulate which is filled into the desiccant receiving space by placing the container cover upside down, and after placing the transponder into the desiccant receiving space.
[0023] According to another advantageous embodiment the desiccant material is a formed body which leaves a hollow space for receiving the transponder, preferably at its upmost portion.
[0024] According to another advantageous embodiment the transponder is held under pressure between the desiccant material and the container cover.
[0025] According to another advantageous embodiment the protector is in snap-fit interaction with a flange formed on the container cover, and covers the desiccant material.
[0026] According to another advantageous embodiment the transponder is in frictional engagement with the desiccant material and/or the container cover.
[0027] According to another advantageous embodiment the container cover comprises a convex depression or protrusion adjacent and protruding towards the transponder.
[0028] According to another advantageous embodiment the depression is arranged centrally in said container cover and has a contact area to the transponder which preferably has a diameter of less than a third, in particular about 10 percent to 20 percent of the diameter of the transponder.
[0029] According to another advantageous embodiment the transponder comprises a RFID chip and a coil made from electrically conductive material which essentially surrounds the chip.
[0030] According to another advantageous embodiment the transponder is received in a tamper-proved manner, and is preferably invisibly received between the container cover and the desiccant material.
[0031] According to another advantageous embodiment the desiccant material contained in the desiccant receiving space desiccates the transponder.
[0032] According to another advantageous embodiment the transponder is connected with a moisture sensor which is received within the container and which upon activation measures the humidity or moisture of the inner space of the container, and by which moisture or humidity may be read out via the transponder.
[0033] Further details of the container according to the invention may be taken from the drawings, in which
BRIEF DESCRIPTION OF THE FIGURES
[0034] FIG. 1 shows a sectional view of a first embodiment of the container according to the invention;
[0035] FIG. 2 shows a second embodiment of the container according to the invention shown as far as the container cover is concerned; and
[0036] FIG. 3 shows a third embodiment of a capsule to be received in a container according to the invention.
DETAILED DESCRIPTION
[0037] The container 10 according to FIG. 1 has a container body 12 and a container cover 14 . The container is intended for taking up moisture-sensitive goods such as drugs. The drugs must be kept dry, and, to this extent, a desiccant material 20 is received within a hollow cylindrical space 22 which is provided in the container cover.
[0038] A protector 24 closes the hollow space 22 . The protector 24 is in the form of a disc and consists of any suitable material which is strong enough for the desired protection but on the other hand permeable for moisture and gas. A sieve with supporting structure, a grid with small grid openings but also cardboard etc may be used.
[0039] According to the invention, a transponder 26 is received within the hollow space 22 and preferably adjacent to the plastic material of the cover 14 which forms an upper wall 28 closing the hollow space 22 upwardly.
[0040] The transponder 26 comprises a RFID chip 30 and a printed circuit board 32 which has an antenna printed on it. The RFID chip 30 has a thickness which is about triple the thickness of board 32 . Thus, as the upper wall 28 has a flat inner surface, there is a small gap 34 between the upper wall 28 and the board or disc 32 which is intended for the desiccant material being operational also in the upper part of board 32 . By this, any moisture which might collect there is safely taken up.
[0041] Thus, preferably, the gap 34 is filled with dry and plain air while according to the drawing of FIG. 1 parts of the desiccant material 20 may be received in gap 34 .
[0042] The container 10 is constructed in a suitable manner allowing a sealed arrangement between cover 14 and body 12 . To this end, line sealings 40 and 42 are arranged between the cover and the rib surrounding the upper body opening.
[0043] According to a different embodiment, the container wall 44 and the container bottom 46 may be provided with layers of desiccant material as is known from EP 454976.
[0044] Another embodiment of the container according to the invention is in part shown in FIG. 2 . This container cover 40 comprises a transponder 26 which has the form of a flat disc 32 i.e. without any protruding chip. In this embodiment, a central depression 50 protrudes downwardly from upper wall 28 of container cover 14 . This ensures the desired gap 34 .
[0045] In this embodiment, the desiccant material 20 is a pre shaped press or solid body 20 which fits into the hollow space of the cover 14 , the solid body having a recess 23 to receive the transponder 26 .
[0046] As may be taken from FIG. 2 , the protector 24 is received at a shoulder 52 on a flange 54 of the container cover 14 . The protector 24 is hold in place by resilient support fingers 56 . Even if the overall volume of the desiccant material 20 increases through taking up moisture, the resilient support fingers 56 will ensure that protector 24 is kept in place. In this design the transponder 26 is held under pressure between the cover and the desiccant.
[0047] FIG. 2 also shows a tamper-barrier 60 which is intended to be broken if the container cover is opened. The container body has an upper and outwardly extending flange surrounding its upper opening, and a line sealing 40 is provided close to this opening.
[0048] As previously noted, the transponder ( 26 ) is connected with a moisture sensor which is received within the container ( 10 ) and which upon activation measures the humidity or moisture of the inner space of the container ( 10 ), and by which moisture or humidity may be read out via the transponder ( 26 ).
[0049] FIG. 3 shows another embodiment of the invention, being formed as a capsule which is shown in section on the left side and in a perspective view on the right side of FIG. 3 . The capsule 62 is provided with desiccant material 20 and is formed like the middle portion of the container cover 14 of FIGS. 1 and 2 . The protector 24 closes the hollow space 22 , and the desiccant material has a recess 23 to receive a transponder 26 .
[0050] Such a capsule 62 may be used in a container for receiving drugs, or a small bottle entity. It may also be received in the container cover 14 which then has an enlarged hollow space 22 to receive the capsule 62 . In this case, the wall thickness of the capsule may be reduced. Alternatively, it may be attached to a container cover 14 , e.g. by means of a snap-fit connection.
[0051] In another embodiment of the invention, the capsule has an outer diameter which exactly fits to the inner diameter of the container body. In this case, the capsule may be pushed into the container upside-down, and it is preferred that the protector has a surface which resists the drugs.
[0052] While a preferred form of this invention has been described above and shown in the accompanying drawings, it should be understood that applicant does not intend to be limited to the particular details described above and illustrated in the accompanying drawings, but intends to be limited only to the scope of the invention as defined by the following claims. In this regard, the term “means for” as used in the claims is intended to include not only the designs illustrated in the drawings of this application and the equivalent designs discussed in the text, but it is also intended to cover other equivalents now known to those skilled in the art, or those equivalents which may become known to those skilled in the art in the future.
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The invention relates to a container, in particular for moisture-sensitive goods, with a container body and a container cover which can be opened and closed, and with a transponder which is arranged in the container cover. The transponder is covered by at least a layer of a desiccant material and is therefore protected against moisture damage which could influence the electrical characteristics of the antenna.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field of the Invention
[0002] The present invention relates generally to a fuel injector for internal combustion engines, and more particularly to an improved structure of a fuel injector for installation of a piezoelectric device used as a valve actuator of the fuel injector.
[0003] 2. Background Art
[0004] Typical fuel injectors used in, for example, internal combustion diesel engines of automotive vehicles are designed to drive a three-way valve or a two-way valve connected to a common rail in which a high pressure fuel is stored for opening and closing a fuel supply passage selectively. When it is required to inject the fuel into the engine, the fuel injector changes the fuel pressure acting on a needle to lift up the needle for opening a spray hole to initiate the fuel injection.
[0005] As a valve actuator to open and close the three-way valve or the two-way valve, a solenoid valve has been usually used. In recent years, however, an attempt is made to utilize an piezoelectric device which expands or contracts in response to input of an electric signal to actuate a valve for controlling the fuel injection precisely. For example, a valve actuator is proposed which consists of a piezoelectric device made up of a stack of piezoelectric layers and a piston. In operation, the voltage is applied to the piezoelectric device. The piezoelectric device then contracts or expands to move the piston to open or close, for example, a three-way valve to control the back pressure of a nozzle needle of a fuel injector. The three-way valve works to switch communications between a back pressure chamber formed adjacent the nozzle needle and a high-pressure fuel path and between the back pressure chamber and a drain passage. When the back pressure chamber communicates with the fuel passage so that the pressure in the back pressure chamber drops, it will cause the nozzle needle to be lifted up to initiate a jet of fuel from a spray hole. Alternatively, when the back pressure chamber communicates with the high-pressure fuel passage, the fuel flows from the high-pressure fuel passage to the back pressure chamber, thereby moving the nozzle needle downward to close the spray hole.
[0006] The piezoelectric device is made by laminating the piezoelectric layers each having upper and lower surfaces on which electrodes are formed and applying a conductive paste to a side surface of the lamination to form side terminals which connect negative and positive sides of the electrodes, respectively. Installation of the piezoelectric device in a housing is accomplished by coupling the side terminals to a connector through leads, fitting an insulator tube on the periphery of the piezoelectric device, and inserting it into a vertical chamber of the housing. After the installation of the piezoelectric device, a hermetic seal is formed by placing the whole of the housing in a mold and forcing resin into the mold to seal an upper end of the housing.
[0007] The piezoelectric device is usually made from PZT (lead zirconate titanate). The PZT contains the lead that is a harmful substance and thus needs to be withdrawn after the piezoelectric device is used up. The withdrawal of the lead requires cutting the housing because the upper end of the housing is, as described above, sealed by resin. It is, thus, quite inconvenience. Further, there is a problem that parts cannot be removed from the housing after assembly thereof, therefore, it is impossible to replace the parts and adjust characteristics of the fuel injection finely.
[0008] The piezoelectric device, the insulator tube, and the connector are not secured completely during assembly thereof and thus are not easy to handle, which may lead to the breakage of the insulator tube. The connector is covered with a resin material using a mold after the fu(:l injector is assembled to insulate the connector from the injector body and thus is fixed in orientation thereof in a circumferential direction of the injector. Accordingly, it is necessary to prepare a connector mold for every type of engine, resulting in an increase ill manufacturing cost of the injector.
[0009] Japanese Patent No. 3010835 discloses a piezoelectric device which is disposed hermetically within a casing which has a bellows for avoiding the ingress of moisture or foreign objects into the piezoelectric device. This structure, however, has the drawbacks in that the bellows has a larger diameter and is difficult to install in small-sized fuel injectors. If the size of the piezoelectric device is decreased to match with that of the fuel injectors, it may cause the performance thereof to be reduced. For theses reasons, fuel injectors equipped with the piezoelectric device as an actuator are not yet put into practical use.
SUMMARY OF THE INVENTION
[0010] It is therefore a principal object of the invention to avoid the disadvantages of the prior art.
[0011] It is another object of the invention to provide an improved structure of a fuel injector which is easy to install and remove a piezoelectric actuator in and from the fuel injector and to adjust fuel injection characteristics finely and which allows an overall size of the fuel injector to be decreased.
[0012] According to one aspect of the invention, there is provided an improved structure of a fuel injector for an internal combustion engine. The fuel injector comprises: (a) a housing to be installed in the engine with a portion of the housing exposed outside the engine; (b) an actuator including an electrically deformable element which works to be deformed in response to input of an electric signal for opening and closing a spray hole selectively; and (c) a structural element installing the actuator in the housing detachably.
[0013] In the preferred mode of the invention, the housing has a length and an end portion thereof exposed outside the engine. A nozzle needle is disposed within the housing in alignment with the actuator so as to be moved in a lengthwise direction of the housing by the deformation of the actuator to open and close the spray hole selectively. The structural element secures the actuator so that the actuator is detachable from the end portion of the housing opposite the nozzle needle across the actuator.
[0014] The actuator has a length with a first end oriented toward the portion of the housing exposed outside the engine. A connector is coupled integrally with the first end of the actuator for establishing an electric connection between the actuator and a power source.
[0015] The housing has firmed therein a vertical chamber which has an opening oriented to a first end of the housing exposed outside the engine. The structural element includes a fastening member which retains the actuator detachably within the vertical chamber. The nozzle needle is disposed in alignment with the actuator within a chamber formed in the housing opposite the first end across the vertical chamber so as to be moved in a lengthwise direction of the housing by the deformation of the actuator to open and close the spray hole selectively.
[0016] The connector may alternatively be installed detachably in the opening of the vertical chamber.
[0017] The connector may include a connector body which is coupled integrally with the actuator and has retains therein leads connecting with the actuator in an electrically insulating fashion.
[0018] A spacer may be disposed between a flange coupled with the first end of the actuator and a shoulder formed in the housing for adjusting a lengthwise location of the actuator within the vertical chamber.
[0019] The fastening member is fastened to the opening of the vertical chamber in the housing to hold the actuator detachably within the vertical chamber. A positioning means is provided for positioning the actuator within the vertical chamber without being subjected to torque or unbalanced load arising from fastening of the fastening member.
[0020] The connector includes an electric terminal portion and a connector body extending from a surface of the electric terminal portion. The fastening member may be implemented by a retaining nut through which the connector body extends. The retaining nut is installed in the opening of the vertical chamber with an outer end facing the surface of the electric terminal portion of the connector through a gap of 5 to 10 mm so that a portion of the connector body is exposed outside the retaining nut.
[0021] The structural element may alternatively be implemented by one of a screw and a structural member joined to the housing by one of staking, welding, and bonding.
[0022] A joint of the structural member and the housing may be set more fragile than any other portions.
[0023] At least one fragile portion may be formed on the housing for facilitating ease of cutting or breaking up the housing for withdrawing the actuator.
[0024] The electrically deformable element may be implemented by a piezoelectric device designed to expand and contract in response to the input of the electric signal. The piezoelectric device is made up of a stack of piezoelectric layers and electrode layers each interposed between adjacent two of the piezoelectric layers.
[0025] According to the second aspect of the invention, there is provided a fuel injector for an internal combustion engine which comprises: (a) a hollow cylindrical housing having a first and a second opening formed in opposed ends thereof, respectively; (b) an actuator disposed within the housing, the actuator including an electrically deformable element which works to be deformed in response to input of an electric signal; (c) a first plate installed on one of the ends of the housing to seal the first opening hermetically; and (d) a second plate installed on the other end of the housing to seal the second opening hermetically, the second plate being so coupled to the housing as to transform the deformation of the electrically deformable element of the actuator into a stroke of a needle for opening and closing a spray hole selectively.
[0026] In the preferred mode of the invention, the second plate is coupled to the housing so as to be displaced in response to the deformation of the electrically deformable element to produce the stroke of the needle.
[0027] The second plate may alternatively be coupled to the housing so as to be deformed elastically in response to the deformation of the electrically deformable element to produce the stroke of the needle.
[0028] The housing includes a bellows which expands and contracts following the deformation of the electrically deformable element.
[0029] A piston is coupled at an end thereof to the electrically deformable element so as to move following deformation of the electrically deformable element within the cylindrical housing. The second plate may be a diaphragm coupled to the housing in contact with the other end of the piston.
[0030] The diaphragm may be coupled to the housing in contact with an end of the rod of the piston. An annular seat member is installed within the second opening of the cylindrical housing through which the rod of the piston extends. A spring member is disposed on the seat member to exert a given pressure on the electrically deformation member in a lengthwise direction thereof.
[0031] The cylindrical housing may have a bellows formed on the end in which the second opening is defined. In this case, the second plate made of a diaphragm is coupled to an end of the bellows to close the second opening.
[0032] The cylindrical housing may be so designed as to extend following the deformation of the electrically deformable element. At least two of the cylindrical housing, the first plate, and the second plate may be formed integrally with each other. The electrically deformable element may be isolated from fluid within the fuel injector.
[0033] The electrically deformable element may be implemented by a piezoelectric device designed to expand and contract in response to the input of the electric signal. The piezoelectric device is made up of a stack of piezoelectric layers and electrode layers each interposed between adjacent two of the piezoelectric layers.
[0034] According to the third aspect of the invention, there is provided a fuel injector for an internal combustion engine which comprises: (a) a hollow cylindrical housing; (b) an actuator disposed within the housing, the actuator including an electrically deformable element which works to expand and contract selectively in a lengthwise direction thereof in response to input of an electric signal; (c) a piston coupled at an end thereof to the electrically deformable element in alignment therewith so as to move following the expansion and contraction of the electrically deformable element; and (d) an extensible member in which the piston is disposed, the extensible member extending in a lengthwise direction thereof so as to allow the piston to move to displace a needle for opening and closing a spray hole selectively, the extensible member being coupled to the housing in alignment therewith in a direction of expansion and contraction of the electrically deformable element.
[0035] In the preferred .mode of the invention, the extensible member is implemented by a bellows.
[0036] A plate is joined to the other end of the piston. If a minimum diameter of the cylindrical housing is defined as A, a minimum diameter of the plate is defined as B, and a maximum diameter of the extensible member is defined as C, at least one of relations of A>C and B>C is satisfied.
[0037] The end of the piston coupled the electrically deformable element is disposed within the cylindrical housing. If a maximum clearance between the end of the piston and an inner wall of the cylindrical housing is defined as d, and a minimum clearance between the piston and an inner wall of the extensible member is defined as e, a relation of d<e is satisfied.
[0038] A first plate is joined to a first end of the cylindrical housing. A second plate is Jointed to a second end of the cylindrical housing opposite the first end. At least two of the cylindrical housing, the extensible member, the first plate, and the second plate are formed integrally with each other. The electrically deformable element is isolated from fluid within the fuel injector.
[0039] The electrically deformable element may be implemented by a piezoelectric device designed to expand and contract in response to the input of the electric signal. The piezoelectric device is made up of a stack of piezoelectric layers and electrode layers each interposed between adjacent two of the piezoelectric layers.
BRIEF DESPCRIPTION OF THE DRAWINGS
[0040] The present invention will be understood more fully from the detailed description giver, hereinbelow and from the accompanying drawings of the preferred embodiments of the invention, which, however, should not be taken to limit the invention to the specific embodiments but are for the purpose of explanation and understanding only.
[0041] In the drawings:
[0042] [0042]FIG. 1 is a vertical sectional view which shows a fuel injector according to the first embodiment of the invention;
[0043] [0043]FIG. 2 is a perspective view which shows a common rail system for a diesel engine using fuel injectors of the types shown in FIG. 1;
[0044] [0044]FIG. 3 is a vertical sectional view which shows an actuator installed in the fuel injector of FIG. 1;
[0045] [0045]FIG. 4 is a vertical sectional view which shows an actuator according to the second embodiment of the invention;
[0046] [0046]FIG. 5 is a partially sectional view which shows an actuator according to the third embodiment of the invention;
[0047] [0047]FIG. 6 is a partially sectional view which shows an actuator according to the fourth embodiment of the invention;
[0048] [0048]FIG. 7( a ) is a side view which shows a connector for establishing an electric connection between a power supply and an actuator of FIG. 6;
[0049] [0049]FIG. 7( b ) is a bottom view of the connector of FIG. 7( a );
[0050] [0050]FIG. 8 is a vertical sectional view which shows a fuel injector according to the fifth embodiment of the invention;
[0051] [0051]FIG. 9 is a vertical sectional view which shows a fuel injector according to the sixth embodiment of the invention;
[0052] [0052]FIG. 10 is a vertical sectional view which shows an actuator installed in the fuel injector of FIG. 9;
[0053] [0053]FIG. 11 is a perspective view which shows a piezoelectric device built in the actuator of FIG. 10;
[0054] FIGS. 12 ( a ) and 12 ( b ) are views which show adjacent piezoelectric layers raking up the piezoelectric device of FIG. 11;
[0055] [0055]FIG. 12( c ) is an exploded view which shows a stack of piezoelectric layers making up a drive portion of the piezoelectric device of FIG. 11;
[0056] FIGS. 13 ( a ) and 13 ( b ) are perspective views which show modifications of the piezoelectric device of FIG. 11;
[0057] [0057]FIG. 14 is a vertical sectional view which shows an actuator according to the seventh embodiment of the invention;
[0058] [0058]FIG. 15 is a vertical sectional view which shows an actuator according to the eighth embodiment of the invention;
[0059] [0059]FIG. 16 is a vertical sectional view which shows an actuator according to the ninth embodiment of the invention;
[0060] [0060]FIG. 17 is a vertical sectional view which shows an actuator according to the tenth embodiment of the invention, FIGS. 18 ( a ), 18 ( b ), 18 ( c ), and 18 ( d ) are sectional views which show modifications of the actuator of FIG. 17;
[0061] FIGS. 19 ( a ), 19 ( b ), 19 ( c ), 19 ( d ), 19 ( e ), and 19 ( f ) are sectional views which show modifications of the actuator of FIG. 10;
[0062] FIGS. 20 ( a ), 20 ( b ), 20 ( c ), 20 ( d ), 20 ( e ), and 20 ( f ) are sectional views which show modifications of the actuator of FIG. 15;
[0063] [0063]FIG. 21 is a partially sectional view which shows a fuel injector according to the eleventh embodiment of the invention;
[0064] [0064]FIG. 22 is a partially sectional view which shows a fuel injector according to the twelfth embodiment of the invention; and
[0065] [0065]FIG. 23 is a partially sectional view which shows a fuel injector according to the thirteenth embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0066] Referring to the drawings, wherein like reference numbers refer to like parts in several views, particularly to FIG. 1, there is shown a fuel injector 100 according to the invention. The following discussion will refer to, as an example, a common rail fuel injection system, as shown in FIG. 2, in which the fuel injector 100 is provided for each cylinder of a diesel engine 300 .
[0067] The common rail fuel injection system includes a common rail 200 which accumulates therein fuel supplied from a fuel tank 400 elevated in pressure by a fuel pump installed in the engine 300 . When it is required to inject the fuel into the engine 300 , the fuel stored under high pressure in the common rail 200 is supplied to the fuel injectors 100 .
[0068] The fuel injector, 100 includes, as shown in FIG. 1, an upper housing 2 in which an actuator 1 is disposed and a lower housing 3 which is jointed to the upper housing 2 in alignment therewith and has a injection nozzle 4 .
[0069] The upper housing 2 is made of a hollow cylindrical member and has a vertical chamber 21 formed eccentrically with a longitudinal center line thereof. In the vertical chamber 21 , the actuator 1 is disposed. The upper housing 2 has formed therein a high-pressure fuel passage 22 which extends in parallel to the vertical chamber 21 and connects at an upper end thereof to a fuel inlet connector 23 . The fuel inlet connector 23 projects outside the upper housing 2 (i.e., the cylinder of the engine 300 ) and communicates with the common rail 200 , as shown in FIG. 2. An fuel outlet connector 25 is installed in an upper portion of the upper housing 2 opposite the fuel inlet connector 23 . The fuel flowing into a drain passage 24 is discharged from the fuel outlet connector 25 to the fuel tank 400 . The drain passage 24 leads to a gap 50 between an inner wall of the vertical chamber 21 and the actuator 1 and to a three-way valve 51 through a passage (not shown) extending vertically through the upper and lower housings 2 and 3 .
[0070] The injection nozzle 4 has a needle 41 and a spray hole 43 . The needle 41 is slidable vertically within a nozzle block 31 to spray fuel in a fuel sump 42 from the spray hole 43 . The fuel sump 42 is defined around a middle portion of the needle 41 and leads to a lower end of the high-pressure fuel passage 22 . The needle 41 is applied with the pressure of the fuel in the fuel sump 42 which works to move the needle 41 in an upward direction (also referred to as a valve-opening direction below) and the pressure of the fuel in a back pressure chamber 44 which works to move the needle 41 in a downward direction (also referred to as a valve-closing direction below). When the pressure in the back pressure chamber 44 drops, it will cause the needle 41 to be lifted upward to open the spray hole 43 , initiating a fuel jet.
[0071] The pressure in the back pressure chamber 44 is controlled by the three-way valve 51 . This pressure control is achieved by selectively establishing communications between the back pressure chamber 44 and the high-pressure fuel passage 22 and between the back pressure chamber 44 and the drain passage 24 . The switching of these communications is achieved by moving a ball of the three-way valve 51 , as indicated by a broken line in FIG. 1. The movement of the ball is accomplished by displacing a large-diameter piston 52 and a small-diameter piston 54 through the actuator 1 . The small-diameter piston 54 is hydraulically coupled with the large-diameter piston 52 through a pressure chamber 53 . Three-way valves are known per se, and explanation thereof in detail will be omitted here.
[0072] The actuator 1 , as clearly shown in FIG. 3, consists essentially of a thin-walled metallic hollow cylindrical housing 11 , a laminated piezoelectric device (also called a piezo stack) 61 , and a piston 62 . The piezoelectric device 61 is disposed within an upper portion of the housing 11 . The piston 62 is disposed slidably within the housing 11 in alignment with the piezoelectric device 61 .
[0073] The piezoelectric device 61 may be of a known type which is, as will be described in detail later, made up of a stack of piezoelectric discs each having electrodes formed on both surfaces thereof. A conductive paste is applied to a side wall of the stack of the piezoelectric discs to form side terminals (not shown) connecting positive and negative sides of the electrodes, respectively. The side terminals are coupled to leads 72 a and 72 b of a connector 7 . The application of voltage to the piezoelectric device 61 through the connector 7 will cause the piezoelectric device 61 to contract or expand in a longitudinal direction thereof. An insulator 63 is disposed within the housing 11 so as to surround the periphery of the piezoelectric device 61 to isolate the piezoelectric device 61 electrically from the housing 11 .
[0074] The connector 7 has, as clearly shown in FIG. 3, a cylindrical connector body 71 welded to an upper open end of the housing 11 . The leads 72 a and 72 b extend through vertical holes (not shown) formed in the connector body 71 and connect with a connector terminal or plug 73 disposed on the connector body 71 . The leads 72 a and 72 b are hermetically sealed in the connector body 71 for providing for airthghtness and electric insulation. The connector body 71 has a flange 71 on which a retaining nut 74 is disposed around the periphery of the connector body 71 . The retaining nut 74 is, as shown in FIG. 1, screwed into an upper end of the upper housing 2 to install the connector 7 in the upper housing 2 . The plug 73 of the connector 7 is held at an interval a of 5 to 10 mm away from an upper end of the retaining nut 74 so as to expose an upper portion of the connector body 7 outside the retaining nut 74 for facilitating, as will be described later in detail, ease of positioning the actuator 1 within the vertical chamber 21 .
[0075] The piston 62 has a small-diameter rod 64 extending downward, as viewed in FIG. 3, from a lower surface thereof. An annular seat 12 is welded to an inner wall of the housing 11 . A coil spring 65 is disposed between an upper surface of the annular seat 12 and the lower surface of the piston 62 around the rod 64 to urge the piston 62 upward into constant engagement with a lower end of the piezoelectric device 61 . The rod 64 extends slidably through a central hole of the annular seat 12 and reaches a diaphragm 66 mounted on a lower end of the housing 11 . The diaphragm 66 is made of a thin metallic disc in the form of a conical spring and welded at a peripheral edge thereof to a ring formed on a lower end of the annular seat 12 , thereby sealing a lower opening of the housing 11 hermetically.
[0076] The diaphragm 66 is elastically deformed by vertical movement of the rod 64 . Specifically, when energized, the piezoelectric device 61 expands vertically and pushes the piston 62 downward, as viewed in FIG. 3, to project the diaphragm 66 downward through the rod 64 . This causes the large-diameter piston 52 disposed, as shown in FIG. 1, in the upper housing 2 in contact with the diaphragm 66 to move downward. Specifically, a stoke of the piston 62 produced by the expansion of the piezoelectric device 61 is transmitted through the diaphragm 66 to the large-diameter piston 52 . The large-diameter piston 52 is installed coaxially with the vertical chamber 21 of the upper housing 2 so as to be slidable within the upper housing 2 . The downward movement of the large-diameter piston 52 is transformed into a rise in pressure in the pressure chamber 53 , as shown in FIG. 2, defined between the upper and lower housings 2 and 3 , which is, in turn, causes the small-diameter piston 54 to be shifted downward. The small-diameter piston 54 is disposed slidably within a cylindrical chamber 32 formed in the lower housing 3 coaxially with the fuel injector 100 . The vertical movement of the piezoelectric device 61 (i.e., the stoke of the large-diameter piston 52 ) is amplified as a function of a difference in diameter between the large-diameter piston 52 and the small- diameter piston 54 .
[0077] The fabrication of the actuator 1 is accomplished by inserting the annular seat 12 having the diaphragm 66 welded to the bottom thereof into the housing 11 from the lower opening, welding the annular seat 12 to the inner wall of the housing 11 , putting the spring 65 , the piston 62 , and the piezoelectric device 61 covered with the cylindrical insulator 63 into the housing 11 from the upper opening, welding the connector body 71 to the upper end of the housing 11 , and placing this assembly in a mold to form a resinous block of the plug 73 of the connector 7 .
[0078] The installation of the thus fabricated actuator 1 in the upper housing 2 is accomplished by inserting the actuator 1 into the vertical chamber 21 from the upper opening thereof, holding the upper portion of the connector body 71 , as indicated at a in FIG. 3, using a given jig or a tool, and fastening the retaining nut 74 . A shoulder 21 a is formed on the inner wall of the vertical chamber 21 to define an upper large bore whose inner wall is threaded. The flange 75 of the connector body 71 is seated on the shoulder 21 a through a ring shim 13 . The shim 13 works to seal a gap between the flange 75 and the shoulder 21 a and also serves as a spacer for adjusting the vertical position of the actuator 1 within the vertical chamber 21 to regulate :he injection characteristics of the fuel injector 100 (e.g., the amount of fuel to be sprayed) finely.
[0079] The use of the retaining nut 74 to secure the actuator 1 in the upper housing 2 facilitates ease of removal of the actuator 1 after used up and allows the plug 73 of the connector 7 to be adjusted in orientation easily. When the retaining nut 74 is fastened, the gap a of 5-10 mm is kept between the bottom of the plug 73 and the upper end of the retaining nut 74 . The upper portion of the connector body 71 is held by a tool such as a damper or nipper. This avoids application of undesirable torque or unbalanced load to the actuator 1 during installation in the upper housing 2 .
[0080] The piezoelectric device 61 is protected by the housing 11 . The leads 72 a and 72 b connected to the piezoelectric device 61 are held by the connector body 71 welded to the housing 11 , thus facilitating ease of handing of the actuator 1 and ensuring high degrees of airtightness and electric insulation of the whole of the actuator 1 . This also enables use of the gap 50 between the inner wall of the vertical chamber 21 and the outer wall of the actuator 1 as a drain passage, thus resulting in a decrease in holes to be drilled in the upper housing 2 . The small-diameter piston 54 is formed coaxially with the upper housing 2 , thus resulting in a decrease in overall length of an eccentric hole (i.e., the vertical chamber 21 and a chamber in which the large-diameter piston 52 is disposed), thereby facilitating ease of machining of the eccentric hole.
[0081] In operation of the fuel injector 1 , when it is required to inject the fuel into the engine 300 , an engine controller (not shown) applies the voltage to the piezoelectric device 61 , so that the piezoelectric device 61 extends and pushes the piston 62 , the diaphragm 66 , and the large-diameter piston 52 downward, as viewed in FIG. 1. The downward movement of the large-diameter piston 52 causes the volume of the pressure chamber 53 to be decreased, thus resulting in a rise in pressure in the pressure chamber. 53 This causes the small-diameter piston 54 to move to push the ball of the three-way valve 51 downward, so that the fuel in the back pressure chamber 44 flows to the drain passage 24 , thereby decreasing the fuel pressure in the back pressure chamber 44 . This causes the needle 41 to be lifted up to open the spray hole 43 , so that the fuel in the fuel sump 42 is sprayed into the engine 300 . When it is required to stop the spray of the fuel, the engine controller drops the voltage applied to the piezoelectric device 61 to contract it, thereby causing the piston 62 to be lifted upward by the spring pressure of the coil spring 65 . The diaphragm 66 and the large-diameter piston 52 are thus moved upward, so that the pressure in the pressure chamber 53 drops, thus causing the small-diameter piston 54 to be lifted upward. The lifting of the small-diameter piston 54 causes the ball of the three-way valve 51 to be moved upward to establish the communication between the high-pressure fuel passage 22 and the back pressure chamber 44 , so that the fuel pressure in the back pressure chamber 44 is elevated to push the needle 41 downward, thereby closing the spray hole 43 .
[0082] [0082]FIG. 4 shows the actuator 1 according to the second embodiment of the invention.
[0083] A bellows 11 b is coupled with the lower end of the housing 121 . The bellows 11 b is closed at a lower opening thereof by a diaphragm 11 a . The diaphragm 11 a is in contact with the bottom of the rod 64 of the piston 62 . The bellows 11 b has substantially the same length as that of the rod 64 and urges the piston 62 into constant engagement with the bottom of the piezoelectric device 61 . The downward movement of the rod 64 will cause the bellows 11 b to expand, so that the diaphragm 11 b moves downward.
[0084] Other arrangements are identical with those in the first embodiment, and explanation thereof in detail will be omitted here.
[0085] [0085]FIG. 5 shows the fuel injector 100 according to the third embodiment of the invention.
[0086] The connector body 71 is fitted directly in the upper opening of the upper housing 2 with a flange 78 placed on the upper end of the upper housing 2 . A mount plate 76 is secured on the upper end of the upper housing 2 using bolts 16 to nip the flange 78 between itself and the upper end of the upper housing 2 to retain the actuator 1 in the upper housing 2 firmly. The gap a of 5-10 mm is kept, like the first embodiment, between the bottom of the plug 73 and the upper end of the mount plate 76 for avoiding application of undesirable torque or unbalanced load to the actuator 1 during installation in the upper housing 2 .
[0087] Other arrangements are identical with those in the first embodiment, and explanation thereof in detail will be omitted here.
[0088] [0088]FIG. 6 shows the fuel injector 100 according to the fourth embodiment of the invention.
[0089] The connector body 71 of the connector 7 is machined to an illustrated shape. Specifically, a threaded portion identical with the retaining nut 74 in the first embodiment is formed on the connector body 71 to screw the connector body 71 directly into the upper opening of the upper housing 2 .
[0090] The connector 7 has a plug 73 ′, as shown in FIGS. 7 ( a ) and 7 ( b ), which is fitted on an upper portion of the connector body 71 . The plug 73 ′ has formed on the bottom thereof an annular rail 77 . The annular rail 77 has a plurality of protrusions formed around an outer periphery thereof which establish firm engagement with the connector body 71 when the plug 73 ′ is fitted in the connector body 71 for holding the plug 73 ′ from rotating about the connector body 71 . A positive terminal 74 a is, as clearly shown in FIG. 7( b ), provided in the center of the annular rail 77 . A negative annular terminal 74 b is disposed coaxially with the positive terminal 74 a . The annular rail 77 is fitted in an annular groove formed in the upper end of the connector body 71 to establish electric connections of the positive and negative terminals 74 a and 74 b with the leads 72 a and 72 b.
[0091] Other arrangements are identical with those in the first embodiment, and explanation thereof in detail will be omitted here.
[0092] [0092]FIG. 8 shows the fuel injector 100 according to the fifth embodiment of the invention.
[0093] The upper housing 2 consists of two parts: a head 2 a and a cylinder 2 b . The head 2 a has, like the first embodiment, the fuel inlet connector 23 and the fuel outlet connector 25 and also has formed therein a cylindrical chamber 21 ′ and a fuel inlet passage 22 ′. When the head 2 a is fitted on the cylinder 2 b , the cylindrical chamber 21 ′ and the fuel inlet passage 22 ′ communicate with the vertical chamber 21 and the high-pressure fuel passage 22 , respectively. The connector 7 has the plug 73 ′ identical in structure with the one in the fourth embodiment of FIG. 6. The connector body 71 ′ consists of an upper small-diameter portion and a lower large-diameter portion. The lower large-diameter portion is fitted in the cylindrical chamber 21 ′ in engagement with an upper inner wall of the cylindrical chamber 21 ′ through the shim 13 .
[0094] The installation of the actuator 1 in the upper housing 2 is initiated without fitting the plug 73 ′ on the connector body 71 ′. Specifically, the actuator 1 is first inserted into the cylinder 2 b of the upper housing 2 , after which the head 2 a is coupled to the connector body 71 ′ in a screw fashion. The head 2 a has formed in a bottom thereof an annular chamber 26 which has a threaded inner wall. The cylinder 2 b has an tipper flange whose peripheral wall is threaded and engages the inner wall of the annular chamber 26 . The connector body 71 ′ is, as described above, retained in the cylindrical chamber 21 ′ through the shim 13 . Finally, the plug 72 ′ is fitted on the connector body 71 ′ in a desired orientation.
[0095] The cylindrical chamber 21 ′ is formed in the head 2 a coaxially with a vertical center line of the head 2 a , thereby resulting in a decreased in length of an eccentric hole (i.e., the vertical chamber 21 and the chamber in which the large-diameter piston 52 is disposed), thereby facilitating ease of machining of the eccentric hole.
[0096] Other arrangements are identical with those in the first embodiment, and explanation thereof in detail will be omitted here.
[0097] FIGS. 9 to 12 ( c ) shows the fuel injector 100 according to the sixth embodiment of the invention which is a modification of the fifth embodiment.
[0098] The actuator 1 , as clearly shown in FIG. 10, includes a piston 62 coupled to the lower end of the piezoelectric device 61 , a metallic hollow cylindrical housing 11 , and an extensible member 14 coupled to the lower end of the housing 11 . The piston 62 is disposed in the extensible member 14 in alignment with the piezoelectric device 61 installed within the housing 11 . A head plate 81 is joined to a head 144 of the extensible member 14 . A plate 82 is joined to the upper end of the housing 11 to seal it hermetically.
[0099] The piezoelectric device 61 may be used in any of the above described first to fifth embodiments. The piezoelectric device 61 , as clearly shown in FIGS. 11 to 12 ( c ), consists of a stack of piezoelectric layers 61 A and positive and negative inner electrodes 621 and 622 which are disposed alternately between the piezoelectric layers 61 A, respectively. Each of the positive inner electrodes 621 extends at one side thereof to a side: surface 601 of one of the piezoelectric layers 61 A, while each of the negative inner electrodes 622 extends at one side thereof to a side surface 602 opposite to the side surface 601 . Specifically, the positive and negative electrodes 621 and 622 are exposed to opposite side walls of the piezoelectric device 61 , respectively. The positive and negative electrodes 621 and 622 are coupled at the exposed sides thereof to each other through vertically extending side electrodes 631 and 632 . The side electrodes 631 and 632 are each made by baking a silver paste containing 97% of Ag and 3% of glass frit.
[0100] Outer electrodes 643 are, as shown in FIG. 10, coupled to the side electrodes 631 and 632 using a conductive adhesive. The outer electrodes 643 are each made of a 18-8 stainless steel. The conductive adhesive is made from a resinous silver containing 80% of Ag and 20% of epoxide.
[0101] The piezoelectric device 61 , as clearly shown in FIG. 11, consists essentially of three parts: a drive portion 611 ranging over a central portion of the piezoelectric device 61 in a lengthwise direction thereof, buffer portions 612 located on both sides of the drive portion 611 , and dummy portions 613 located at the ends of the piezoelectric device 61 .
[0102] The piezoelectric device 61 is produced using known green sheets. The green sheet is made in the following manner. First, powders of lead oxide, zirconium oxide, titanium oxide, niobium oxide, and strontium carbonate that are main components of a piezoelectric material are prepared at a given rate. For compensating for a loss of the lead caused by evaporation in a subsequent process, it is preferably enriched by about 1 to 2% in a stoichometric ratio. Next, the powders are mixed and dried in a mixing chamber and then baked temporarily at 800 to 950° C. To this mixture, demineralized water and dispersant is added to produce slurry. The slurry is subjected to the wet grinding using a mill, dried, and then decreased to remove binder, after which it is mixed with solvent, binder, plasticizer, and dispersant in a ball mill. This is then agitated using an agitator within a vacuum device to be degassed and adjusted in viscosity.
[0103] Next, the slurry is, shaped using a doctor blade device into a layer of a constant thickness to produce a green sheet. The green sheet withdraws from the doctor blade device is cut in a cutting machine or a press machine to a rectangular shape. Note that the drive portion 611 , the buffer portions 612 , and the dummy portions 613 are made of the same green sheets.
[0104] An Ag/Pd paste containing of silver and palladium of 7:3 ratio is applied to one surface of the rectangular green sheet to print an electrode pattern (i.e., the inner electrode 621 or 622 in FIG. 12( a ) or 12 ( b )), using screen printing techniques to form each of the piezoelectric layers 61 A.
[0105] Each of the inner electrodes 621 and 622 , as can be seen from FIGS. 12 ( a ) and 12 ( b ), occupies one surface of the piezoelectric layer 61 A other than a side portion 619 . Specifically, each of the inner electrodes 621 and 622 of a stack of the piezoelectric layers 61 A reaches either of the side surfaces 601 and 602 . The inner electrodes 612 and 622 may alternatively be made of copper, nickel, platinum, or silver or a mixture thereof.
[0106] The piezoelectric layers 61 A of a number required to provide a desired amount of expansion of the whole of the drive portions 611 and the buffer portions 612 are prepared in the above manner. Additionally, the rectangular green sheets on which no electrodes are formed are also prepared which are employed as piezoelectric layers 61 B, as will be described below in detail, in forming the buffer portions 612 and the dummy portions 613 .
[0107] The piezoelectric layers 61 A and 61 B are stacked up in the following manner to produce the piezoelectric device 61 . FIG. 12( c ) illustrates only the drive portion 611 for convenience. The drive portion 611 is made by stacking the piezoelectric layers 61 A so that the electrode-nonformed side portions 619 are alternately oriented in opposite directions. Half of the inner electrodes 621 of the piezoelectric layers 61 A exposed to the side surface 601 , as shown in FIG. 11, are used as positive electrodes, while the remainders exposed to the side surface 602 are used as negative electrodes.
[0108] The buffer portions 612 are each made by stacking the piezoelectric layers 61 A and the electrode-nonformed piezoelectric layers 61 B alternately. The dummy portions 613 are each made by stacking only the piezoelectric layers 61 B. In this manner, a stack of the piezoelectric layers, 61 A and 61 B, as shown in FIG. 11, is produced.
[0109] The thus produced piezoelectric stack is thermo-compressed using, for example, a hot-water rubber press, after which it is degreased at 400 to 700° C. in an electric furnace and baked at 900 to 1200° C.
[0110] An Ag paste is applied to the side surfaces 601 and 602 of the piezoelectric stack and baked to form the side electrodes 631 and 632 which lead electrically to the inner electrodes 621 and 622 , respectively. The side electrodes 631 and 632 may alternatively be made of an Ag/Pd paste or using copper, nickel, platinum, or silver/palladium.
[0111] External electrodes 634 are, as shown in FIG. 10, joined to the side electrodes 631 and 632 using a conductive adhesive. Next, a dc voltage is applied to the inner electrodes 621 and 622 through the external electrodes 634 to polarize a stack of the piezoelectric layers 61 A to produce the piezoelectric device 61 . The external electrodes 634 may alternatively be soldered or brazed to the side electrodes 631 and 632 or bonded directly to the inner electrodes 621 and 622 , respectively, without using the side electrodes 631 and 632 . The external electrodes 634 are preferably formed by a waved strip made of a metallic foil or a waved metallic wire which may be sheathed.
[0112] The dummy portions 613 are, as described above, made up of the piezoelectric layers 61 B which are identical in material with the piezoelectric layers 61 A, thus resulting in a decrease in manufacturing cost of the piezoelectric device 61 .
[0113] Finally, the thus produced piezoelectric device 61 is disposed in the housing 11 and compressed through the piston 62 and the head plate 81 by the reactive force from the extensible member 14 .
[0114] The piston 62 , as shown in FIG. 10, consists of a base 62 b substantially identical in sectional area with the piezoelectric device 61 and a rod 62 a . The rod 62 has an outer diameter of 6 mm. The piston 62 is made of a quenched stainless steel. To the end of the rod 62 , the head plate 81 is joined which is made of a disc member having an outer diameter B of 10.2 mm.
[0115] The housing 11 made of a stainless steel pipe which is 0.3 mm in thickness and 10.2 mm in outer diameter A. The extensible member 14 is implemented by a bellows which is made of a stainless steel having a thickness of 0.17 mm and consists of large-diameter portions 141 and small-diameter portions 142 arrayed alternately. The large-diameter portions 141 have a diameter C of 9.5 mm. The small-diameter portions 142 have a diameter of 6.5 mm. The bellows also includes the rear end 143 joined to the end of the housing 11 and the head 144 joined to the head plate 81 The rear end 143 has substantially the same diameter as the diameter A of the housing 11 . The head 144 has substantially the same diameter as the diameter B of the head plate 81 .
[0116] The extensible member 14 is joined at the rear end 143 thereof to the housing 11 and at the head 144 to the head plate 81 hermetically. The upper plate 82 is installed on the upper end of the piezoelectric device 61 to seal the upper opening of the housing 11 hermetically. The upper plate 82 has formed therein holes 821 through which the external electrodes 634 extend outside the housing 11 . The upper plate 82 has an outer diameter equal to the outer diameter A of the housing 11 . Sealing members 822 are fitted in the through holes 821 to seal gaps between the external electrodes 634 and inner walls of the holes 821 , respectively.
[0117] The minimum outer diameter A of the housing 11 , the maximum outer diameter B of the head plate 81 joined to the rod 62 a of the piston 62 , and the maximum outer diameter C of the extensible member 14 meet the relations of A>C and B>C. Specifically, the extensible member 14 is smaller in diameter than the housing 11 and the head plate 81 installed on both sides of the extensible member 14 , thereby avoiding physical contact with the inner wall of the vertical chamber 21 of the fuel injector 100 during operation of the actuator 1 , thus resulting in an increase in lifespan of the extensible member 14 . Note that at least one of the relations of A>C and B>C may be satisfied.
[0118] If a maximum clearance between an inner wall of the housing 11 and the base 62 b of the piston 62 and a minimum clearance between an inner wall of the extensible member 42 and the rod 62 a of the piston 62 are defined as d and e, then d<e. This causes the piezoelectric device 61 and the base 62 b of the piston 62 to hit on the inner wall of the housing 11 when the piston 62 deflects horizontally during the operation of the piezoelectric device 61 , thereby avoiding physical contact of the piston rod 62 a with the extensible member 14 thus resulting in an increase in lifespan of the extensible member 14 .
[0119] The installation of the actuator 1 assembled in the above manner in the fuel injector 100 of FIG. 9 is accomplished by inserting the actuator 1 into the vertical chamber 21 while keeping the gap 50 through which the fuel flows and securing the housing 11 in the same manner as that in the fifth embodiment of FIG. 8 so that the head plate 81 may move in a lengthwise direction of the actuator 1 .
[0120] As apparent from the above discussion, the actuator 1 of this embodiment has the extensible member 14 joined to the end of the housing 11 in alignment therewith so as to absorb a lengthwise movement of the piezoelectric device 61 and the piston 62 , thus eliminating the need for the housing 11 to have an extensible portion in itself. This allows the housing 11 to be minimized in thickness, so that the outer diameter of the housing 11 can be decreased, thereby allowing the size of the actuator 1 to be reduced without sacrificing the performance of the piezoelectric device 61 .
[0121] The piezoelectric Crevice 61 is not limited in cross section to a square shape and may alternatively be made up of barrel-shaped piezoelectric layers 61 A and 61 B, as shown in FIG. 13( a ) or octagonal piezoelectric layers 61 A and 61 B, as shown in FIG. 13( b ).
[0122] [0122]FIG. 14 shows the actuator 1 according to the seventh embodiment of the invention which is a modification of the sixth embodiment. Specifically, the piston 62 is reverse in location on the piezoelectric device 61 to that in the sixth embodiment.
[0123] The piston 62 is installed on the upper end of the piezoelectric device 61 . The extensible member 14 is joined at the rear end 143 to the upper end of the housing 11 and at the head 144 to the plate 83 . The plate 83 has formed therein holes 831 through which the external electrodes 634 extend. Sealing members 832 are fitted in the holes 831 to seal gaps between inner wall of the holes 831 and the external electrodes 634 hermetically. The external electrodes 634 are welded to wires 63 A which extend outside the plate 83 and to conductive members 63 B which extend downward, as viewed in the drawing, and connect with the side electrodes of the piezoelectric device 61 . The external electrodes 634 may alternatively be soldered or brazed to the wires 63 A and the conductive members 63 B or staked to establish electric communications therewith. Each of the conductive members 631 is joined to an overall length of one of the side electrodes of the piezoelectric device 61 .
[0124] The housing 11 is made of a stainless steel and stores therein the piezoelectric device 61 . The housing 11 is identical in diameter with the one in the first embodiment. The extensible member 14 is made of a stainless steel and identical in structure with the one in the sixth embodiment.
[0125] A lower plate 84 having the same diameter as that of the housing 11 is joined to a lower end of the housing 11 .
[0126] The actuator 1 of this embodiment is installed in the fuel injector 100 identical in structure with the one in the sixth embodiment. Specifically, the piezoelectric device 61 is so secured in the upper housing 2 that the housing 11 can be moved vertically by the activation of the piezoelectric device 61 . Other arrangements are identical with those in the sixth embodiment, and explanation thereof in detail will be omitted here.
[0127] [0127]FIG. 15 shows the actuator 1 according to the eighth embodiment of the invention which is different from the sixth embodiment only in that a diaphragm 85 is used. Other arrangements are identical, and explanation thereof in detail will be omitted here.
[0128] The diaphragm 85 is joined to the head 144 of the extensible member 14 in physical contact with the end of the rod 62 a of the piston 62 so that a central portion of the diaphragm 85 may be deformed vertically by a vertical movement of the piston 62 . The diaphragm 85 has the sane diameter as that of the head 144 and is made of a metallic disc spring.
[0129] [0129]FIG. 16 shows the actuator 1 according to the ninth embodiment of the invention.
[0130] The piston 62 has the rod 62 a which is shorter than that in the eighth embodiment of FIG. 15 and connects at an end thereof to a central portion of the diaphragm 11 c . The diaphragm 11 c is formed integrally with a lower end of the housing 11 . Other arrangements are identical with those in the eighth embodiment, and explanation thereof in detail will be emitted here.
[0131] [0131]FIG. 17 shows the actuator 1 according to the tenth embodiment of the invention which is different from the above embodiments in that the movement of the piezoelectric device 61 is transmitted directly to the large-diameter piston 2 without use of a piston.
[0132] The housing 11 ′ is made of a metallic cylindrical bellows consisting of large-diameter portions 111 and small-diameter portions 112 arrayed alternately. The housing 11 ′ is closed by an upper plate 86 and a lower plate 87 hermetically. The upper plate 86 has formed therein holes 861 through which the external electrodes 634 extend outside the housing 11 ′. The sealing members 832 are fitted ill the holes 861 to seal gaps between inner wall of the holes 861 and the external electrodes 634 hermetically.
[0133] The piezoelectric device 61 is disposed within the housing 11 ′ and compressed elastically by the upper and lower plates 86 and 87 through the housing 11 ′. When energized, the piezoelectric device 61 expands vertically along with expansion of the housing 11 ′ to push the lower plate 87 downward, as viewed in the drawing. The structure of this embodiment results in decreases in parts to be assembled and parts-joining process, thereby simplifying the parts management and production processes.
[0134] The housing 11 ′ may alternatively be formed integrally, as shown by circles in FIGS. 18 ( a ) and 18 ( b ), at a lower end or an upper end thereof with the lower plate 87 or the upper plate 86 . Additionally, the lower plate 87 may be replaced, as shown in FIG. 18( c ) or 18 ( d ), with a diaphragm 85 . In FIG. 18( c ), the housing 11 ′ is formed integrally at the lower end thereof with the diaphragm 85 . In FIG. 18( d ), the housing 11 ′ is formed integrally at the upper end thereof with the upper plate 86 . The diaphragm 85 is joined to the lower end of the housing 11 ′.
[0135] It is important for the structure in which the piezoelectric device 61 is disposed in the housing 11 to ensure the airtightness. However, as the number of parts making up the actuator 1 increases, the possibility that failures in joining the parts increase, resulting in leakage of air will increases, and the manufacturing costs will also increase. In order to avoid these problems, it is advisable that at least two of the housing 11 ′, the upper plate 86 , and the lower plate 87 be formed integrally with each other. This results in a decrease in joint of the actuator 1 thereby assuring the actuator remains highly airtight and also decreasing the manufacturing costs.
[0136] Similarly, the actuator 1 of the sixth embodiment in FIG. 10 may also have parts formed integrally with each other, as shown in FIGS. 19 ( a ) to 19 ( f ). In FIG. 19( a ), the upper plate 82 is formed integrally with the housing 11 . In FIG. 19( b ), the rear end 143 of the extensible member 14 is formed integrally with the lower end of the housing 11 . In FIG. 19( c ), the head plate 81 is formed integrally with the extensible member 14 . At least two of these parts, as clearly shown by circles in FIGS. 19 ( d ) to 19 ( f ), may also be formed integrally with each other.
[0137] Additionally, the actuator 1 of the eighth embodiment in FIG. 15 may also have parts formed integrally with each other, as shown in FIGS. 20 ( a ) to 20 ( f ). In FIG. 20( a ), the upper plate 82 is formed integrally with the housing 11 . In FIG. 20( b ), the rear end 143 of the extensible member 14 is formed integrally with the lower end of the housing 11 . In FIG. 20( c ), the diaphragm 85 is formed integrally with the extensible member 14 . At least two of these parts, as clearly shown by circles in FIGS. 20 ( d ) to 20 ( F ), may also be formed integrally with each other.
[0138] [0138]FIG. 21 shows the fuel injector 100 according to the eleventh embodiment of the invention.
[0139] The piezoelectric crevice 61 is disposed directly within the vertical chamber 21 of the upper housing 2 without use of the housing 11 . The connector body 71 is secured on the upper end of the piezoelectric device 61 . The installation of the piezoelectric device 61 in the vertical chamber 21 of the upper housing 2 is accomplished, similar to the first embodiment, by inserting the piezoelectric device 61 to which the connector 7 is joined into the vertical chamber 21 from the upper opening of the upper housing 2 , holding an upper end portion of the connector body 71 , as indicated by a, using a given tool, and fastening the retaining nut 74 to nip the flange 75 of the connector body 71 between the retaining nut 74 and the shoulder 21 a of the upper housing 2 through the shim 13 . The shim 13 serves as a spacer for adjusting a vertical location of the piezoelectric device 61 within the upper housing 2 . This avoids application of undesirable torque or unbalanced load to the actuator 1 during installation in the upper housing 2 .
[0140] It is impossible for this structure to define a drain passage between the outer wall of the piezoelectric device 61 and the inner wall of the vertical chamber 21 . A fuel passage (not shown) is, therefore, formed directly in the upper housing 2 which leads to the three-way valve 51 . The vertical displacement of the piezoelectric device 61 is transmitted to the large-diameter piston 52 through the rod 64 . Other arrangements are identical with those in the first embodiment, and explanation thereof in detail will be omitted here.
[0141] In a case where there is no need for replacing or adjusting the piezoelectric device 61 , and it is required only to withdraw the piezoelectric device 61 from the fuel injector 100 for discarding it, the connector body 71 , as shown in FIG. 22 as the twelfth embodiment, may be secured in the upper housing 2 by staking, welding, or bonding a flange 711 formed on a middle portion of the connector body 71 in the upper end of the upper housing 2 . It is advisable that the strength of a joint of the connector body 71 and the upper housing 2 be lower than that of another portion for facilitating ease of removal of the piezoelectric device 61 .
[0142] [0142]FIG. 23 shows the fuel injector 100 according to the thirteenth embodiment of the invention.
[0143] The upper housing 2 has at least one fragile portion 27 formed near the lower end of the piezoelectric device 61 for facilitating ease of cutting or breaking up the upper housing 2 in order to withdraw the piezoelectric device 61 . The fragile portion 27 is defined by an annular groove formed in a peripheral outer wall of the upper housing 2 .
[0144] While the present invention has been disclosed in terms of the preferred embodiments in order to facilitate better understanding thereof, it should be appreciated that the invention can be embodied in various ways without departing from the principle of the invention. Therefore, the invention should be understood to include all possible embodiments and modifications to the shown embodiments witch can be embodied without departing from the principle of the invention as set forth in the appended claims. For example, the three-way valve 51 is used to open and close the injection nozzle 4 , however, the invention is not limited to the same. Another known mechanism may be used to open and close the injection nozzle 4 . Further, the actuator 1 is implemented by a piezoelectric device, however, another element may be used as long as it is so constructed as to be expand and contract in response to input of an electric signal.
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A fuel injector for an internal combustion engine is provided. The fuel injector has a simple structure that is easy to install and remove a piezoelectric valve actuator in and from the fuel injector and to adjust fuel injection characteristics finely and that allows an overall size of the fuel injector to be decreased. The fuel injector includes a housing to be installed in the engine and a structural element serving to install the piezoelectric valve actuator in the housing to be detachable easily. The piezoelectric valve actuator is retained in an actuator casing fitted in the housing so that it can expand or contract to move a needle valve. The actuator casing has an extensible portion in itself or is coupled to a bellows in alignment for enabling the piezoelectric valve actuator to expand, thereby allowing the size of the actuator casing to be minimized.
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This application is a continuation of application Ser. No. 09/399,200 filed on Sep. 17, 1999 (issuing on Jul. 3, 2001 as U.S. Pat. No. 6,254,480) which, in turn is a continuation-in-part of application Ser. No. 09/989,599 filed on Dec. 12, 1997 and issued on Sep. 21, 1999 as U.S. Pat. No. 5,954,582.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to computerized wagering systems generally, and more specifically to a wagering system with improved communication between a central computer and remote terminals.
2. Description of the Related Art
Lotteries are used by many countries, states and localities as a way to generate revenue without raising taxes. There are various games available for wagering, such as Lotto and Keno, dependent upon the locality. In a typical lottery, a player will select or may be assigned a set of numbers upon which to wager. Each number set is referred to as a play, and the combination of all plays is referred to as the pool. From the pool an administrator will usually withdraw a percentage of money wagered, and the remainder will be available to the players in the form of winnings. The winnings may be distributed to one or more players, once again depending upon the rules of the particular game. The numbers chosen by the player in a single play may be required to be unique in some games, while in pari-mutuel games a number may be shared by many players, resulting in divided winnings. Furthermore, there may also be winnings for numbers that only partially match the winning number. For example, games that require six different numbers will often pay winnings to players that have matched three, four or five of the six numbers. The biggest prize, however, will typically be reserved for a player who matches all six numbers. In many games, some or all of the winnings may be rolled over to a new game, in the event there are not any matches for the particular category of winnings.
One lottery game which assigns number sets to players uses random numbers generated by a central computer to produce so-called “quick picks.” These games reduce the probability of duplicate winners and consequential lowering of payoff prices common in pari-mutuel games. The larger top prize payouts help with publicity, and the games are popular among casual users. Tickets are preferably generated on-site, which reduces the risk of tickets being improperly printed or altered, while also simplifying distribution of tickets. A very desirable feature of the computer generated number selections is the speed at which the player and agent may both complete a wagering transaction, so the benefits of concurrent ticket generation can only be realized if tickets can truly be generated instantly.
Unfortunately, one of the challenges of lotteries, particularly with wide geographical participation, is that a wagering system may be required to process tens or even hundreds of thousands of plays each day. These transactions must be secure, since pay-outs may involve millions of dollars. Security not only includes fraud prevention, but also includes secure storage and retention of each play from a pool. In the prior art, security of the system has been ensured by requiring an agent or vendor to submit wagers to a central location for verification. The central location then relays authorization, often in the form of a ticket serial number which may be used by the vendor to print the lottery ticket. The player gets a printed receipt, while the agent and the central computer may each have a record of the wager. Security is enhanced, since each play is recorded against the particular selling agent, and the central computer will have data necessary to monitor and regulate the activity occurring at an agent's terminal. Inappropriate activity occurring at a single terminal can be quickly recognized, so liabilities from attempted break-ins or theft of sales agent equipment can be constrained. A significant challenge with this system, however, is the need for frequent communication with the central computer.
In older wagering systems, communication with a central location occurred through an exchange of paper documents. However, the paper was easily altered or damaged, and clerical errors were a problem. Furthermore, wide geographic areas were difficult to process quickly, limiting such systems mostly to relatively small, local pools. With more economical desktop data processing capability came the ability to reduce or eliminate human intervention, thereby eliminating clerical errors. Some systems began using magnetic media instead of paper to transport plays to the central location. The magnetic media addressed some clerical issues, but exchanging magnetic media did not improve turn-around time or system security, since the media could still be tampered with and still required time for physical transport to a central location.
Today, improved telecommunications systems allow nearly instantaneous exchange between agent terminals and the central computer, eliminating the need for a package courier and reducing any delay that might be associated therewith. Desktop computers process a play and then establish a telecommunications link with a central computer through either a dial or dedicated line. Therein lies a constraint, however. The amount of data exchanged between an agent terminal and central computer is relatively small, which would normally dictate a dial up line. Unfortunately, the cost associated with remote locations dialing in using long distance circuits can be prohibitive, limiting the geographical region for the lottery to the local calling area. Furthermore, any delay in processing is inconvenient to both players and agents, particularly with the computer selected numbers games. Yet the dial line requires the added delay of establishing the telephone connection. When larger payouts are available and the lottery widely publicized, sales should be most rapid. Unfortunately, it is those same days when demand is the greatest that the telecommunication lines tend to encounter more “busy” connections. As a result, dial up lines are generally unacceptable.
One alternative to the dial-up connection is the use of a dedicated telecommunications link which is available for immediate data exchange. With this type of link, dialing delays, including “busy” signals, are eliminated. Unfortunately, such links are prohibitively expensive and can usually only be justified for the busiest of agent systems, or where there are a number of agent terminals in close physical proximity which can be grouped together to share such a link. Furthermore, in spite of the high costs associated with hard-wired links, there is nothing to be gained in terms of system delays which occur on the busiest days. While each play may contain a seemingly small amount of data, the central computer must still receive and process the data on each play. On those busy days when tens or hundreds of thousands of plays need to processed, even fairly small data amounts can easily flood a system and tremendously delay processing. State of the art systems address this problem by designing networks and systems capable of handling these peak loads (although requiring a capital investment in facilities). In developed countries, the communications infrastructure can support these requirements. In areas where the infrastructure is not available, alternate technologies may be required involving private networks using satellite and radio links custom designed for this purpose. These methods substantially increase the cost of lottery systems.
The prior art has disclosed various improvements, but these improvements are not completely satisfactory.
For example, McCarthy, in U.S. Pat. No. 5,276,312 incorporated herein by reference, proposes another more recent alternative. In the McCarthy system, desktop or hand held agent terminals are used to process and accumulate plays off-line, with subsequent transmission to the central computer. Upon establishing a connection with the central computer, the agent terminals will download complete information such as a unique agent terminal identification, serial numbers of tickets sold, numbers selected on each play, and other similar known information which may be desired, even, in some instances, including complete demographic information on the player. By enabling the agent terminals to process and accumulate data in a secure manner, the wagering system may operate in either an on-line mode or an off-line mode, allowing the system to operate nearly instantaneously, even in the event the central computer becomes intermittently inaccessible. Unfortunately, however, the McCarthy system must still transmit a full, potentially very large record of data for each ticket sold, including selected wager numbers and ticket serial numbers.
Moreover, Burr et al, in U.S. Pat. No. 4,982,337, discloses an instant ticket wagering system. In the Burr et al wagering system, agent terminals (therein referred to as point-of-sale terminals) are equipped with modems, enabling communication with a central computer over standard dial-up telephone lines. Either the agent terminals or the central computer can initiate communication, and preferably the sales agent is not responsible for initiating or making the connection, but instead the terminals are accordingly programmed. Communication may advantageously be during off hours, allowing the agent terminals to respond instantaneously to players during sales periods and instantaneously to the central computer at other times. However, the Burr et al system disadvantageously uses pre-printed tickets which are bearer instruments having value. The tickets may be altered or stolen more readily, and must be accounted for carefully. The Burr et al disclosure illustrates this accounting system. However, there is no disclosure nor suggestion on how to improve the performance of on-line or off-line wagering systems using “quick pick” tickets generated at the point-of-sale terminal or how to reduce the data transmission requirements of such a system.
Additionally, Kapur, in U.S. Pat. No. 5,119,295 discloses an off-line method of selling lottery tickets using a large number of security techniques and encryption methods useful for security purposes. While many of these techniques could find application in the present invention and are therefore also incorporated herein by reference, there are no teachings which illustrate how to reduce the amount of data transferred to the central, or host computer. Rapp, in U.S. Pat. No. 4,713,787 is also incorporated herein by reference for his disclosure of suitable algorithms which could be used together with the present invention to generate random numbers.
SUMMARY OF THE INVENTION
In a first manifestation, the invention comprises a method of operating a computerized lottery system, wherein the necessity for spontaneously transmitting each individual wager from a remote terminal to a host computer is eliminated, and wherein the total amount of data transmitted therebetween is substantially reduced, thereby reducing the consequent cost of transmission and enhancing the number and types of economically viable transmission alternatives. This manifestation of the invention includes the steps of providing a host computer and a remote terminal; generating a seed number at the host specific to a pool and the remote terminal; transmitting the seed to the remote terminal; producing pseudo-random wager numbers sequentially for sequential plays within the pool; conveying from remote to host a total number of sequential plays; and reconstructing at the host pseudo-random wager numbers and serial numbers associated with each of the plays from the total number of sequential plays.
In a second manifestation, the invention comprises a method of securely and compactly communicating wagering information regarding plays of a game between remote computers. This manifestation of the invention comprises the steps of establishing one remote computer as a host terminal and establishing one remote computer as an agent terminal; delivering to the remote computers a pseudo-random number generating algorithm; generating and delivering a seed number to the remote computers; using the algorithm and seed number to produce pseudo-random wager numbers; assigning at the agent terminal wager numbers and sequential serial numbers to sequential plays made at the agent terminal, and creating a wager receipt for each of said plays therefrom; closing the game; conveying a total number of sequential plays from agent terminal to host terminal; reconstructing wager numbers and serial numbers at the host terminal from the algorithm, seed number and total number of said plays provided by the agent terminal; determining winning wagers; ascertaining a liability of remote computers based upon winning wagers and wager numbers; and communicating winning selections and liability data to the remote computers.
Other manifestations of this invention are also disclosed herein, comprising additional steps, such as printing wager tickets, developing multiple algorithms for different games, and cashing winning tickets.
OBJECTS OF THE INVENTION
A first object of the present invention is to provide off-line, instantaneous sales of computer selected number plays. A further object of the invention is to reduce the amount of data transmitted between a central computer and each agent terminal. Another object of the invention is to improve system security over the prior art for such an off-line wagering system. A further object of the invention is to enable remote terminals to economically access a central computer through short message satellite packet transmission systems as well as dial up networks, possibly including the Internet. Yet a further object of the invention is to enable rapid setup of lottery agents, without investment and delay attributable to communication infrastructure of traditional on-line lottery systems. These and other objects of the invention are achieved in the preferred embodiment, which offers significant advantage over prior art communication systems.
In an alternate embodiment of the system and method of the present invention, the algorithm is located only in the host and a series of tickets is generated in the host and transmitted to the terminal, say by floppy disk. The terminal would then merely transmit a total to the host.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart which illustrates various steps of the preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Wagering system communication method 100 comprises various steps, or protocol, for communication between sales agent terminals and a host computer. Step 102 is the provision of host computer and terminals. In the prior art, the host computer was usually a main frame computer designed for rapid, high volume transaction processing. While that is still the preferred embodiment, it should be understood that with the rapid advances in computer hardware a variety of other types of computers are contemplated. Exemplary are distributed processing systems and the progressively more powerful workstations and desktop computers. Similarly, terminals may take many forms, ranging from specially designed lottery dispensers to multi-purpose devices such as grocery checkout scanners and may even include portable or mobile hand-held devices.
The present invention does not require any dedicated communications lines, thereby avoiding any delays that might arise from waiting for the establishment of the line. By not demanding unusual or unavailable computer hardware, method 100 offers significant advantages to many existing systems, as will be outlined and described hereinbelow, and makes new, previously uneconomical systems economically viable.
In step 104 , pseudo-random number generator algorithms are developed for each different lottery game to be controlled by the host computer. While not essential to the rest of the invention, the inclusion of step 104 provides improved security across various wagering games. If security provisions of one game should be violated, including accessing the algorithm used for that game, only that game will be affected. The algorithms may be of the type described in Rapp, previously incorporated herein by reference, or may be of the type employed in some programming languages. The particular algorithm used is not critical to the invention, and many alternatives are known and available, though algorithms that provide good statistical distribution of numbers are most preferred.
The algorithm must be delivered to both the host computer and all remote terminals in step 106 . In order for communication method 100 to work, the host and terminals must all be using the same algorithm for the same game. The algorithm may be delivered to all of the computers and changed periodically by transmission over the telecommunications line, or may be provided through some other media, depending upon the level of security required. Various media are contemplated for delivery, including magnetic and optical media, and semiconductor chips such as EPROM and EEPROM devices including those incorporated into cards and other portable devices. Once again, the particular delivery media is not critical to the invention, and depending upon particular security requirements, various media may offer relative advantage at different times. Even the courier methods may be varied to include telecommunications transmissions, package courier services, personal visits and other known methods.
Once the agent terminals are provided with an algorithm, they must be provided with a seed number to start a new pool in a game. The seed numbers are generated in step 108 at the host computer, normally through the generation of a set of random seed numbers using an algorithm similar to those developed in step 104 . The seed numbers are transmitted from the host computer to each agent terminal in step 110 . The host computer will record and store the seed numbers together with data fields to identify which terminal received a particular seed and which game the seed will be used for. Transmission 110 will most frequently occur over a telecommunication link, and will require very few data bytes, since a seed number will typically only be a few digits in length. While it should be noted that the seed itself provides enhanced security against intercepted transmissions due to its random nature, systems requiring more extensive security transmission of the seed numbers may encrypt the seed with various digit scrambling techniques to prevent unauthorized access. Once transmission 110 is completed, agent terminals are self-sufficient and will generally operate in an off-line mode through steps 112 - 118 , which describe the sale of each individual play.
In step 112 , a ticket agent or terminal will request a player to select a particular denomination of wager. The unit denomination is predetermined for each game, and so the wager can only be in whole number multiples of the unit denomination. For example, a five dollar unit denomination game will only allow wagers of one, two, three or more times the unit denomination, amounting to five, ten, fifteen, or more dollars. Each unit denomination will represent an individual play, so a wager of three times the unit denomination will be treated as three separate plays. The terminal will use the algorithm delivered in step 106 and the seed number transmitted in step 110 to generate pseudo-random wager numbers in step 114 . Each sequential play will be assigned the next pseudo-random wager number in the sequence, and a sequential serial number will also be assigned to the play in step 116 . In addition to the sequence number, additional information on the ticket will include the terminal identifier and the date of the ticket draw. This information may be encrypted to aid against attempted alteration of the ticket as is done in traditional systems.
It is important to note that the exact sequence of step 114 relative to steps 112 and 116 is not critical. For example, the sequence of pseudo-random numbers may be generated well in advance of actual wagering. Once wager numbers and serial numbers have been assigned to all of the plays in a particular wager, the wager will most preferably be printed onto lottery tickets in step 118 . The lottery tickets serve as a receipt and claim check for use by the player. Many alternatives are known and available to the printing of tickets and will be understood to be incorporated herein. However, and for various reasons, the printing of tickets is most preferred and widely accepted. Once all tickets associated with a wager are printed, the agent terminal is ready to process the next wager at step 112 , as shown by flow line 150 .
At some time, usually announced in advance, a game will be scheduled to be closed as shown in step 120 . The actual closing will be accomplished in the preferred embodiment by a message sent from the host computer to each terminal. An alternate means would be to transmit the closing time and date along with the original seed data which was transmitted before the pool was opened for sales. Accurate timing information can be obtained by the terminal from various sources including an internal clock and or timing information from WWV transmissions provided by the National Bureau of Standards or GPS signals available worldwide from inexpensive receivers. The terminals then calculate the number of tickets sold for each game, herein referred to as counts, and then convey the counts back to the host in step 122 . The counts are conveyed to the host using a fixed length message which is independent of the number of tickets sold in each game. In addition to conveying the counts, the terminals will identify themselves in a way unique to each terminal. The identifier may be as simple as a few digit indicia or may be more advanced, potentially using the caller identification sequence used on many telecommunications systems. Once again, the level of security desired for the system will dictate the particular indicator, as illustrated by the Kapur reference previously incorporated herein.
The conveyance of counts to the host requires a very short block of data. The data block may be many orders of magnitude shorter than blocks of data transmitted in the prior art. For example, a typical terminal may generate several thousand transactions per week. In a typical prior art system, each wager results in approximately 50 bytes of data and may yield about 100 kilobytes of data per week. The present invention requires less than 100 bytes of data to accomplish the same exchange of information, or only one thousandth the data. Because of the vastly reduced amount of data to be exchanged, and because the agent terminals may be operated off-line for extended periods, many communications methods may be used to convey the counts. For example, the price of access to satellite packet transmission systems is based in part on the amount of data to be transmitted, and is not normally economical using prior art wagering methods. Satellite transmission, specifically VSAT technology, is used for transmission of lottery information; dedicated links are required, and the costs are high.
However, the present invention enables economical usage of such packet transmission systems. Furthermore, the off-line sale of wagers allows each sales agent terminal to process wagers instantaneously, meeting the timing requirements not achieved by other prior art systems. In effect, each agent terminal acts as a distributed processor, separately and independently handling the actual sales transactions and accumulating them for simple transmission back to the host after poll closing step 120 . In the present invention then, the host computer does not act as a block or delay on peak wagering days. Customers may continue to be served nearly instantaneously, thereby improving both short and long term sales achieved by each agent terminal and enhancing the goodwill associated with the agent.
Once all of the data is conveyed to the host as in step 122 , the host begins to reconstruct each play including the wagering selection and serial number of each ticket, as shown in step 124 . Since the host has each algorithm and each seed number used at a terminal, the host can reproduce the pseudo-random sequence of wagers sold by the terminal. As long as the host has stored or receives the first serial number and the total count, all of the ticket information can be reproduced by the host for each wager. Next, winning tickets are determined in step 126 . There are many methods presently employed for determining winning tickets, ranging from widely televised and elaborate drawings of winning number combinations to simple computer random number picks using yet another seed number or algorithm. Once the winning numbers are determined, this information is introduced to the host computer, and winning tickets are determined. Within the host the liability of each terminal is ascertained in step 128 . A new random seed number is generated for each pool for each terminal in step 130 , which is identical to step 108 , and the new seed numbers, winning selections and liability data are all transmitted to each agent terminal in step 132 . The order of steps 128 and 130 is not critical.
Each agent terminal is now ready to begin processing wagers for a new pool, and so the steps of selling wagers will restart beginning with step 112 , as shown by flow line 160 . Separately, each agent terminal will reproduce each pool and compare the wager numbers sold to the winning numbers and compute liabilities. The liabilities should correspond with the host computer data transmitted in step 132 , to confirm accurate reception of all data, as shown in step 134 . The sales agent may then cash winning tickets and return the tickets to a central lottery office for proper crediting of agents' accounts, thereby concluding a single pool of plays.
Each agent terminal may be adapted to simultaneously process several different games, in which case each game might preferably follow a separate flow through method 100 , though the overall method will be the same. Additionally, the number of agent terminals is nearly limitless, in view of the minimal amount of interchange between host and agent. Furthermore, agent terminals may be fixed in location, such as the grocery store bar code scanners mentioned earlier, or could conceivably be remote, mobile hand-held devices useful, for example, on board a ship and interconnected via satellite and/or cellular telephone links. The drastic reduction in data transmission afforded by the present invention advantageously offers new degrees of freedom to wagering systems.
While the foregoing details what is felt to be the preferred embodiment of the invention, no material limitations to the scope of the claimed invention are intended. Further, features and design alternatives that would be obvious to one of ordinary skill in the art are considered to be incorporated herein. With this in mind, the scope of the invention is set forth and particularly described in the claims hereinbelow.
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The necessity for spontaneously transmitting each individual wager from a remote terminal or terminals to a host computer in a computerized lottery system is completely eliminated. As a result, the total amount of data transmitted between the remote terminals and the host computer is substantially reduced. This reduces the consequent cost of transmission and enhances the number of economically viable transmission alternatives. A total number of sequential plays is conveyed from the remote terminal or terminals to the host computer. Pseudo-random wager numbers and serial numbers associated with each of the plays is reconstructed at the host computer from the total number of sequential plays. The reduced data exchange facilitates novel methods of data transfer, such as satellite packet transmission and cellular service.
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FIELD OF THE INVENTION
The present invention pertains to relief printing and in particular to preparation of an enhanced relief printing plate.
BACKGROUND OF THE INVENTION
Flexography, which is one example of relief printing, produces an image on a substrate by transferring ink from the surface of a relief plate, representing the image, directly to a substrate. Relief features in a flexographic plate are typically formed by subjecting a plate precursor to a curing radiation (e.g. ultraviolet light) through an image-wise mask and then developing the precursor to wash away parts of the plate that have not received sufficient curing radiation. The resulting relief features typically comprise solid areas and halftone dots of varying sizes and/or quantities per area to represent a range of tones specified by the image data. For example, a highlight tone can be represented by an array of very small relief dots in an area, a shadow tone can be represented by an array of large dots in an area, and a full tone can be represented by a solid relief area.
A number of challenges exist in preparing and printing with relief plates. One challenge is to produce relief features that accurately represent image features. Another challenge is to transfer an optimal quantity of ink from relief features so that printed ink densities on the substrate have a wide range and relatively linear correlation with image tonality. Another challenge is to transfer ink with a uniform density to the substrate so that areas representing a specific image tonality have a consistent appearance. The prior art teaches a number of techniques to address individual challenges, as described below. However, similar techniques appear to produce a variety of results.
U.S. Pat. No. 6,063,546 (Gelbart) teaches the use of a mask with varying optical density to control the amount of curing radiation delivered to individual plate precursor features. In particular, Gelbart teaches that relief feature accuracy can be improved by allowing a full exposure for highlight features, and gradually reducing exposure as tonality increases to some optimal level for full tone features. Gelbart teaches an analog method for varying optical density. For example, one or more layers of UV light-absorbing mask material can be removed to provide partial transparency for an image feature in a mask. Gelbart also teaches a digital method for varying optical density. For example, Gelbart teaches an area modulation technique involving a pseudo-random distribution of opaque features in an image area of a mask to effect an average reduction in exposure for the corresponding relief feature. Gelbart teaches that these opaque features should be small enough that upon exposure and developing they are not resolved in the relief plate (e.g. as relief holes).
U.S. Pat. No. 7,279,254 (Zwadlo) teaches laminating a mask to a plate precursor prior to exposure to improve the accuracy of relief features. It is believed that laminating reduces the gap between the mask and precursor so that curing radiation is less likely to scatter into areas of the precursor surrounding a transparent area of the mask. Zwadlo also teaches using a mask that includes a transparent substrate layer as a barrier. It is believed that laminating such a mask on a precursor prevents oxygen from reaching the plate precursor during exposure. In the presence of oxygen, some plate precursor materials require higher exposure levels to cure and thus image features can shrink in size, resulting in less accurate features.
U.S. Pat. No. 6,492,095 (Samworth) teaches using a pattern of opaque features in a mask to form a pattern of ink-carrying cells (holes) in solid relief areas to improve ink transfer to the printing substrate. Samworth teaches that the cell size should be small enough so that the aggregate volume of ink-carrying cells is less than that of the cells in the inking roller but big enough to form holes in the relief. Samworth suggests a suitable size is approximately 30 microns in diameter corresponding to a cluster of typical (e.g. 2400 DPI or approximately 10 micron) image pixels. Thus, in contrast with Gelbart, Samworth teaches deliberately creating holes in the relief media but only in areas of solid relief.
U.S. Pat. No. 6,731,405 (Samworth) extends the idea to also create ink-carrying cells in other halftone relief features according to the associated tonality. Samworth teaches using smaller or fewer ink-carrying cells in lower-tone features and to vary the size or quantity so that a greater aggregate cell volume is achieved for areas of higher tone than for areas of lower tone.
U.S. Patent Publication No. 2007/0002384 (Samworth et al.) teaches controlling ink film thickness on halftone dots by controlling the dimension of halftone dot relief features. For example, an approximately circular halftone dot will include at least one concentric ring of pixels that receives ink and one concentric ring of pixels that does not receive ink. This is in contrast with U.S. Pat. Nos. 6,492,095 and 6,731,405 (both to Samworth) which teaches creating ink-receptive cells in ink-receptive relief areas.
U.S. Patent Publication No. 2007/0002384 (Samworth et al.) also teach that the dimension of ink-receptive portions of halftone dots should vary to allow different thicknesses of film to be delivered for different tonalities. In particular, Samworth et al. teaches that near 50% tone, ink film thickness should be increased by increasing the dimension of ink-receptive portions of halftone features. Further, Samworth et al. teaches increasing the dimension (e.g. ring width) to make a smooth transition to a solid ink-receptive area for 100% tone.
U.S. Pat. No. 6,701,847 (Weichmann) teaches varying ink density on the printed substrate by superimposing a basic halftone image raster with a fine microraster to reduce the quantity of transferred ink. The microraster serves to reduce the area coverage of image areas (e.g. create holes in the printed image) to reduce the quantity of transferred ink. Weichmann further teaches varying the microraster to provide a gentle transition in reduced area coverage from a maximum amount at full tone to a minimum amount at some lower tone. Weichmann teaches, for example, the use of a checkerboard microraster with 5 micron by 10 micron holes arranged in a checkerboard pattern to achieve a 50% area coverage and corresponding ink density reduction.
Thus, it is clear from the prior art that creating a pattern of holes in halftone data can be used for a variety of purposes. It is not clear from the prior art why seemingly similar techniques produce significantly different results in the printing plate and printed image. It may be that some techniques produce different results for different printing processes. From empirical study of the state of the art of relief printing, however, it is clear that there is room for improvement.
For example, accurate representation of halftone relief features throughout the tonal range is still a challenge. In particular, it is desirable that relief features have relatively steep shoulders in order to resolve very fine features and to provide a precise delineation of relief boundaries. It is also desirable that printed ink densities range from a maximum amount for full tone image areas to minimal amounts in the extreme highlight tonal areas. It is also desirable that printed tonality vary with nearly a linear correlation to requested tonality. It is also desirable that ink be transferred with a uniform appearance in areas of consistent tonality.
SUMMARY OF THE INVENTION
The present invention provides a system and method for producing a relief image article that, when used in a printing process, produces a printed image with good image accuracy, dynamic range, ink density uniformity, and tonal linearity.
According to one aspect of the invention, a pattern can be applied to substantially all image feature sizes of the halftone image data to reduce the transparency of image areas of a mask by a constant amount. The resultant mask can be affixed to a plate precursor to form an intimate contact with, and a gaseous barrier to, the plate precursor. The plate precursor can then be exposed to curing radiation and the mask removed. After processing, the precursor forms a relief plate carrying a relief image that resolves the pattern in the surface of relief features. Solid ink densities are substantially maintained or increased when the pattern is applied to solid relief features.
According to another aspect of the invention, the pattern comprises an arrangement of nearly opaque and nearly transparent features. In preferred embodiments, the opaque features reduce image area transparency by at least 25%. In one preferred embodiment the opaque features reduce image area transparency by approximately 50%.
According to preferred embodiments of the invention, the pattern comprises a regular pattern of opaque features each of which is of a size smaller than 10 microns by 10 microns. In one preferred embodiment, the opaque feature size is approximately 10 microns by 5 microns. In one preferred embodiment, the regular pattern comprises a checkerboard pattern of opaque features.
According to another aspect of the invention, the pattern can be applied to nominal halftone data representing image features larger than a minimum size corresponding to a very small halftone dot. In one preferred embodiment, the minimum size corresponds to a halftone dot corresponding to tonality of 3% at a resolution of 2400 DPI. In another preferred embodiment, the predetermined size corresponds to halftone image features with an effective diameter of at least 30 microns.
According to some embodiments of the invention, the pattern can be excluded from certain areas of halftone features. For example, the pattern may be excluded from perimeter pixels. As another example, the pattern may be excluded from small feature protrusions.
These and other aspects of the present invention are illustrated in the detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are diagrams illustrating an exemplary relief plate and precursor according to the prior art.
FIG. 2 is a diagram illustrating an exemplary pattern of opaque features according to one preferred embodiment of the present invention.
FIGS. 3A and 3B are diagrams illustrating nominal and processed halftone data according to one embodiment of the present invention.
FIGS. 4A and 4B are diagrams illustrating an exemplary relief plate and precursor produced according to the present invention.
FIGS. 5A and 5B are micrographs of exemplary shoulder angles of relief features according to the prior art and the present invention.
FIGS. 6A-6E are micrographs of exemplary portions of relief plates produced according to the present invention.
FIG. 7 is a graph illustrating exemplary printed ink densities according to the prior art and the present invention.
FIG. 8 is a graph illustrating exemplary uncalibrated tonal response according to the prior art and the present invention.
FIGS. 9A and 9B are micrographs of solid image areas of an exemplary printed substrate according to the prior art and the present invention respectively.
FIGS. 10A and 10B are micrographs of negative text features of an exemplary printed substrate according to the prior art and the present invention respectively.
FIGS. 11A and 11B are micrographs of positive text features in non-image areas of an exemplary printed substrate according to the prior art and the present invention respectively.
FIGS. 12A and 12B are micrographs of mid-tone image areas of exemplary printed substrate according to the prior art and the present invention respectively.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1A is a diagram illustrating an exemplary relief plate 20 according to the prior art. For example, relief plate 20 can be made from photopolymers and used in flexographic printing. Relief plate 20 includes a plate floor 21 which, for example, can be formed from photopolymer material cross-linked by exposure to curing radiation through the back surface. Relief plate 20 also includes relief features 22 - 24 , whose top surfaces are intended to transfer ink to a printing substrate to reproduce image features.
Small relief feature 22 is amongst the smallest relief feature that can reliably transfer ink to the printing substrate. Some of the smallest small relief features 22 may not have sufficient relief height to reliably accept ink. Alternatively, small relief features 22 that are too small may have sufficient relief height but may not reliably transfer ink to the printing substrate. For example, a small relief feature 22 that is too small may be so narrow that it bends or breaks under pressure. Typically, small relief feature 22 corresponds to a halftone dot of less than approximately 3% tonality at about 2400 DPI.
Nominal relief feature 23 represents halftone image features having a nominal size ranging from the minimum (e.g. 3% tonality) to below the maximum (i.e. solid tone). Solid relief feature 24 corresponds to the largest size image feature or solid tone (e.g. maximum ink density per unit area on the printed substrate).
Relief features 22 - 24 are formed through exposure to curing radiation 9 so that malleable photopolymer is cross-linked into a more stable state. Relief features 22 - 24 can typically have an approximately conical shape with a shoulder 25 . The angle of shoulder 25 can vary somewhat for different features 22 - 24 . Ideally, the angle of shoulder 25 is relatively steep so that the top surface of relief feature 22 - 24 is precise.
FIG. 1B is a diagram illustrating an exemplary relief plate precursor 1 according to the prior art. Plate precursor 1 can, for example, comprise an uncured photopolymer material. One exemplary embodiment of plate precursor 1 is Flexcell NX flexographic media, manufactured by Eastman Kodak Company. Processing of plate precursor 1 includes at least formation of an image-wise mask 2 and exposure of plate precursor 1 to radiation 9 (e.g. UV light) through mask 2 .
Mask 2 can be made from a variety of materials and with a variety of structural compositions. In general, however, mask 2 is a substantially planar article that is typically formed as an integral part of plate precursor 1 or is arranged in close proximity to the surface of plate precursor 1 . Mask 2 includes areas that are highly opaque to curing radiation 9 and areas that are relatively transparent to curing radiation 9 .
According to preferred embodiments of the invention, mask 2 is initially a separate article and comprises at least a substantially transparent barrier layer 3 and a substantially opaque layer 4 . In preferred embodiments, mask 2 is laminated to plate precursor 1 prior to exposure with curing radiation 9 . One exemplary embodiment of mask 2 is thermal imaging layer film manufactured by Eastman Kodak Company.
Prior to lamination, however, portions of opaque layer 4 are removed to leave image areas 5 that will allow exposure of plate precursor 1 to curing radiation 9 . Portions of opaque layer 4 can be removed by thermal ablation as an example. After exposure to curing radiation 9 , plate precursor 1 can be further processed, for example, to remove portions that have not been cured. Areas typically removed below opaque layer 4 are outlined with dashed lines.
Depth dimensions of plate precursor 1 and mask 2 can vary. As an example, plate precursor depth 8 for Flexcell NX media can be in the range of 45-67 mils. As another example, mask depth 7 for thermal imaging layer film can be approximately 6-7 mils with the depth of opaque layer 4 being approximately 1-2 microns. Note that, for the embodiment of thermal imaging layer film laminated to Flexcell NX media, opaque layer 4 at least partially deforms plate precursor 1 .
In pursuit of further improvements to laminated Flexcell NX media, the applicants experimented with the composition of image areas 5 . In particular, instead of completely removing opaque layer 4 to reveal image area 5 , portions of opaque layer 4 were retained in image areas 5 in an attempt to optimize the exposure of relief features 22 - 24 and in particular to increase the angle of shoulders 25 .
A variety of arrangements of opaque features within image areas 5 were evaluated. For example, the opaque coverage area (i.e. percentage of image area 5 covered by opaque portions) was varied. As another example the opaque coverage area was varied according to the size of the corresponding image area 5 . As another example, the size of opaque features used for image area 5 was varied. As another example, the positioning of opaque features used for image area 5 was varied (e.g. randomized and regular patterns). As another example, the placement of opaque features in relation to the border of image area 5 was varied. One patterned arrangement of opaque features appeared to provide good improvement in the angle of shoulders 25 .
FIG. 2 is a diagram illustrating an exemplary pattern 10 of opaque features according to one preferred embodiment of the present invention. Pattern 10 comprises a regular arrangement (i.e. checkerboard) of portions of opaque layer 4 . For halftone image data with a square resolution of approximately 2400 DPI, certain dimensions of pattern 10 were found to improve shoulder angles. For example, a value of approximately 10 microns was determined for opaque portion width 11 . Also, a value of approximately 5 microns was determined for opaque portion length 13 . Since halftone image pixel length 12 at 2400 DPI is approximately 10 microns, pattern 10 reduces the transparency of image area 5 by approximately 50%.
Surprisingly, pattern 10 could be applied with good results to most image areas 5 . In particular, pattern 10 could be beneficially applied to all but the smallest image areas 5 (i.e. corresponding to small relief feature 22 ). In one preferred embodiment, pattern 10 could be excluded from certain boundary portions of image area 5 .
In one preferred embodiment, application of a pattern can involve a simple post-processing operation performed by a data processor on nominal halftone data. The process can involve first up-sampling the halftone data to 4800 DPI in one dimension. Next, the up-sampled halftone data can be eroded by one pixel at image feature boundaries to produce a secondary halftone data. Isolated image features that have been eroded from the up-sampled data can then be added back to the secondary halftone data. Next, the original up-sampled data can have the checkerboard pattern applied and then be combined with the modified secondary halftone data so that very small image features are not patterned. In other embodiments, patterning may be avoided at the boundary of halftone features to more precisely delineate those boundaries.
FIGS. 3A and 3B are diagrams illustrating nominal and processed halftone data according to one preferred embodiment of the present invention. FIG. 3A illustrates exemplary nominal halftone data at a resolution of 2400 DPI. Nominal halftone image feature 14 A is very small, comprising three adjacent pixels. Nominal halftone image features 14 B and 14 C are somewhat larger, comprising seven and eight adjacent pixels respectively. Nominal halftone image features 14 D and 14 E are thin lines with maximum height of two and three pixels respectively. Larger dots, lines, and other solid tone features of varying sizes are also depicted for clarity.
FIG. 3B illustrates the nominal halftone data of FIG. 3A , processed by one preferred pattern processing method of the present invention. The resolution is now 4800 DPI across the page. Processed halftone image features 15 A and 15 B, corresponding to nominal halftone image features 14 A and 14 B respectively, are un-patterned but now comprise six and fourteen pixels respectively. Processed halftone image features 15 C and 15 E are partially patterned in areas where their original dimensions were sufficiently large between boundaries. Processed halftone image feature 15 D is un-patterned since nominal halftone image feature 14 D is only two pixels high.
AM halftoning generally produces dots of varying sizes in an area to represent tonality. Thus, dots of size approximately 30 microns in diameter will be patterned and substantially all of the halftone dots (e.g. for tonality 3% and above) will be patterned accordingly. FM halftoning generally produces dots of about the same size but with varying density per unit area. In flexography, FM dot sizes can be selected from a range of about 10 microns to 70 microns (or larger). Typically, larger FM dots sizes (25 microns or larger) are preferred so that patterning would be applied to substantially all FM halftone dots for the larger FM dot sizes.
FIGS. 4A and 4B are diagrams illustrating an exemplary relief plate 20 and plate precursor 1 produced according to the present invention. Small relief feature 22 is the same in both prior art and inventive relief plates 20 . Patterned nominal relief feature 26 and patterned solid relief feature 27 have pattern 10 resolved in their top surface. Patterned relief features 26 and 27 also have shoulders 25 that are steeper than those of corresponding relief features 23 and 24 of the prior art. Patterned image areas 6 in FIG. 4B represent corresponding image areas 5 that are modified by applying pattern 10 to opaque layer 4 in those areas.
Note that scale of features in FIGS. 3A , 3 B, 4 A, and 4 B are not exact. Empirically, the applicants have found that for an opaque layer 4 with a depth of approximately 1 micron, corresponding depressions of approximately 2-3 microns are formed by pattern 10 in patterned relief features 26 and 27 .
FIG. 5A depicts cross section 30 of a portion of a Flexcell NX printing plate produced according to the prior art. Adjacent nominal relief features 23 were produced by exposing the plate precursor through a laminated thermal imaging layer mask produced with nominal halftone data. Nominal relief features 23 include shoulders 25 having shoulder angle 35 A.
FIG. 5B depicts cross section 31 of a portion of a Flexcell NX printing plate produced according to one embodiment of the present invention. Adjacent highlight image patterned nominal relief features 26 were produced by exposing the plate precursor through a laminated thermal imaging layer mask produced with processed halftone data. Processing was consistent with the methods describe above for applying pattern 10 . Patterned nominal relief features 26 include shoulders 25 having shoulder angle 35 B, which is approximately 20% steeper than shoulder angle 35 A.
FIGS. 6A-6E are micrographs of exemplary portions of relief plate 20 produced according to the present invention. FIG. 6A depicts a portion of a first relief plate 20 corresponding to a portion of reverse text. That is, patterned solid relief feature 27 transfers ink while the plate floor 21 , corresponding to the text character, does not carry ink and thus a reverse image of the text is formed on the printing substrate. At magnification of 100×, one can begin to see pattern 10 resolved in patterned solid relief feature 27 .
FIG. 6B depicts a 750× magnified view of patterned solid relief feature 27 and plate floor 21 . The appearance of regular pattern 10 is now easier to discern in patterned solid relief feature 27 . FIG. 6C depicts a 2500× magnified view of patterned solid relief feature 27 . At this magnification, it is apparent that relief surfaces 28 and relief depressions 29 have geometries that are highly correlated with pattern 10 . In particular, relief depressions 29 correspond to opaque portions of pattern 10 while relief surfaces 28 correspond to transparent portions of pattern 10 . For increased clarity, FIG. 6D depicts an 8000× magnified view of patterned solid relief feature 27 . Relief surfaces 28 are relatively smooth and flat.
FIG. 6E depicts a 500× magnified view of highlight portions of a second relief plate 20 produced according to the present invention. In particular, relief plate 20 includes small relief features 22 , produced without pattern 10 , and patterned nominal relief features 26 , produced with pattern 10 . Clearly, patterned nominal relief features 26 resolve pattern 10 while features 22 are relatively flat and smooth. Although difficult to accurately measure with the 70 degree tilt, shoulder angle 35 B of feature 26 appears to be steeper than shoulder angle 35 A of small relief feature 22 . In particular, shoulder angle 35 B appears to be approximately 10% steeper than shoulder angle 35 A.
The foregoing description clearly shows the intended effect of shoulder angles 35 A and 35 B by applying pattern 10 to image areas 5 . Although resolving pattern 10 in relief features 26 - 27 of relief plate 20 was surprising, the resulting improvements in print quality were even more surprising. In particular, when compared with the prior art approach, printed ink densities were effectively maintained or improved across entire tonal range. Further, the uncalibrated tonal response of the printing process was more linear with the use of pattern 10 than without.
FIG. 7 is a graph illustrating exemplary printed ink densities according to the prior art and the present invention. The graph depicts average ink densities measured by a densitometer for each process colorant for a range of constant tint patches. The patches were printed using a single plate including relief features produced with and without pattern 10 . Ink density values 40 - 43 correspond to patches produced according to the prior art. Ink density values 45 - 48 correspond to patches produced according to the present invention.
Since small relief features 22 are the same for both approaches, the ink densities for the lowest tints are the same, as expected. Throughout the remaining highlight and mid-tones, the ink densities for both nominal relief feature 23 and patterned nominal relief feature 26 increase monotonically as desired. Except for the yellow colorant, the ink densities produced throughout the highlight and shadow tones are similar for both nominal features 23 and 26 . However, approaching and at solid tone, relief features 26 and 27 produce significantly higher ink densities that relief features 23 and 24 respectively. Thus, using pattern 10 throughout substantially the entire tonal range produces improved ink density results.
FIG. 8 is a graph illustrating exemplary uncalibrated tonal response according to the prior art and the present invention. FIG. 8 was produced using the Murray/Davies dot area formula, to estimate effective dot area values from ink density measurements of FIG. 7 . Dot areas 50 - 53 correspond to patches produced according to the prior art. Dot areas 55 - 58 correspond to patches produced according to the present invention. Patterned nominal relief features 26 appear to generally incur less dot gain than nominal relief features 23 and thus provide a more linear uncalibrated tonal response.
FIGS. 9A and 9B are micrographs of solid image areas of an exemplary printed substrate according to the prior art and the present invention respectively. Clearly, in addition to improved ink density, the distribution of ink is much more uniform when printing with patterned solid relief feature 27 as compared with solid relief feature 24 .
FIGS. 10A and 10B are micrographs of negative text features of an exemplary printed substrate according to the prior art and the present invention respectively. Clearly, solid inked areas produced by patterned solid relief features 27 , surrounding the negative text are uniformly dense and have precisely formed edges, indicative of steep shoulders.
FIGS. 11A and 11B are micrographs of positive text features in non-image areas of an exemplary printed substrate according to the prior art and the present invention respectively. The relative improvement in uniformity and boundary precision is similar to that depicted in FIGS. 10A and 10B .
FIGS. 12A and 12B are micrographs of mid-tone image areas of exemplary printed substrate according to the prior art and the present invention respectively. Clearly, the printed halftone dots produced by patterned nominal relief features 26 have more precise boundaries and more uniform ink distribution within those boundaries when compared with the printed halftone dots produced by nominal relief features 23 .
Embodiments of the present invention may comprise any medium which carries a set of computer-readable signals comprising instructions which, when executed by a computer processor, cause the computer processor to execute a method of the invention. Embodiments may be in any of a wide variety of forms. Embodiments may comprise, for example, physical media such as magnetic storage media including floppy diskettes, hard disk drives, optical data storage media including CD ROMs, DVDs, electronic data storage media including ROMs, flash RAM, or the like or transmission-type media such as digital or analog communication links. The instructions may optionally be compressed and/or encrypted on the medium.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the scope of the invention.
PARTS LIST
1 plate precursor
2 mask
3 transparent barrier layer
4 opaque layer
5 image area
6 patterned image area
7 mask depth
8 plate precursor depth
9 curing radiation
10 pattern
11 opaque portion width
12 halftone image pixel length
13 opaque portion length
14 A nominal halftone image feature
14 B nominal halftone image feature
14 C nominal halftone image feature
14 D nominal halftone image feature
14 E nominal halftone image feature
15 A processed halftone image feature
15 B processed halftone image feature
15 C processed halftone image feature
15 D processed halftone image feature
15 E processed halftone image feature
20 relief plate
21 plate floor
22 small relief feature
23 nominal relief feature
24 solid relief feature
25 shoulder
26 patterned nominal relief feature
27 patterned solid relief feature
28 relief surface
29 relief depression
30 cross section
31 cross section
35 A shoulder angle
35 B shoulder angle
40 ink density
41 ink density
42 ink density
43 ink density
45 ink density
46 ink density
47 ink density
48 ink density
50 dot area
51 dot area
52 dot area
53 dot area
55 dot area
56 dot area
57 dot area
58 dot area
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An improved relief printing plate and method for producing said plate is disclosed. Substantially all sizes of relief features resolve a fixed pattern which improves print quality. The pattern is applied to image areas in halftone data used to produce an image mask that is subsequently used to convert a plate precursor into a relief plate. The accuracy, ink density and tonal response of printed images corresponding to relief features that include the pattern are comparable or better than relief features produced without the pattern.
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This invention relates to the treatment of filamentary material and more particularly to a method and apparatus for imparting crimp to a bundle or tow of continuous filaments. In particular, this invention relates to stuffer box crimping.
BACKGROUND OF THE INVENTION
In the process for conventional stuffer box crimping, a continuous product of filamentary material (hereinafter referred to as a "tow") is passed through a pair of nip rolls which forcibly feed the tow into a confined passage from which its emergence is resisted so that the tow assumes a crimped or buckled form and is subjected to a substantial degree of pressure by subsequently entering portions of the tow thereby fixing the crimp and causing it to be retained in the tow subsequent to its emergence from the confined passage.
Representative apparatus for conventional stuffer box crimping is disclosed in U.S. Pat. Nos. 2,156,723; 2,693,008; 2,862,279 and 3,571,870.
Such apparatus generally comprises a pair of cylindrical feed rolls mounted to form a nip and a crimping chamber positioned in close proximity to the point where the tow exits from the nip. The crimping chamber conventionally comprises two oppositely positioned doctor blades maintained near or against the surface of the cylindrical feed rolls as they rotate past the nip point and forming the entrance to the chamber, two side or cheek plates to confine the lateral movement of the tow in the chamber and a confining means at the exit of the crimping chamber to provide resistance to the forward movement of the tow.
The confining means may be an adjustable positioned flap or gate as in the above mentioned U.S. Pat. No. 2,693,008 or may be the outer end of one of the doctor blades of the chamber which is pivotally mounted to permit an increase or decrease in the space between the blades at the exit end of the chamber as disclosed in the aforementioned U.S. Pat. Nos. 2,156,723; 2,862,279 and 3,571,870.
In the case of any of this apparatus, the nature of the crimp imparted to the strand is a function of the size of the crimping chamber and, in particular, the depth of the chamber which is determined by the distance which the doctor blades are positioned away from each other. When the doctor blades are positioned relatively close together, they form a shallow crimping chamber which will induce a multiplicity of small, relatively uniform crimps. When the doctor blades are positioned relatively far apart, they form a relatively large, or deep, crimping chamber which will produce predominantly large but also less uniform crimps in a tow. A relatively small crimping chamber would, therefore, usually be preferred for most crimping operations and particularly for those in which uniformity of crimp is of primary importance.
However, since the edges of the doctor blades forming the entrance to the crimping chamber must be maintained against or at least in close proximity with the cylindrical surfaces of the feed rolls, a shallow or small crimping chamber with the doctor blades relatively close together requires the use of relatively small feed rolls to avoid having to place the crimping chamber far into the nip of the feed rolls in order to obtain contact between the closely spaced apart doctor blades and the corresponding surfaces of the feed rolls.
The utilization of small feed rolls is not generally preferred in any feeding operation since the smaller feed rolls present a smaller surface area for wear, necessitate higher rotational speeds to obtain equivalent feed and, in the case of a crimping apparatus, make the installation and maintenance of the chamber side or cheek plates difficult. Therefore, a conventional small stuffer box crimper could be utilized with large feed rolls only by utilizing long, extremely narrow doctor blades which would fit deep into the nip of the two large diameter rolls. These doctor blades are difficult to produce and easily damaged. Furthermore, such a crimping chamber is difficult to position against the feed rolls because of the nature of the doctor blades but, moreover, because the entire chamber is ultimately positioned far in toward the nip of the rolls. This position additionally makes access to the chamber for servicing difficult. As a result, conventional stuffer box crimping apparatus generally utilizes cylindrical feed rolls which have a diameter equal to from about 15 to about 40 times the depth of the crimping chamber.
The foregoing discussion has centered on stuffer box crimpers having a crimping chamber in line with the bite of the feed rolls. Such conventional stuffer box crimpers crimp tow in what is best described as a stick-slip motion. Stuffer box crimping apparatus however, exists wherein the crimping chamber is offset with the bite of the feed rolls. Offset stuffer-box crimpers are known to reduce damage to the fiber being crimped and moreover to affect a high degree of uniformity in the crimped product. This improvement is at least partially due to preventing stick-slip motion in the crimping process. U.S. Pat. No. 2,917,784 for instance, discloses in FIG. 13 thereof a stuffer box crimper having an offset crimping chamber formed by a fixed curved doctor blade and a floating feed roll. Back pressure is provided by means of a pivoted flapper. The curved doctor blade is curved so that the cross-section of the crimping chamber is relieved away from its entrance by being tapered slightly outwardly in that direction, usually about two to six degrees. In other words, the depth of the crimping chamber increases toward the exit portion thereof. A second scrapper blade may optionally be used to remove the crimped tow from the floating roll.
U.S. Pat. No. 3,146,512 employs a conventional feed roll pair with a stuffer box offset from the bite thereof. The salient feature of U.S. Pat. No. 3,146,512 is the use of a grooved doctor blade which connects with a circumferential groove of an abutting wheel member. U.S. Pat. No. 3,146,512 does not disclose a rectangular cross-section crimping chamber, but rather relies upon an elongated crimping chamber having a unique cross-sectional configuration designed to trap and prevent premature release of filamentary material.
U.S. Pat. No. 3,441,988 employs a curved doctor blade which at least partially surrounds the external surface of a roller to produce a gap-forming segment or crimping chamber. Filaments are fed into the zone and their exit is restrained by a retarding means positioned at the exit of the zone. U.S. Pat. No. 3,441,988 however, cannot be construed as a stuffer-box crimper in the classic sense inasmuch as it does not crimp tow issuing from the bite of a feed roll pair.
None of the foregoing patents disclose a two roll feed system offset stuffer box crimper wherein yarn is set in the crimped configuration within a rectangular cross-section crimping chamber formed by means of a curved doctor blade which converges toward one of the feed rolls and wherein the cross-sectional area of the crimping chamber diminishes toward the exit portion thereof.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided an improved stuffer box crimper of the type in which tow is fed into a rectangular cross-section crimping chamber off-set from the bite of a pair of feed rolls, the improvement comprising forming the crimping chamber from a single doctor blade and a portion of the rotating surface of one of the cylindrical feed rolls, said doctor blade being pivotally mounted to that feed roll which is nearest the tip portion of the doctor blade, the cross-sectional area and depth of the crimping chamber diminishing toward the exit portion thereof. Most preferably, the roll which is not pivotally mounted to the doctor blade has the larger diameter of the feed roll pair.
According to another aspect of the invention, there is provided a process for crimping a tow or bundle of continuous filaments by feeding the strand through a set of nip rolls into a rectangular cross-section crimping chamber formed by a doctor blade and a portion of the rotating surface of one of the nip rolls, said rectangular cross-section of the confining chamber continually diminishing toward the exit portion thereof. Stick-slip motion in the crimping operation is prevented by the continuous wiping action of the roll which forms on face of the crimping chamber. Moreover, by pivotally mounting the doctor blade to that feed roll which forms a part of the crimping chamber, the volume of the crimping chamber will not be substantially affected even though one of the rolls may ride up or down due to variations in the tow being processed.
The apparatus itself, both as to its construction and its mode of operation, together with additional features and advantages thereof as well as the process of the invention, will best be understood subsequent to a discussion of the following specific embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows schematically, inside elevation, a band of tow being passed through a crimper of this invention.
FIG. 2 shows schematically, inside elevation, another embodiment of the crimper of this invention utilizing one large diameter and one small diameter feed roll.
FIG. 3 shows schematically, inside elevation, the critical paramaters of the crimper of this invention.
FIG. 4 shows in projected view, not to scale, the crimper of this invention.
FIG. 5 is a photomicrograph of a prior art conventional stuffer box crimped cellulose acetate tow.
FIG. 6 is a photomicrograph of individual crimped filaments stripped from the tow of FIG. 5.
FIG. 7 is a photomicrograph of cellulose acetate tow crimped by the process and apparatus of this invention.
FIG. 8 is a photomicrograph of individual crimped filaments stripped from the tow of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, one form of the apparatus comprises a set of cylindrical feed rolls 101, 102 which are mounted so as to be pressed together to form a nip as by means (not illustrated) of springs under the control of adjusting screws whereby the pressure can be varied and either one or both of which are driven by a driving means (not illustrated) in the direction indicated. A single doctor blade 103, having an arcuate surface 107 is mounted on an arm 104, pivoted about the shaft 105 of the upper feed roll 101, and loaded by means of a pressure rod 106. The doctor blade is positioned to fit closely into the nip between the rolls 101, 102, the arcuate surface of the doctor blade being positioned in a spaced-apart relationship with the cylindrical surface of the lower feed roll 102 to form a confining passage 108 between the arcuate surface of the doctor blade and the cylindrical surface of the feed roll. The tip of the doctor blade is positioned against or in close proximity to the cylindrical surface of the upper feed roll 101 so as to define the opening to the confining passage between the tip of the doctor blade and the surface of the lower feed roll 102 at a point just after the exit of the tow from the nip. For ease of illustration, side or cheek plates of the apparatus have not been shown.
Large diameter feed rolls have generally not been practical in prior art conventional crimping apparatus in that long and narrow doctor blades were necessary to reach into the nip and contact the surface of the rotating feed rolls. In addition to being more difficult to fabricate, the long and narrow doctor blades are more easily damaged and more difficult to correctly position in the nip between the rolls. As a result, small crimping chambers of the prior art conventional stuffer box crimpers are used almost exclusively with small diameter feed rolls because the advantages of using large diameter feed rolls are outweighed by the disadvantages of the prior art doctor blades which must be used in combination with the large feed rolls. However, in the instant invention, as can be seen in FIG. 2 of the drawings, the diameter of one of the feed rolls is easily increased to take advantage of the larger surface area available for wear, lower operating speeds and ease of mounting of rolls and confining side or cheek plates. More specifically, doctor blade 203 is pivotally mounted on upper roll member 201. Doctor blade 203 is positioned to fit closely into the nip between rolls 201 and 202, the arcuate surface 207 of the doctor blade being positioned in a spaced-apart relationship with the cylindrical surface of the lower feed roll 202 to form a confining passage 208 between the arcuate surface of the doctor blade 207 and the cylindrical surface of the feed roll 202. While in the case of FIG. 2, lower feed roll member 202 is larger than upper feed roll member 201, it should be understood that both roll members may be enlarged roll members. In any event however, it is essential that the doctor blade be pivotally mounted to that roll nearest the tip portion of the doctor blade and urged downwardly by suitable means such as pressure rod 206.
As previously noted, various dimensions in addition to roll diameters of the apparatus of the instant invention are critical. The roll diameter of the apparatus of this invention may be in the range of from 2 to 7 inches and preferably from 2 to 5 inches. The critical areas, other than roll diameters of the apparatus of the instant invention, may best be described by turning to FIG. 3 of the drawings which schematically illustrates an upper and lower feed roll pair with a doctor blade positioned so as to form a crimping chamber in conjunction with the upper feed roll member 301, lower feed roll member 302 and doctor blade 303. The critical areas are the chamber depth (D), doctor blade radius (BR), doctor blade heel radius (HR), heel contact angle (HA) and convergence angle (CA). As can be seen from FIG. 3 of the drawings, maximum chamber depth is the maximum distance between doctor blade 303 and lower feed roll 302. Doctor blade radius (BR) is the radius of curvuture of the crimping chamber wall forming portion of doctor blade 303 which forms a crimping chamber in conjunction with lower feed roll member 302. Doctor blade heel radius (HR) is the radius of curvuture of the terminal tow contacting portion of doctor blade 303. Convergence angle (CA) is that angle formed by a line drawn through the tip and the heel of doctor blade 303 and the horizontal line passing through the center of lower feed roll 302, the horizontal line forming a 90° angle with a line passing through the center of upper feed roll 301 and lower feed roll 302. Heel contact angle (HA) is that angle formed by a line drawn from the center of lower feed roll member 302 to the heel contact point of that line running from the tip of doctor blade 303 tangent to the heel of doctor blade 303 and a horizontal line passing through the center of lower feed roll member 302, the horizontal line forming a 90° angle with a line passing through the center of upper feed roll 301 and lower feed roll 302.
The following specific ranges have been found to be suitable for the apparatus and process of the instant invention.
______________________________________Maximum chamber depth (D) .003 to 0.3 inchesand preferably .03 to 0.18 inchesDoctor blade radius (BR) .250 to 3.50 inchesand preferably .250 to 2.50 inchesDoctor blade heel radius (HR) .01 to .50 inchesand preferably .01 to .25 inchesConvergence angle (CA) 20° to 45°and preferably 30° to 40°Heel contact angle (HA) 0° to 80°and preferably 30° to 80°______________________________________
A better understanding of the process and apparatus of the instant invention may be had from a discussion of FIG. 4 of the drawings. The method of the instant invention involves feeding a bundle or tow of continuous filaments through the nip of a set of rotating cylindrical feed rolls 401 and 402 into a confining chamber 408 formed by the arcuate surface of doctor blade 403 which is pivotally mounted on swing arms 404 and positioned to fit closely into the nip of feed rolls 401 and 402 and the rotating cylindrical surface of roll 402. Doctor blade 403 is also designed to be top loaded such as to provide a back pressure within chamber 408 to impede the movement of the continuous filaments from the chamber and causing the formation of a crimped tow which is then advanced along and out of the chamber by the rotating cylindrical surface of feed roll 402. Clearance adjustments between doctor blade 403 and feed roll 401 may be made by means of set screw 412 which is mounted in slot member 413. As can be seen, the crimping chamber 408 is rectangular in cross-section, the sides of the rectangular cross-section crimping chamber being formed by side or cheek plate members 409 and 410. Crimping chamber 408 diminishes in cross-section toward the exit portion thereof by causing the tip portion of doctor blade member 403 to be spaced a greater distance from the surface of nip roll member 402 than the heel portion of doctor blade 403. Preferably, the crimped tow exiting from crimping chamber 408 is released from nip roll 402 by means of scraper blade 411 positioned immediately beneath the heel of doctor blade member 403. While not illustrated, either or both of nip roll members 401 and 402 may be driven by suitable power means secured in driving relationship to shaft members 405. While the apparatus and process of this invention are suitable for crimping a wide variety of thermoplastic continuous filament tows, the apparatus and process of the instant invention have special utility when employed in conjunction with cellulose acetate cigarette tow.
As previously noted, the process and apparatus of the instant invention provide a means for minimizing crimp variations and more specifically, minimizing crimp variations in cellulose acetate cigarette tow. It has been found that the process and apparatus of the instant invention will reduce primary crimp coefficient of variation to less than 10. The statistical investigation of the improvement obtained by the use of the apparatus and process of the instant invention is based on F-distribution. In F-distribution, when samples are taken from two independent populations, their variances are also independent and both S 1 2 and S 2 2 are unbiased estimators of the population variances, if the populations are infinite or if sampling with replacement. That is to say S 1 2 is an unbiased estimator of σ 1 2 (population standard deviation 1) and S 2 2 is an unbiased estimator of σ 2 2 (population standard deviation 2). The ratio of σ 1 2 to σ 1 2 is equal to 1.00 if the two variances are equal, and the mean ratio of S 1 2 to S 2 2 is also equal to 1.00 if the population variances are equal.
If the two populations are both normal and have equal variances, then the ratio of the two sample variance values are distributed as F with n 1 -1 and n 2 -1 degrees of freedom.
The term coefficient of variation (CV) is a means for comparing the dispersion of two series by expressing the standard deviation as a percent of the mean of the series. In the instant invention, the mean of the series σ is a value encompassing 66% of all samples. The coefficient of variation (CV) may then be defined as follows: ##EQU1##
The following specific examples of crimping cellulose acetate cigarette tow show the improvement in crimp uniformity obtained by the process and apparatus of the invention.
EXAMPLE I
Cellulose acetate tow having an F cross-section, a total denier of 39,000 and a denier per filament of 3.3 is treated in an apparatus of the kind shown in FIG. 4 of the drawings.
The nip roll pressure is maintained at about 390 pounds per square inch and operated at speeds of 397 meters per minute. The downward loading on the doctor blade is adjusted such that slippage of the tow at the nip rolls is approached, but not obtained so that a crimp level of 35.4 crimps per inch is possible. The crimping chamber is cooled with a water/air mist spray to prevent filament fusion.
The crimped tow product which is illustrated in FIG. 7 of the drawings, the individual filament of which is illustrated in FIG. 8 of the drawings, is found to have an average primary crimp of 23.4 crimps per inch and a coefficient of variation of 8.3.
EXAMPLE II
Cellulose acetate tow having an F cross-section, a total denier of 39,000 and a denier per filament of 3.3 is processed in the conventional stuffer box crimping apparatus substantially as illustrated in FIG. 2 of U.S. Pat. No. 2,693,008. A processing speed of about 400 meters per minute is employed. The nip roll pressure is maintained at about 390 pounds per square inch. The flapper is loaded with a pressure of less than 390 pounds per square inch, but sufficient to obtain maximum crimps per inch. The crimping chamber is cooled with a water/air mist spray to prevent filament fusion.
The crimped tow product which is illustrated in FIG. 5 of the drawings, the individual filaments of which are illustrated in FIG. 8 of the drawings, is found to have an average primary crimp of 19.6 crimps per inch and a coefficient of variation of 21.5.
As can be seen, the coefficient of variation of the primary crimp of the product produced by the process and apparatus of the instant invention as represented by Example I, is substantially less than the coefficient of variation of the primary crimp of the product produced by the process and apparatus of the prior art as represented by Example II.
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An improved stuffer box crimping apparatus of the type in which tow is fed into a rectangular cross-section crimping chamber off-set from the bite of a pair of feed rolls, the apparatus employing a crimping chamber wherein one wall is predominantly formed by a single doctor blade and an opposite wall is formed by a portion of the rotating surface of one of the cylindrical feed rolls of the feed roll pair, the doctor blade being pivotally mounted on the feed roll nearest the tip portion of the doctor blade. The cross-sectional area of the crimping chamber diminishes toward the exit portion thereof, whereby crimped filamentary material within the crimping chamber is subjected to both back pressure and a constant forwarding action by the rotating surface of the cylindrical feed roll. The pivotal mounting of the doctor blade provides precise clearance and allows the volume of the crimping chamber to adjust in accordance with tow variations.
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BACKGROUND OF THE INVENTION
[0001] This invention applies to portfolio or list trading. The subject invention specifically pertains to a securities execution management system designed for lists trading or single stock trading. There are known execution management systems that allow one to manipulate portfolio lists, a list being a group of equities. An execution management system allows an equity (i.e., stock) trader to send orders to different destinations for execution, such as the NYSE, Nasdaq or other regulated equity exchanges. FlexTrader manufactured by Flex Trade Systems, Inc., of Long Island, N.Y., is an example of an execution management system which uses the FIX engine, a popular financial software protocol. Via FlexTrader the user is able to also create rules or algorithms with which one can trade equity portfolios. FlexTrader specifically relates to algorithmics trading which allows traders to automate their execution. For example, when a stock reaches a certain price, an order is automatically sent by the FlexTrader. FlexTrader is extensively used by hedge funds and financial institutions.
[0002] The prior art portfolio data organizational software programs allow one to select characteristics of a particular equity or equities. These characteristics could be a derivative of the underlying stock price, underlying stock movement, underlying volume, for example. However, in order to select any of the above characteristics, a cumbersome and unwieldy “macro” interface has to be employed, and repetitively so far each characteristic desired.
SUMMARY OF THE INVENTION
[0003] The subject invention allows the user to graphically apply a set theory approach to selecting certain equities on the “blotter” screen or on the main screen of the computer application. After selecting certain equities, particular characteristics of these equities, for example, profit and loss, are shown. Next, unique to the subject invention, an action is applied to those equities selected. For example, without the subject invention a user would code separate text macros for each created criteria by which certain equities are selected, e.g., any stock that has a volume greater than 500,000 shares traded today and a price greater than $10. With the subject invention, in contrast, certain criteria or characteristics that apply to a specific equity (such as, for example, its current spread or its current relative performance to the market or to the sector) can be selectively added to a matrix type of user interface by “drag-and-drop” functionality. Within that matrix of selected criteria the user is able to select an equity that has the previously chosen criteria, either regardless of the portfolio location of a specific equity or limited to one or more specific portfolios. The subject invention preferably employs three types of selection criteria, “exclusion”, “inclusion” and “selective inclusion.”
[0004] “Inclusion” is a Boolean operator that adds a specific item to a set, for example, all stocks that have a spread less than 5 cents regardless of all of the other criteria that equity also possesses. “Exclusionary” is a Boolean operator that removes a specific item from a set, for example, all stocks that have a spread greater than 0.15 cents, regardless of all of the other criteria that equity also possesses. “Selective Inclusion” requires more than one characteristic being in the matrix, and is a Boolean operator that adds a specific item to a set, provided that two or more criteria are met, for example, all stocks that have a spread greater than 0.02 cents with the ask size being less than 100 shares. The subject invention thus provides the user the ability to see, for example, profit and loss based on a selection criteria that can be applied during different steps of the trading process, i.e., the pre-trade process, the execution process and then the post-trade process. In the pre-trade process one can assess what characteristics most of the portfolio of stocks falls into. During the execution process based on realtime data one can apply or change an action based on the inclusion, exclusion and selective exclusion criteria. In the post-trade process one can again assess a varied analytical data based on certain characteristics: how, for example, does profit and loss rank.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] These and other subjects, features and advantages of the present invention will become more apparent in light of the following detailed description of a best mode embodiment thereof, as illustrated in the accompanying Drawings.
[0006] FIG. 1 is a schematic of the hardware and software modules of the subject invention;
[0007] FIG. 2 is a first screen shot of a graphical user interface for an execution management system of the subject invention;
[0008] FIG. 3 is a first screen shot of the graphical user interface for the data matrix of the subject invention;
[0009] FIG. 4 is a logic flow diagram of the present invention;
[0010] FIG. 5 is a screen shot of the control panel of the data matrix of the subject invention;
[0011] FIG. 6 is a second screen shot of the graphical user interface for the data matrix of the subject invention;
[0012] FIG. 7 is a third screen shot of the graphical user interface for the data matrix of the subject invention;
[0013] FIG. 8 is a second screen shot of a graphical user interface for an execution management system of the subject invention;
[0014] FIG. 9 is a fourth screen shot of the graphical user interface for the data matrix of the subject invention;
[0015] FIG. 10 is a third screen shot of a graphical user interface for an execution management system of the subject invention;
[0016] FIG. 11 is a fifth screen shot of the graphical user interface for the data matrix of the subject invention;
[0017] FIG. 12 is a fourth screen shot of a graphical user interface for an execution management system of the subject invention;
[0018] FIG. 13 is a sixth screen shot of the graphical user interface for the data matrix of the subject invention;
[0019] FIG. 14 is a fifth screen shot of a graphical user interface for an execution management system of the subject invention;
[0020] FIG. 15 is a seventh screen shot of the graphical user interface for the data matrix of the subject invention;
[0021] FIG. 16 is a sixth screen shot of a graphical user interface for an execution management system of the subject invention;
[0022] FIG. 17 is a eighth screen shot of the graphical user interface for the data matrix of the subject invention; and
[0023] FIG. 18 is a seventh screen shot of a graphical user interface for an execution management system of the subject invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0000] 1. Hardware Elements and Software Modules
[0024] Referring first to FIG. 1 , the hardware elements and software modules of the subject invention are described. Multiple execution management system work stations 101 are preferably IBM compatible PC computers each having an Intel Pentium-based central processing unit with 512 MB of RAM and a Linux or Microsoft Windows XP operating system. There are preferably multiple user groups 103 running the above workstations, preferably interconnected by a local area network (LAN), with each user group 103 comprised of individual users U 1 , U 2 . . . U n . If FlexTrader is the execution management system software program of choice on workstations 101 , each of user U 1 , U 2 . . . U n can tailor the graphical user interface of the FlexTrader software program to suit their personal preferences. An API (application program interface) communicates with the users U 1 , U 2 . . . U n of each user group 103 and sends and receives data pertaining to, for example, populating financial data columns or obtaining the results of calculations or the results of actions.
[0025] Inbound order flow module 107 , operating under the FIX protocol engine, accepts incoming orders described further below. There is network interconnection between inbound order flow module 107 and a software router that is preferably a private network or proprietary network such as TNS (transaction network services) that is a secure high speed connection widely used in the financial industry. Via inbound order flow 107 FIX clients communicate via the TNS network and send FIX-based messages to execution management system workstations 101 . Also in electronic communication with inbound order flow module 107 is OMS (order management system) such as, for example, Network Cloud, McGregor, Bloomberg, Brass NYFix, Trade Route, which allows the OMS client to review their portfolios.
[0026] Direct web based order flow 125 is in communication, or has connectivity with, execution management system 101 , that allows web based order flow 125 to interconnect with the execution management system workstations 101 via front end of the web client.
[0027] Order match module 111 includes a FIX-based engine that is in electronic communication with execution management system workstations 101 . Order match module 111 is also in electronic communication with other FIX-based trade destinations 113 , such as NYSE, and other brokers or ECNs such as Arca, Island, Brut, Instinet, for example. Trade orders are sent from execution management workstations 101 to order match module 111 , then to one of the trade destinations 113 where the orders are filled or another trade based action happens, which is then relayed back to order match module 111 with the result being displayed on execution management workstations 101 , then continuing to the desired one of the user groups 103 and, finally, to the appropriate one of the users U 1 , U 2 . . . U n . API 135 is in communication with order match module 111 and monitors outbound order data.
[0028] Next referring to real time pricing module 115 , which is a consolidator and data re-formatter of prices from different destinations, real time pricing module 115 communicates to execution management system workstations 101 , and specifically to a specific ones of user U 1 , U 2 . . . U n . Data vendors 116 , such as Reuters and Comstock, provide real time prices on equities and other types of securities to real time pricing protocol 115 .
[0029] Flex services module 131 communicates with execution management system workstations 101 via transaction network services 133 (TNS), an example of a viable proprietary data network. Flex services module 131 provides: fundamental data, (Morgan Stanley Country Index) a classification of securities bases on industry and sector level; deep feed level 2 data, the specific information from a price feed similar to real time pricing module 115 ; and level 1 data, again similar to pricing module 115 data and the basic view of security prices.
[0030] File based order input 106 is the input of external trade files (or list of trades to be executed) in, for example, text, Excel or ASCII format, to users U 1 , U 2 . . . U n . File based order input 106 is thus in communication with execution management system workstations 101 in order to facilitate trading.
[0000] 2. Execution Management System Graphical User Interface
[0031] Next referring to FIG. 2 , an example of a graphical user interface is described for an execution management system, in this example FlexTrader, within which the software of subject invention resides. First referring to 201 the main screen of the EMS program is shown. The main FlexTrader “blotter” screen 201 is part of the execution management system described in FIG. 1 . The “blotter” is configurable to allow the user to perform specific actions. These actions can be unilateral actions or they can be actions on specific rows of the blotter. The actions performed include computation of a certain value, a screen snap shot, or an actual travel action such as “send an order down to the floor,” “correct an order,” “cancel an order” for example.
[0032] Spreadsheet 207 of blotter 201 lists portfolio information in rows identified by, for example, portfolio name (SLR 2 ) 209 , the number of shares (1,200) 211 and specific symbol (WDFC) 213 . Further regarding portfolio name 209 , one possible nomenclature denotes SL as “sell long”, SH for “sell short”, BL for “buy long” and BC for “buy cover”, with r2 in all instances being the specific portfolio identifier.
[0033] Columns intersect the above described portfolio rows of spread sheet 207 , and each column represents a certain characteristics associated with that specific portfolio. In the first column 215 , VOL 20 , is a measurement of that particular portfolio's volatility per stock. Second column 217 , PCT ADV 20 , is the percentage of an equity's shares to trade relative to its average 20 day volume. For example, if over the last 20 days 100,000 shares are traded on the average a day, then 1,200 shares (element 211 ) is 1.2% of an average day. Third column 219 , MED SPREAD, denotes, on the average, the difference between the buying and selling price of the security. Fourth column 221 denotes SPREAD BP, which is calculated by taking that median spread value and dividing it by the stock price. This value is shown in basis points which is 1/1000 (or 0.1 percent) of the median spread. It is to be understood that the above four share characteristics 215 - 221 are just examples of share characteristics, they are not intended to be all inclusive. Other characteristics include, by not limiting example, the percent change in the stock price from yesterday's close, profit and loss information in either dollars, basis points or cents per share, difficulty to trade factors, and sector or industry grouping (i.e., technology, a biochemical, biotechnology industry group).
[0034] Again referring to column 217 , PCT ADV 20 , there are highlighted ranking numbers 223 (i.e., numbers 1, 2 or 3) in the same cell to the left of the actual PCT ADV number. “Ranking” of ranking numbers 223 is broadly defined as a grouping of specific attributes. For example, all the values in second column 217 , PCT ADV 20 , that are above 1 and below 2 fall into rank 1, and all the values that are above 2 and below 4 fall into rank 2.
[0035] Next referring to highlighted rows 225 of a plurality of portfolios, highlighted rows 225 are highlighted by left clicking the mouse, holding the left mouse down, and dragging across the desired number of rows. Alternatively, a computer keyboard button tied to a specific portfolio or to a predetermined characteristic of some portfolios can highlight specific portfolio rows. Next, the highlighted rows 225 can be acted upon by the execution management system software by implementation by the user of one or more of command lines 205 to invoke the computation action associated therewith. The result, in one possibility, being the population or re-population of ranking numbers 223 .
[0000] 3. Set Theory Based Graphical User Interface
[0036] Next referring to FIG. 3 , an exemplary graphical user interface for the functionality of the subject invention is shown, the output of the graphical user interface of FIG. 3 having been in part previously discussed in reference to FIG. 2 in reference to ranking numbers 223 .
[0037] The graphical user interface of FIG. 3 includes a matrix 300 populatable with one or more columns, four of such columns being shown in FIG. 3 . Programmable function buttons 301 populate matrix 300 with the column of the execution management system software spread sheet 207 of FIG. 2 associated with that particular programmable function button 301 . For example, programmable function button 303 , PCT ADV, creates another column in matrix 300 that correlates with, but is not identical to, second column 217 , PCT ADV 20 , (in FIG. 2 ) of the execution management system software spread sheet 207 . The column created in matrix 300 by activating the PCT ADV 20 function button 303 is column 305 in FIG. 3 . Windows 307 , 309 , 311 and 313 , respectively, in column 305 each represent a different “ranking” that corresponds to ranking number 223 of spread sheet 207 of FIG. 2 with respect to second column 217 thereof. It is important to note that, as these rankings or numbers 223 are altered as further described below by operation within windows 307 , 309 , 311 and 313 of matrix 300 , the aforesaid ranking numbers 223 are likewise altered on spread sheet 207 of FIG. 2 .
[0038] More specifically, window 307 has a data summary of all of the securities that have a rank of 1 based on ranking number 223 of spread sheet 207 of FIG. 2 . Thus, in window 309 , 39 shares have a 1 rank, the total number of shares is 199,500, and the percentage of all the stocks on spread sheet 207 that are in window 309 is 42%. The value (the last price times the number of shares), the executed value (value of the total numbers that have been executed), the real P&L and unreal P&L are all also provided. Finally, in window 309 , boundary conditions 329 are shown. Boundary conditions 329 do not denote the theoretically acceptable range of stocks that could possibly satisfy a 1 rank, but instead denotes the actual minimum and maximum value of actual stocks that populate rank 1 of window 309 (MED_SPREAD).
[0039] FIG. 4 is a software logic flow diagram of the matrix filter 400 of the subject invention. Block 401 represents a unique column on the blotter ( 201 of FIG. 2 ) such that each entry in the column may (or may not) have a rank from 1, 2, 3 or 4, for example. More than one column, blocks 401 through 407 , may be ranked on the blotter 201 . Block 409 invokes the matrix filter by, for example, an actuation button on the blotter 201 . The matrix filter 400 is a graphical user interface described in detail, for example, as 501 in FIG. 5 that allows data specific and function specific information filtering. Matrix population functions 411 through 415 corresponds to actuation buttons further described in relation to the matrix filter 400 ( 501 of FIG. 5 ), and provide the population of matrix filter 501 with the related blotter 201 columns satisfying the functionality of 401 through 407 upon activation of the appropriate actuation button of matrix filter 501 . Matrix population functions 411 through 415 populate the matrix filter 400 as shown at block 417 . At block 419 the matrix cell selector, which encompasses filter blocks 423 , 425 and 427 is shown. At blocks 423 , 425 and 427 , specific individual cells of the matrix are “called.” Specifically, block 423 calls cells 1 , 1 , block 425 calls cell 1 , 2 and block 427 calls cell n, n with the first number denoting the row and the second number denoting the column of the “called” cells of the matrix. It is to be noted that only three “called” cell groups are shown for purposes of example, and more or less cells can be “called.” The cell groups that are “called” at 423 through 427 correspond to the functionality customized for the subject matrix filter; in this example the functionality is based on the “ranking” 1-4 of the data of the individual cells, as divided by the different columns, of blotter 201 as further described below.
[0040] In addition Summary Information Per Cell block 421 provides the number of cells of blotter 201 (i.e., data locations) that fit into that criteria. For cell 1 , 1 (i.e., all the data of blotter 201 in column 1 that have rank 1) if there are 10, the summary statistic can provide, for example average value of that data of that matrix cell. Other summary statistics of block 201 can include realized and un-realized p&l, the value of the stocks that fall into that specific matrix cell, and so forth. As described in further detail below each individual matrix cell has control buttons (“radio buttons”) that allow matrix filter 400 to “ignore”, among other functions, the information present in any matrix cell whereby matrix filter 400 does not include blotter 201 data of that matrix cell in its processing.
[0041] As further shown in selection block 429 , the aforesaid radio buttons can indicate any of “ignore” (which is the default mode), “include”, “exclude”, or “conditional include” matrix filter 400 functionality. Preferably, a screen color is associated with each of the above functionality of matrix filter 400 on both blotter 201 and matrix filter ( 600 of FIG. 6 , for example). For “ignore” there is no color highlighted. “Include” is a green color, “exclude” is a red color, and “conditionally include” is a yellow color, for example.
[0042] Also, Summary Statistics Aggregate are complied in the same manner as Summary Information per cell 421 , and additionally, the number of items that are in each of the “include”, “exclude”, and “conditionally include” categories are provided. At block 431 the above described color-based highlighting based on the applied functionality (“ignore”, “include”, “exclude” and “conditionally include”) is implemented. At Apply Action block 433 , actions to the underlying equities present in the color-based highlighted cells of the matrix filter and blotter 201 are implemented. These actions include, by non-limiting example, order cancellation buying, selling or analytical non-trade, actions.
[0043] FIG. 5 shows an exemplary matrix filter control panel 501 of the subject invention, the matrix filter, itself, being not populated with data. File panel 503 denotes the files that have been loaded into the subject matrix control panel 501 . File panel 503 can also denote a sequential file listing of an entire group of files.
[0044] Configuration button 505 allows the configuration of the remainder of buttons (for example buttons 507 and 509 ) of matrix control panel 501 . For example, button 507 is named RET VS. INDEX is created by actuation of configuration button 505 in conjunction with the appropriate script commands programs which will facilitate the addition of a return versus index column into the matrix filter. Likewise, the CLIENT A button 509 can drop in the percent ADV 20 column, as well as the return versus sector column into the matrix filter based on actuation of configuration button 505 and associated script commands.
[0045] Button 511 has the “unselect all” functionality to return the matrix filter data to the default starting condition. Apply strategy button 513 allows the user to apply a specific action on selected matrix filter data items. Select button 515 allows the user to reselect all the actions that have been made to the matrix filter data if, for example, there has been manual intervention where the user has un-highlighted some items and would like to reapply the selection mechanism.
[0046] Next referring to FIG. 6 , a populated matrix filter is shown having two columns that were dropped via the two buttons RET VS. SECTOR 601 which is the return versus sector that added the column of RETURN VERSUS SECTOR 603 , and VOLATILITY 605 that dropped in VOLATILITY column 607 . Now referring to individual matrix cell 608 , (cell row 1 , column 2 or 1 , 2 ) this cell, like all cells have 4 radio buttons, only one of which can be selected at any given time. The “ignore” radio button 611 is the default radio button that active when the column is initially added. Radio button 613 , the “inclusion” radio button, may be, for example, denoted by a green color. Radio button 615 may be, for example yellow and represents “selective inclusion”. Radio button 617 may be, for example, red and represents “exclusion”. Range indicator 619 indicates the high and low of the items that fall into cell 1 , 2 of the VOLATILITY column 607 , in this instance from 0.11 to 0.20. Equity number indicator 621 displays the number of equities that fall into cell 1 , 2 in the VOLATILITY column 607 (there are 51), as well as the total number of shares (which is 1.21 million) and the percent of equities ranked that fall in cell 1 , 2 (42 percent). Data window 623 displays other characteristics for the equities that fall into cell 1 , 2 , specifically (but not-limiting) the value, the executed value, realized p&l (profit and loss) and un-realized p&l, in both numerical values as well as in percentages. These four items of data window 623 are also configurable by the users to add additional items to those four items, or instead of those four items, such that more or less than four items can be dispatched.
[0047] Next referring to FIG. 7 the addition of two more columns to the matrix of FIG. 6 is now described. First cross-referencing FIG. 6 , FIG. 7 also shows the RETURN VERSUS SECTOR column, denoting it as 701 instead of 603 . Additionally, FIG. 7 also shows the VOLATILITY column denoting it as element 703 instead of element 607 .
[0048] Two additional columns are PCTADV 20 705 , which was dropped in by actuating CLIENT A button 707 , and column MED_SPREAD 709 which was dropped in by actuating MED_SPREAD button 711 . It is to be noted that all of columns 701 through 709 have the first radio button, i.e. the “ignore” radio, button activated such that no functionality has been applied to any of these columns in FIG. 7 .
[0049] Next referring to FIG. 8 , the blotter 801 (cross referenced as 201 of FIG. 2 ) is shown in its initial condition or state prior to any functionality being implemented via the matrix filter panel 501 . This initial condition was previously noted in regard to FIGS. 6 and 7 where it had been stated that these Figures denoted the matrix filter prior to initiation of functionality therein. The blotter rows 801 are not highlighted because FIG. 8 refers to the effect of the matrix filter on blotter 801 , and there is no functionality at present.
[0050] VOLATILITY column 801 is directly related to the VOLATILITY column 607 and the cell 608 of FIG. 6 where equities of rank 1 are located. Likewise, blotter cells 809 and 811 both relate to matrix cell 608 on FIG. 6 , blotter cell 813 relates to the matrix cell immediately below 608 , which is unlabeled. Also, PCT ADV 20 803 directly relates to PCT ADV 20 in FIG. 7 RETURN vs. SECTOR 805 relates to 701 and MED_SPREAD 807 refers to MED_SPREAD 709 . Note that each of these columns (VOLATILITY 801 , PCT ADV 20 803 , RETURN vs. SECTOR 805 and MED_SPREAD 807 ) have blotter cells, (e.g. 809 , 811 , 813 ) each of which have a ranking from 1-4 that denotes the specific matrix cell, based on row number of the particular matrix column, that the blotter cell will populate.
[0051] More specifically the numerical ranking of the blotter cells is implemented in one embodiment by a subroutine that takes stock or trading data or other reference data (calculated or historical) and partitions the equities amongst a predetermined number of levels based upon the location of the equities within a hierarchy as defined by the characteristics coded in the subroutine.
[0052] Blotter cells 809 and 811 are ranked 1 (note the number 1 in the cells) and thus fit into matrix cell 608 of FIG. 6 which has been specifically configured to accept all blotter cells in the VOLATILITY column 801 having a rank of 1. Blotter cell 813 displays a rank of 2 which would place this data into the matrix cell below matrix cell 608 . The ranking information for each individual blotter cell, as denoted in the lower left of the blotter cell, reflects the row number for the specific column in the matrix that defines the equity distinction of that column i.e., VOLATILITY. The blotter cell rankings thus control population of the data into the matrix cell of the cross-referenced (i.e., rank 1) row number of that column.
[0053] Next referring to FIGS. 9 and 10 , FIG. 9 displays of the matrix filter of the subject invention in which the “conditional inclusion” functionality has been executed. Cells 901 , 905 , 907 , 909 , 911 and 913 have been selectively added, as shown by the yellow highlighting of these cells. Any matrix cells that are selected have to satisfy the following criteria: the matrix cells in the return versus sector column (RETURN_VS_SECTIOR) 917 have to be ranked 2 (as is matrix cell 901 ), the matrix cells in the volatility column (VOLATILITY) 919 have to be of rank 1 (as is matrix cell 905 ) or rank 2 (as is matrix cell 907 ), the matrix cells in the percent ADV 20 column 921 have to have a rank of 2 (as is matrix cell 909 ) or the matrix cells MED_SPREAD column 923 have to have rank 1 or 2 (the rank of matrix cell 911 being 1 and the rank of matrix cell 913 being 2). All of these rankings have been selected based on the actuation of the “conditional inclusion” radio buttons within the previously mentioned boxes 901 , 905 , 907 , 909 , 911 and 913 . This radio button of “conditional inclusion” in the present embodiment, which is a non-limiting example, and as further described below, provides, for example, a yellow coloring on the users screen, as stated above.
[0054] All the equities which satisfy the above criteria and are thus present in matrix cells 901 , 905 , 907 , 909 , 911 or 913 are shown in selected stock listing window 916 of summary information area 915 (e.g., 26 stocks shown). Selected stock listing window 915 also shows “value,” “realized profit and loss” and “unrealized profit and loss.” In addition to the implementation of selected criteria, as noted above, the present invention also encompasses the notation of unselected criteria within the parameters detailed above for selected criteria.
[0055] Next referring to FIG. 10 which shows the main blotter 201 as highlighted based upon the “conditional inclusion” matrix filter selection criteria of FIG. 9 , highlighted blotter row 1001 includes blotter cell 1003 which is a cell of rank 1 that thus falls into matrix column 919 , matrix cell 905 of FIG. 9 . Likewise, blotter cell 1005 , having a rank 2, satisfies the criteria of matrix cell 909 . Blotter cell 1007 which shows a ranking of 2 satisfies the criteria of matrix column 917 , matrix cell 901 . Blotter cell 1009 , with a rank of 2 satisfies the criteria of matrix cell 913 , thus again being included. It is important to thus note that blotter row 1001 is highlighted because all of the blotter cells in blotter row 1001 that were analyzed (i.e., blotter cells 1003 , 1005 , 1007 , 1009 ) for the particular criteria specific to each of these blotter cells actually possessed those criteria. This is the rule set for “conditional inclusion”. Another blotter row highlighted is blotter row 1011 which shows specifically blotter cell 1013 , having a rank of 2, satisfies the criteria of matrix column 919 and matrix cell 907 . Note that blotter cell 1003 has the rank of 2 while blotter cell 1013 in blotter row 1001 , above has a rank of 1, but both blotter rows 1001 and 1011 are highlighted because the ranking can fall into either rank 1 or 2 to satisfy the matrix volatility column 919 , (matrix cells 905 and 907 ). Still referring to blotter row 1011 , blotter cell 1015 denotes a rank of 2 which satisfies the criteria of matrix cell 909 , blotter cell 1017 has a rank of 2 which satisfies the criteria of matrix cell 901 , and blotter cell 1019 satisfies the criteria of matrix cell 911 . Blotter cell 1023 is of rank 2 which satisfies the criteria of matrix cell 907 , which is selected. But blotter cell 1024 , which is of rank 1, corresponds to an unselected matrix cell 910 ; hence, blotter row 1021 is not highlighted. Also, blotter cell 1025 , of rank 3, corresponds to matrix cell 915 which is again unselected, and is another reason for blotter row 1021 not being highlighted. Note that while blotter row 1027 does correspond to selected matrix cell 913 , because one or more blotter cells, namely blotter cells 1024 and 1025 , do not have selected corresponding matrix cells, blotter row 1021 is not selected or highlighted.
[0056] FIG. 11 denotes the “inclusion” function of the subject invention as referenced by depression of radio button 613 of FIG. 6 in the desired cells of the matrix of FIG. 11 , described in further detail below. More specifically, the “inclusion” radio buttons of matrix filter cells 1101 , 1103 , 1105 , 1107 and 1109 have been depressed, resulting in these matrix cells to be highlighted for example, green.
[0057] FIG. 12 , shows the effect on certain blotter rows and blotter cells thereof by the “inclusion” radio button actuation of FIG. 11 , above. Blotter row 1201 is highlighted because blotter cell 1205 corresponds to the “inclusion” criteria of matrix cell 1107 , although blotter cell 1203 is not part of any inclusion criteria of any cell of the matrix of FIG. 11 since blotter cell 1203 corresponds to matrix cell 1104 . Note that although blotter cell 1203 , which corresponds to matrix cell 1104 is not selected, because blotter cell 1205 was selected under the “inclusion” criteria, the entire blotter row 1201 is highlighted, in contrast to the “conditional inclusion” functionality of FIGS. 9 and 10 where each of the blotter cells either had to be “ignored” or had to satisfy the related matrix cell selection criteria in order for the blotter row to be highlighted. The above differentiates the rule set for “conditional inclusion” and “inclusion.”
[0058] Further, blotter cell 1207 falls into matrix cell 1106 which is also not selected, and blotter cell 1209 falls into matrix cell 1117 which, again, falls outside of the “inclusion” selection, of the matrix filter of FIG. 11 . Yet, as a result of blotter cell 1205 corresponding to the “inclusion” criteria of matrix cell 1107 , no other blotter cell in blotter row 1201 need satisfy a selection criteria of a corresponding matrix cell for blotter row 1201 to be highlighted.
[0059] Blotter row 1211 , in contrast, is not highlighted because none of its blotter cells corresponds to a matrix cell that is selected. For example, blotter cell 1213 falls into matrix cell 1111 , which is unselected; blotter cell 1215 falls into matrix cell 1113 which is again unselected; blotter cell 1217 falls into matrix cell 1115 which is also unselected; and blotter cell 1219 which maps to matrix cell 1117 is again unselected. In contrast, if any one of the above matrix cells had been selected, the entire blotter row would be highlighted based on the blotter cell that maps to the selected matrix cell.
[0060] Next referring to FIGS. 13 and 14 , the “exclusion” function is discussed. When referring to FIG. 13 like elements in FIG. 13 to those of FIG. 11 are denoted with similar element numbers, i.e., element 1115 in FIG. 11 being equivalent to element 1315 in FIG. 13 . Also, it is to be noted that the data previously discussed in FIG. 12 is the same data shown and to be discussed in FIG. 14 . Furthermore, elements again discussed in FIG. 14 that had been discussed in FIG. 12 share similar element numbers, i.e., element 1201 in FIG. 12 is equivalent to element 1401 in FIG. 14 . First referring to FIG. 13 , two alterations from FIG. 11 are present, specifically matrix cell 1307 was changed from “inclusion” (or green color) to “exclusion” (red color) based on actuation of radio button 1308 . Likewise, matrix cell 1309 , as contrasted with matrix cell 1109 , was changed from “inclusion” (green) to “exclusion” (red,) based on actuation of radio button 1310 . As a result matrix cell 1301 is “included”, matrix cell 1303 is “included,” matrix cell 1305 is “included” and matrix cells 1307 and 1309 are “excluded.”
[0061] The exclusion function thus has the following general rule set: Items that fall into the “exclusion” function are excluded regardless of any other criteria of “inclusion” or “conditional inclusion.” Hence, any equities that fall into matrix cell 1307 , which is equivalent to having PCTADV column 1316 and a rank of 4 , will be excluded from this selection criteria, and equities in MEDIUM_SPREAD column 1320 with a rank of 1, i.e., matrix cell 1309 , will be excluded from this selection criteria regardless of whether any other selection criteria prescribes their inclusion or conditional inclusion.
[0062] Next referring to FIG. 14 , which corresponds to the selection criteria implemented in FIG. 13 , and as differentiated as a result of changing matrix cells 1307 and 1309 from “inclusion” to “exclusion,” the blotter row 1401 is now excluded because blotter cell 1405 falls into matrix cell 1307 which now is mapped as “excluded.” Thus, blotter cell 1405 causes the blotter row 1401 to be not highlighted as opposed to the highlighted blotter row 1201 in FIG. 12 . Thus, although blotter cells 1403 , 1407 and 1409 satisfy the criteria of being “included” based on: blotter cell 1403 corresponding to matrix cell 1304 , which is the “ignore” the selection criteria; blotter cell 1407 being “ignore” based on matrix cell 1306 ; and blotter cell 1409 being “ignore” as a result of matrix cell 1317 , because blotter cell 1405 is interrelated with “excluded” matrix cell 1307 , blotter cell 1405 causes blotter row 1401 to be excluded or un-highlighted. Also note that if any of the above matrix selection criteria had been “include” instead of “ignore” the related blotter cells still would have been “excluded” because of the exclusionary condition.
[0063] Additionally, if any of the matrix cell was criteria “conditional inclusion” the related blotter cells would still have been “excluded” by the exclusionary conditions. In other words, “exclusion” always takes precedence over “inclusion” “ignore” and “conditional inclusion” functionality.
[0064] Next referring to blotter row 1411 , which is highlighted, blotter cell 1413 , which corresponds to matrix cell 1304 , is “ignored”. Blotter cell 1415 corresponds to matrix cell 1318 , which is “ignored.” Blotter cell 1417 , which corresponds to matrix cell 1301 , is “included.” Blotter cell 1419 is “ignored” as it corresponds to matrix cell 1317 . As a result of three matrix and corresponding blotter cells being “ignored” and one being “included,” with none “excluded”, (i.e., no blotter cells falling into matrix cells 1307 or 1309 ) blotter row 1411 is highlighted.
[0065] Next referring to FIGS. 15 and 16 , the data in the matrix filter of FIG. 15 and the blotter of FIG. 16 is the same data present in FIGS. 10 through 14 , however, there is no continuity in the selection of the desired radio button activation in FIG. 15 as compared to the radio buttons selection in FIGS. 11 and 13 . Hence the matrix filtering shown in FIGS. 15 and 16 is entirely different from that of FIGS. 11 through 14 . Still referring to FIGS. 15 and 16 , all three of the functions “conditional inclusion,” “inclusion” and “exclusion” are shown. First referring to FIG. 15 , “conditional inclusion” occurs in matrix cells 1507 , 1503 and 1511 . “Inclusion” is present in matrix cell 1505 and “exclusion” is shown in matrix cell 1513 . It is to be noted that all of the above functionalities are accomplished by the depression of the appropriate before described radio button.
[0066] Next referring to FIG. 16 blotter row 1601 is a highlighted row because blotter cell 1603 refers to matrix cell 1503 which is “conditionally included”; blotter cell 1605 refers to matrix cell 1505 which is “included”; blotter cell 1607 refers to matrix cell 1507 which is “included” and blotter cell 1609 refers to matrix cell 1509 which is “ignored.” As a result, blotter row 1601 is highlighted because of blotter cell 1605 being “included.”
[0067] Because blotter cell 1609 denotes rank 2, not rank 1, it is not “excluded.” Thus, blotter cell 1609 does not fall into a matrix cell category that causes it to be excluded because of “exclusion” functionality or included because of “conditional inclusion” functionality. Alternatively, if blotter cell 1609 was of rank 3 and not of rank 2, blotter cell 1609 would have been another cause for the highlighting (together with blotter cell 1605 being “inclusive”) of blotter row 1601 because blotter cell 1609 would fall in “conditional inclusion” of matrix cell 1511 . But, if blotter cell 1609 was of rank 1, which would fall into matrix cell 1513 which is “exclusion,” then blotter row 1601 would have been un-highlighted.
[0068] Next referring to FIGS. 17 and 18 , all of the “conditional inclusion”, “inclusion” and “exclusion” functions are shown on the same blotter 1801 . “Inclusion” is shown for all blotter cells of blotter 1801 that have a rank of 3 in RETRUN_VS_SECTOR. These blotter cells 1803 are highlighted in FIG. 18 and are logically aligned with matrix cell 1703 of matrix 1701 of FIG. 17 . The reason that any blotter cells are not highlighted, even if an “inclusion” or “conditional inclusion” functionality applies, is due to the “exclusion” functionality. Blotter cells selected by the inclusion functionality can only be unselected via the exclusion functionality.
[0069] “Conditional inclusion” is shown for all items on the blotter 1801 that have a rank of 2 for the VOLATILITY column (logically aligned with matrix cell 1705 of FIG. 17 ). Conditional inclusion means that all conditional inclusion criteria must be satisfied (i.e. population by an equity in both matrix cell 1705 and matrix cell 1707 ). If only one conditional inclusion criteria is satisfied (i.e blotter cell 1807 (symbol CHTT) satisfies the criteria where the VOLATILITY rank is 2 but MED_SPREAD is 3, the criteria of selective inclusion is not satisfied. Blotter cell 1807 could still be added provided it falls under inclusion (green) and is not excluded via exclusion (red). Further, selective inclusion of all equities in blotter 1801 that have a rank of 2 for the MED_SPREAD column, logically aligned with matrix cell 17 is shown at 1707 .
[0070] “Exclusion” of all equities on the blotter 1801 that have a rank of 2 for the PCT_ADV 20 column, logically aligned with matrix cell 1709 , such as blotter cell 1807 (symbol BID), is next shown. Equities that have a rank of 2 for the PCT_ADV 20 column are always excluded regardless of whether they are either conditionally included or included, such as blotter cell 1807 (symbol BID), whose PCT_ADV 20 rank is 2 (excluded) and VOLATILITY rank is 2 (conditional inclusion) and MED_SPREAD rank is 2 (conditional inclusion). Hence, “exclusion” always overrides any type on “inclusion”, be it “conditional inclusion” or “inclusion” per se.
[0071] Logically, the following filter is employed for the selection mechanism:
[0072] (RETURN_S_SECTOR=Rank3) OR
[0073] ((VOLATILITY=Rank2) AND (MED_SPREAD=Rank2)) AND
[0074] (PCT_ADV 20 not equal to Rank2)
[0075] Still referring to FIGS. 17 and 18 , blotter row 1803 ( symbol ATN) is highlighted because it satisfies the logic of “inclusion” matrix cell 1703 where the RETURN_VS_SECTOR rank is equal to 3 and satisfies the logic of matrix cell 1711 (i.e. not in “exclusion” matrix cell 1709 ) where PCT_ADV 20 is not rank 2 (it is rank 1). Logic conditions for “conditional inclusion” matrix cells 1705 and 1707 are not satisfied, but they do not have to be because the logic conditions for “inclusion” matrix cell 1703 is satisfied.
[0076] Blotter row 1809 (symbol CFBX) is not selected for the following reasons: It is not included under “inclusion” matrix cell 1703 and is not “conditionally included” under both matrix cells 1705 and 1703 (although 1707 by itself is satisfied, but 1705 is not). Note that blotter row 1809 is not explicitly excluded under the “exclusion” logic of matrix cell 1709 .
[0077] Blotter row 1811 (symbol CPWM) is selected because it is not “excluded” under the logic of matrix cell 1709 (it falls under matrix cell 1711 ), and is “conditionally included” under both, not just one of, matrix cell 1705 and 1707 .
[0078] Blotter row 1805 (symbol BEIQ) is not selected based on PCT_ADV 20 having a rank of 2 which satisfies the “exclusion” logic of matrix cell 1709 . While any type of “inclusion” would have been overridden by the above “exclusion” functionality, there is also no “inclusion” or “conditional inclusion” functionality because, first, RETURN_VS_SECTOR rank is not 3 (the “inclusion” logic of matrix cell 1703 ) and, second, MED_SPREAD is not of rank 2 (it is 4) even though VOLATILITY is of rank 2 (i.e., the “conditional inclusion” logic of matrix cells 1705 and 1707 is not met; the logic of matrix cell 1705 is met, but matrix cell 1707 is not since matrix cell 1713 is satisfied instead due to the rank of 4 instead of 2). Recall that both logic conditions of matrix cells 1703 and 1705 need to be satisfied for conditional inclusion to apply.
[0079] It will be apparent to those skilled in the art that a number of changes, modifications, or alterations to the present invention as described herein may be made, none of which depart from the spirit of the present invention. All such changes, modifications, and alterations should therefore be seen as within the scope of the present invention.
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A method for organizing a portfolio of financial instruments with a computer comprising providing a first user interface for said portfolio of financial instruments; providing a second user interface for selecting a least one of said financial instruments of said portfolio to form a subset, said subset of said portfolio of financial instruments being formed based on user selected financial criteria of said portfolio of financial instruments in conjunction with at least one of the subset forming rules of financial criteria exclusion, single financial criteria inclusion, and multiple financial criteria inclusion; and reflecting the inclusion of said at least one of said financial instruments of said portfolio within said subset on said first user interface.
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This application claims the benefit of U.S. Provisional Application No. 60/787,139, filed Mar. 29, 2006.
BACKGROUND OF INVENTION
1. Field of the Invention
This invention pertains to drilling of wells in the earth. More particularly, apparatus and method are provided for controlling the direction of a drill bit using a Rotary Steerable System (RSS) having a shape memory alloy (SMA) for applying the controlling force.
2. Description of Related Art
Directional drilling in the earth has become very common in recent years. A variety of apparatus and methods are used. Hydraulic motors driven by a drilling fluid pumped down the drill pipe and connected to a drill bit have been widely used. Directional control is achieved by using a “bent sub” just above or below the motor and other apparatus in a bottom-hole assembly. In this mode of drilling the drill pipe is not rotated while direction is being changed; it slides along the hole. More recently, the use of “Rotary Steerable Systems” (RSSs) has grown. These systems are of two common types: “push-the-bit” and “point-the-bit” systems. The drill pipe rotates while drilling, which can be an advantage is many drilling situations such as, for example, when sticking of drill pipe is a risk.
An RSS using the “point-the-bit” method is disclosed in U.S. Pat. No. 6,837,315. The system includes a power generation section, an electronics and sensor section and a steering section. In the power generating system, a turbine driven by the drilling fluid drives an alternator. The electronics and sensor section includes a variety of directional sensors and other electronic devices used in the tool. In the steering section, the shaft driving the bit is supported within a collar and a variable bit shaft angulating mechanism, having a motor, an offset mandrel and a coupling, is used to change the direction of the bit attached to the shaft. Similar power generation and electronics sections are common to many rotary steerable systems.
An RSS using the “push-the-bit” method is disclosed in U.S. Pat. No. 6,116,354. Thrust pistons are attached to pads and when the thrust pistons are actuated the pad is kicked against the wall of the borehole. Hydraulic fluid driving the pistons is controlled by a battery-driven solenoid.
A simpler and more reliable actuation mechanism is needed for driving the mechanisms of both “point-the-bit” and “push-the-bit” systems. This mechanism should provide the force necessary for a wide range of drilling conditions.
BRIEF SUMMARY OF THE INVENTION
A Rotary Steerable System (RSS) is provided. Either a push-the-bit or point-the-bit mechanism is activated by a shape memory alloy that is changed in length. The change in length, caused by temperature change of the alloy, is converted to transverse movement of a mechanism. The temperature of the alloy is controlled by electrical current in the alloy or by heating of material in proximity to the alloy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of one embodiment of the rotary steerable drilling tool disclosed herein.
FIG. 2 a is a section view of the rotary steerable drilling tool when not activated; FIG. 2 b is a section view of the tool when activated to push the bit.
FIG. 3 is an isometric view of the SMA actuator module.
FIG. 4 a is a section view of the SMA actuator module when not activated; FIG. 4 b is a section view of the activator when activated to exert a force.
FIG. 5 is an illustration of the use of an SMA actuator to push a bit using pads on a sleeve.
FIG. 6 is an illustration of the use of an SMA actuator to point a bit using a flexible shaft.
FIG. 7 is a schematic of an actuator design with straight SMA wires or rods.
FIG. 8 is a block diagram of a directional drilling system using SMA actuators. The same part is identified by the same numeral in each drawing.
FIG. 9 is an illustration of the SMA wire wound about the guides.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , an isometric view of rotary steerable tool 10 is shown. The tool consists of shaft 11 , up-connection pin or box 12 , non-rotating sleeve 13 , three pads 15 (one shown), three hatch covers 16 (one shown) and electronics section 18 . Shaft 11 may be connected to a drill bit and pin or box 12 may be connected to another segment of a bottom-hole assembly (BHA), which will be connected to the bottom of a string of drill pipe. Shaft 11 and connection pin or box 12 may rotate with the drill string while sleeve 13 is stationary.
Referring to FIG. 2 a , sleeve 13 is constrained axially on shaft 11 through two bearing packs 19 . Sleeve 13 does not rotate with shaft 11 during drilling, although slow rotation may occur. The three SMA actuator modules 14 , which will be described in detail below, are bolted in the cavities evenly distributed along the circumference of sleeve 13 . Above each SMA actuator module, hatch cover 16 is screwed on sleeve 13 for protection. Pad 15 is hinged on sleeve 13 with pin 25 , and moves outwards as actuator 14 is being activated. In FIG. 2 b , actuator 14 has been activated, forcing pads 15 outward. A bit attached to shaft 11 would thereby be forced in the opposite direction to movement of the pad, which would cause the creation of a curved trajectory of the borehole formed by the bit.
Shape Memory Alloy (SMA) is the family name of metals that have the ability to return to a predetermined shape when heated. Such materials are available from a variety of sources that may be identified with an internet search. When an SMA is cold, or below its transformation temperature, it has a very low yield strength and can be deformed quite easily into any new shape—which it will retain. However, when the material is heated above its transformation temperature it undergoes a change in crystal structure, which causes it to return to its original shape. During its phase transformation, the SMA either generates a large force against any encountered resistance or undergoes a significant dimension change when unrestricted. This characteristic of SMA is referred to as the “shape memory effect;” it enables SMAs to be used in solid-state actuators. There are SMAs having different transformation temperature, workout, and recovery strain. Fine adjustment of compositions of SMAs and manufacturing procedures will produce the desired properties of an SMA for specified applications. For the applications of the steering tool disclosed herein, the transformation temperature of SMA is chosen such that maximum ambient temperature is 20-30° C. below the transformation point of the material. Then the SMA can be activated only with the intentional addition of heat. The SMA can be heated by conducting electrical current through its length or by conduction effect of electrical heaters that are near or bonded to the SMA or by using environmental temperature, tool waste heat, drilling fluid temperature or a combination of sources. The SMA material used for the steering tool may be in the form of wires or rod. The dimensions and the number of the SMA wires or rods are chosen such that enough actuation force is ensured to push a drilling bit against the reaction resistance from side cutting. Due to the variety of the SMA forms and dimensions, there are various combinations of the SMA wires or rods suitable for the steering tool design. The example shown hereafter is just one of those possible design plans.
The SMA material to be used may be “trained” at a temperature above its transition temperature to have a length shorter than its length below the transition temperature. It is then installed in the RSS disclosed herein. When the material is heated above the transition temperature, length of the material decreases. In the embodiments discussed, this decrease in length is used to drive a pad or shaft in a direction transverse to the direction of the decrease in length.
A representative design of an actuator is shown in FIGS. 3-4 , which is the same design as shown in FIG. 2 . Referring to FIG. 3 , the SMA actuator 14 comprises a linkage system ( 31 , 33 , 34 , 35 , and 36 ), a motion transmission system ( 30 , 32 , 44 and 37 ), and an SMA winding system ( 32 , 38 and 39 ), all on base 17 . Guide 38 of the winding system is held in place by pins 38 A. Guide 39 of the winding system is held in place by pins 39 A. Only a short segment of SMA strand 40 , which may be made of several thin SMA wires, is shown, to provide greater clarity. Strand 40 winds around stationary guide rail 38 and movable guide rail 32 . The winding of SMA strand 40 and the its length are selected so that movable guide rail 32 slides a sufficient distance to ensure that pad 15 ( FIG. 2 a ) may push against the wall of the wellbore with a selected displacement amplitude and magnitude of lateral force when SMA strand 40 is heated above its transition temperature. Spring 43 may be used to pre-tension SMA strand 40 before activation and to reset the SMA after deactivation. The linear sliding motion of rail 32 is transmitted to the movement of slider link 37 A, spring 43 and rod 44 . Rod 44 is connected to rail 32 and slider link 37 A, and its movement is supported by bearing 46 . Rod 30 is attached to rail 32 , and slides on bearing 41 . To ensure a smooth sliding of slider link 37 A, sliding rail 42 is used to guide the slider. A long linkage 33 and short linkage 35 are hinged by pin 34 . The other end of linkage 35 is hinged to stand 48 , which is bolted on sleeve 13 with bolt 49 . Hence, linkage 35 only rotates about the pin 36 . Pin 31 connects slider 37 and long linkage 33 and allows linkage 33 to rotate relative to the slider. The lengths of the two linkages are chosen so that the pad moves a selected amount with a given displacement of rail 32 . Various modifications of the linkage system can meet the displacement amplification requirement.
Upon electrical heating, which can be done by directly heating the SMA elements by passing electrical current through the elements or by using a heating element near or in contact with the SMA elements and/or using any other heat source available downhole, SMA strand 40 contracts as a result of crystal structure changes. The resultant contracting force overcomes the pre-tension force on spring 43 and pushes movable guide rail 32 toward stationary rail 38 . Through the transmission chain consisting of the rod 44 , slider 37 and linkages 33 and 35 , the displacement of the rail 32 results in the transverse movement of pad 15 . Comparison of the positions of the moving components in FIGS. 4 a and 4 b clearly illustrates the actuation mechanism.
The SMA material may be heated by a variety of methods. For example, an oil bath surrounding the SMA material may be heated electrically. Alternatively, a separate resistance wire in thermal contact with the SMA material may be heated to heat the SMA material.
Referring to FIG. 5 a and FIG. 5 b , fully deployed pads 15 may be designed to extend outward to a diameter greater than the nominal diameter of the wellbore. As pads 15 touch wall-of-the-wellbore 50 , they may not fully activated, and continuously heating of SMA strands 40 ( FIG. 3 ) will produce large holding force on the pads. At this moment, pads 15 function like stabilizers, and sleeve 13 is stationary (not rotating). The combination of reaction forces from the three pads determines the steering force and direction. If the three forces are equal, a drill bit attached to shaft 11 remains at the center of the well, as illustrated in FIG. 5 a . To make a deviation of the drilling trajectory, under command from the electronics package, a feedback control loop coded in the electronics may regulate the electrical current applied to the three actuators to adjust their actuation forces so that the combined reaction pushes the attached drill bit sideways (transverse to the axis of the wellbore) and in the desired direction, as shown in FIG. 5 b . One or two pads may be activated to apply greater sideways force and one or two pads may be deactivated to an extent to apply less force. This steering approach is called the “push-the-bit” mode.
The SMA actuator may also be used for “point the bit” RSSs, as illustrated in FIGS. 6 a and 6 b . For this system, three steering pads 51 are directed inwards to apply sideways force between sleeve 53 and bearing 55 , which supports shaft 52 , instead of outwards to wall-of-the-wellbore 50 . As illustrated in FIG. 6 , as the three pads are deployed, they control the axial alignment of the shaft by means of bearing 55 . Similar to the former, the resultant steering force may be applied to shaft 52 to cause FIG. 6 b to point the bit for deviation of the wellbore, as shown.
To retract a pad, the electrical heating current or other source of heating is removed to cool down an SMA strand such as strand 40 ( FIG. 3 ). As the SMA transforms back to its lower temperature phase, spring 43 will keep the SMA strand extended for the next activation. SMA actuators are disclosed herein may be scaled to selected sizes for use in different sized wellbores.
The SMA used to generate the actuation force can be used in different combinations and arrangements, including SMA rods, wires, cables, pre-formed elements, and/or a combination thereof to achieve different forces, different expansion and contraction lengths, different stroke lengths and different actuation cycle times for generation of force and for the subsequent relaxation period of the SMA. The direction of the generated force can also be varied by using different assemblies of pulleys, linkages, levers, springs, rods, in different forms and combinations. For example, the schematic in FIG. 7 shows an actuator using straight SMA wires or rods 70 instead of strands of SMA materials that pass around pulleys. The linkage system remains, but the actuator force comes from two groups of SMA wires or rods symmetrically placed at the two sides of the linkage system. The linkage system is moved by rod 74 , which is attached to slider 72 . Without pulleys, this design eliminates the potential friction of the SMA wires and the rail used in the alternate embodiment, and requires more strain recovery capability of SMA materials.
The same principle of generating a substantial force using SMA material in different forms and shapes and alloys and combinations thereof, can also be used in different temperature ranges and environments; for example, the actuator unit disclosed herein may be used as a valve actuator or for other applications.
The disclosed system when used for rotary steerable drilling may be controlled with an algorithm, as illustrated in FIG. 8 . The electrical current to heat the SMA may come from 3-phase alternator 80 , which may be either driven by a turbine from drilling fluid flow or from relative rotation of shaft 11 in stationary sleeve 13 ( FIG. 1 ) of a drilling assembly. Closed loop control system 82 controls the steering of the device, which may receive downlink commands using well known methods such as industry standard mud pulse telemetry or drill string rpm coding. Once the tool receives commands from the surface, electronics package 84 and software work to immediately implement automatic steering continuously, using heating elements and temperature and force sensors 86 , until another command is sent. Alternatively, commands may not be downlinked from the surface but may be generated when downhole instruments that measure direction of the bit, such as an accelerometer and gyroscope or magnetometer, compare that direction to a pre-selected direction and send a signal to the rotary steerable system disclosed herein.
Although the present invention has been described with reference to specific details, it is not intended that such details should be regarded as limitations on the scope of the invention, except as and to the extent that they are included in the accompanying claims.
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A rotary steerable apparatus is provided having an actuator for pushing the bit or pointing the bit that includes a shape memory alloy. An elongated form of the alloy, such as a wire or rod, is employed in a mechanism that applies force in a direction transverse to the wellbore in response to a change in length of the alloy. Temperature of the alloy is controlled to change shape and produce the desired force on pads for operating the apparatus. The apparatus may be used with downhole power generation and control electronics to steer a bit, either in response to signals from the surface or from downhole instruments.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of German patent application DE 103 27 668.8 filed Jun. 20, 2003 the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention pertains to a process for manufacturing a catalytic converter formed by at least one monolith being held in a catalytic converter housing, especially a motor vehicle catalytic converter, wherein a mounting mat is placed on the outer circumferential surface of the monolith and the monolith is subsequently stuffed together with the mounting mat into the catalytic converter housing. Furthermore, the present invention pertains to a plant for manufacturing a catalytic converter formed from at least one monolith being held in a catalytic converter housing.
BACKGROUND OF THE INVENTION
[0003] A process of the type mentioned in the introduction for manufacturing catalytic converters, especially for manufacturing motor vehicle catalytic converters, is generally known. A catalytic converter housing, which may have a great variety of cross-sectional shapes corresponding to the particular intended use, e.g., a round, oval or elliptical shape, is first manufactured according to the prior-art process by forming and welding. At least one monolith, which is manufactured from a porous ceramic material, is coated with catalyst material, and whose cross section is adapted to the cross-sectional shape of the catalytic converter housing, is stuffed into the catalytic converter housing during the subsequent operation, the so-called canning. Depending on the particular application, two or more monoliths may also be stuffed into the catalytic converter housing, and, if necessary, they are arranged at spaced locations from one another in the catalytic converter housing. The catalytic converter housing is closed after the canning, e.g., by fastening corresponding connection flanges and covers.
[0004] Due to the ceramic material used, the monolith is relatively susceptible to shocks. Any movement of the monolith in relation to the catalytic converter housing must therefore be prevented from occurring to the extent possible in order to prevent the monolith from being damaged. The monolith should also not be set to vibrate due to vibrations of the catalytic converter housing, which are transmitted, e.g., from the motor vehicle to the catalytic converter housing, or by pulsating exhaust gas flows which flow through the monolith.
[0005] To guarantee this, a mounting mat made of glass fibers, rock wool or a similar heat resistant and shock-absorbing material is usually fastened around the outer circumferential surface of the monolith, i.e., the surface that extends rotationally symmetrically to the body axis of the monolith, along which the monolith is stuffed into the catalytic converter housing. The mounting mat assumes essentially two functions. On the one hand, the mounting mat shall keep the monolith under pretension in the catalytic converter housing in order to prevent a relative movement between the monolith and the catalytic converter housing. On the other hand, the mounting mat shall effectively absorb vibrations acting on the catalytic converter housing in relation to the monolith.
[0006] To fasten the mounting mat to the monolith, the monolith is usually beaten manually into the mounting mat and fixed by means of an adhesive to the monolith. However, the drawback of this procedure is that the quality of the positioning of the mounting mat at the monolith is greatly affected by the individual skill and the individual performance capacity of the worker who fastens the mounting mat to the monolith.
[0007] Thus, folds, which make it difficult or even impossible to stuff the monolith provided with the mounting mat into the catalytic converter housing, may be formed during the beating of the monolith into the mounting mat, or a gap may be left at the two mutually abutting lateral edges of the mounting mat during the assembly of the mounting mat, and this gap will form a bypass with the monolith stuffed into the catalytic converter housing, along which exhaust gas can flow untreated through the catalytic converter housing in parallel to the monolith. Furthermore, permanent fastening of the mounting mat with a hot-melt adhesive is not always guaranteed, so that the mounting mat may separate, especially during the canning, and the manufacturing process is interrupted. Since experience has shown that the time necessary for the assembly varies greatly in such an assembly step—it depends on the skill of the particular worker—integration of the winding in an automatic manufacturing cycle is possible with a corresponding intermediate buffer only. Despite the intermediate buffer, canning may be interrupted in case of an excessively long assembly time by the preceding beating in of the monolith into the mounting mat, which is performed manually, i.e., the canning machines are briefly out of use. Due to the large lot sizes in which catalytic converters are usually manufactured, this leads to high additional costs.
[0008] Segmented folding tools, which are to automatically beat the monolith into the mounting mat, have therefore also been used for some time. The folding tool has for this purpose a plurality of arc-shaped folding segments, which are articulated to one another and are activated one after another and lay the mounting mat section by section around the monolith. The drawback of such folding tools is, on the one hand, that the individual folding segments of the folding tool are to be actuated individually, which requires a considerable effort for control, and the folding tool consequently has to be complicated. On the other hand, the mounting mat is often creased at the transition between two folding segments, which may lead to damage to the structure of the mounting mat, which may lead as a consequence to the formation of the above-mentioned bypasses.
SUMMARY OF THE INVENTION
[0009] The object of the present invention is to provide a process and a plant for manufacturing a catalytic converter, which is formed by at least one monolith being held in a catalytic converter housing and in which or by the use of which the mounting mat can be arranged gently and uniformly on the outer circumferential surface of the monolith.
[0010] According to the invention, a process is provided for manufacturing a catalytic converter formed by at least one monolith being held in a catalytic converter housing, especially a motor vehicle catalytic converter. A mounting mat is placed on the outer circumferential surface of the monolith and the monolith is subsequently stuffed together with the mounting mat into the catalytic converter housing. To place the mounting mat on the circumferential surface, the monolith is set into rotation, while the mounting mat is being fed tangentially and is carried by the monolith.
[0011] According to another aspect of the invention, a plant is provided for manufacturing a catalytic converter formed from at least one monolith being held in a catalytic converter housing, especially for carrying out the process discussed above. The plant has a station for applying a mounting mat on the outer circumferential surface of the monolith and a stuffing station for stuffing the monolith provided with the mounting mat into the catalytic converter housing being kept ready. The station for applying the mounting mat has a winding housing, at which a feed gap is provided for feeding in the mounting mat tangentially as well as a clamping means for holding the monolith in the winding housing during the winding around with the mounting mat. The clamping means is provided with a rotary drive for rotating the monolith around its axis of rotation.
[0012] The mounting mat is fastened to the monolith according to the present invention by the mounting mat being wound around the monolith under defined boundary conditions. The monolith is rotated for this purpose around its body axis, while the mounting mat is being fed tangentially to the rotating outer circumferential surface of the monolith. The mounting mat is now being carried by the monolith, and the winding force, which acts on the mounting mat during the winding around the monolith, can be set very specifically depending on the torque with which the monolith is being rotated, on the one hand, and the force with which the mounting mat is being fed, on the other hand. This makes it possible to wind the mounting mat on the monolith very gently, and folding is prevented at the same time from occurring, because a defined, uniform tensile stress acting over the cross section of the mounting mat extending at right angles to the direction of feed acts on the mounting mat due to the feed motion of the mounting mat and the torque acting on the monolith.
[0013] Since the mounting mat has a limited elasticity when viewed over its feed length, it is, furthermore, possible to slightly vary the feed length of the mounting mat by specifically coordinating the speed of rotation of the monolith and the velocity of feed with one another such that the mounting mat can always be wound exactly on the monolith without a fold being formed, and longitudinal edges of the mounting mat that extend at right angles to the direction of winding will be properly in contact with one another after the mounting mat has been wound up on the monolith. The formation of the above-described bypasses in the monoliths stuffed into the catalytic converter housing can thus be prevented in a very specific manner. Furthermore, the lateral edges that are in contact with one another can be additionally interlocked with one another by a tongue-and-groove connection. Furthermore, a common mounting mat can also be wound around two or more monoliths with the process according to the present invention.
[0014] Thus, it is proposed in an especially preferred variant of the process according to the present invention that the speed of rotation of the monolith and the velocity of feed of the mounting mat be coordinated with one another such that the mounting mat will be wound on the monolith with a uniform pretension when viewed in the direction of feed, as a result of which it is achieved that the mounting mat will be in contact with the outer circumferential surface of the monolith extremely uniformly.
[0015] It is proposed, furthermore, for winding the mounting mat on the monolith that the monolith be introduced into a winding housing in which the monolith is set into rotation. It is achieved by using the winding housing that the mounting mat being fed tangentially is held in a defined position in relation to the monolith during the entire winding operation.
[0016] It is, furthermore, advantageous in this process variant for the mounting mat to be fed tangentially through a gap that is formed at the winding housing and extends in parallel to the axis of rotation of the monolith. It is ensured as a result that the mounting mat is fed to the monolith in a defined position already during the initial phase, and the monolith is thus able to take up the mounting mat properly.
[0017] Furthermore, it is proposed in the process variant in which the winding housing is used that the monolith be held in the winding housing such that the axis of rotation of the monolith coincides with the longitudinal axis of symmetry of the winding housing at least during the rotation such that the monolith maintains an at least approximately constant radial distance from the inner circumferential surface of the winding housing when viewed over its entire outer circumferential surface. It is achieved due to the constant distance between the monolith and the inner circumferential circumference of the winding housing that the mounting mat is pressed with a uniform pressing pressure against the outer circumferential surface of the monolith over its entire surface that is in contact with the monolith by the inner circumferential surface of the winding housing during both the introduction into the winding housing and the entire winding operation and is laid uniformly on the monolith.
[0018] The radial distance between the outer circumferential surface of the monolith and the inner circumferential surface of the winding housing is preferably selected to be such that the mounting mat is carried by the rotating monolith by friction during the tangential feed. It is thus possible to do away with additional auxiliary means with which the mounting mat is held at the monolith during the winding. As an alternative or in addition to the carrying of the mounting mat caused by friction, it is, however, also possible either to provide the monolith or the mounting mat with an adhesive at least in some sections, so that the mounting mat is carried, being bonded to the monolith during the initial phase of the winding operation and held by the bonded connection on the monolith.
[0019] In order for the mounting mat to hold the monolith with a defined press fit in the catalytic converter housing, it is proposed in a preferred variant of the process according to the present invention that the mounting mat wound on the monolith be pressed uniformly over its outer circumferential surface and that the monolith be stuffed with the pressed-on mounting mat into the catalytic converter housing. It is achieved by pressing the mounting mat that the arrangement comprising the monolith with the mounting mat wound around it will have predetermined, defined outside dimensions, which are adapted to the inside dimensions of the catalytic converter body for a sufficient press fit of the arrangement. At the same time, any unevennesses that may be preset on the mounting mat will be compensated by the pressing.
[0020] The monolith wound around with the mounting mat can be stuffed in an immediately following process step. As an alternative, e.g., when the monolith wound around with the mounting mat must first be transported from the winding station to another work station, it is advantageous to secure the mounting mat on the monolith after the winding around. For securing, the mounting mat is preferably held by rings made of a heat resistant material, into which the monolith wound around with the mounting mat is pushed. As an alternative, the mounting mat may also be secured on the monolith by a heat resistant adhesive.
[0021] To guarantee a defined seating of the monolith wound around with the mounting mat in the catalytic converter housing, it is proposed, furthermore, to expand the catalytic converter housing radially at least in some sections in a defined manner before the monolith is stuffed in. The catalytic converter housing is expanded now to the extent that the inside dimensions of the catalytic converter housing are adapted to the outside dimensions of the arrangement formed by the monolith wound around with the mounting mat to form a press fit, optionally after pressing the mounting mat. The particular monolith is preferably measured before the mounting mat is wound around it, and the catalytic converter housing is expanded individually corresponding to the determined outside dimensions of the monolith.
[0022] According to another aspect, the present invention pertains to a plant for manufacturing a catalytic converter formed from at least one monolith being held in a catalytic converter housing, which is especially suitable for carrying out the above-described process according to the present invention. The plant according to the present invention has a station for winding the mounting mat around the monolith as well as a stuffing station for stuffing the monolith provided with the mounting mat into a catalytic converter housing kept ready. The station for winding around the monolith has a winding housing, at which a feed gap for tangentially feeding the mounting mat is provided, as well as a clamping means for holding the monolith in the winding housing during the winding around with the mounting mat, wherein the clamping means is provided with a rotary drive for rotating the monolith around its longitudinal axis.
[0023] In a preferred embodiment of the plant according to the present invention, the clamping means has a stamp each on both sides of the winding housing, of which at least one of the two stamps is axially displaceable in relation to the other stamp to clamp the monolith between the stamps and one of the two stamps is to be driven rotatably around the axis of displacement. Furthermore, the winding housing is open at both of its ends, so that the clamping means can be moved into the winding housing and can be removed from the winding housing. The advantage of this embodiment is especially that both the clamping and the rotation of the monolith for being wound around by the mounting mat can be carried out automatically.
[0024] Furthermore, it is proposed that the station be equipped with a feed means adjoining the feed gap of the winding housing for feeding the mounting mat into the winding housing. It is possible by means of the feed means to feed the mounting mat at a defined, preferably variable rate of feed tangentially in relation to the speed of rotation of the monolith, so that a defined tension can be set in the direction of feed due to the mutual coordination of the speed of rotation of the monolith and the velocity of feed of the mounting mat.
[0025] To further increase the degree of automation of the plant, it is proposed, furthermore, in the above-described embodiment of the plant according to the present invention that a handling means for separating the mounting mat from a mounting mat stack and for delivering the mounting mat into the feed means be provided adjacent to the feed means.
[0026] The plant or device according to the present invention may be integrated within a cyclically operating overall plant in which the plants or devices are linked by corresponding handling means for the manufacture of large lots of catalytic converters, in which, e.g., a welding station is provided for the catalytic converter housing in parallel to the station for winding around the monolith, and the stuffing station is arranged directly downstream of the station for winding around the monolith. However, it is also conceivable as an alternative that the individual work stations, for example, the station for winding around the monolith and the stuffing station, are designed as mutually separate stations. It is particularly advantageous in such an application to provide a securing station for securing the mounting mat at the monolith between the station for winding around the monolith and the stuffing station, which said securing station is preferably used for holding rings, into which the monolith wound around with the mounting mat is to be introduced for securing. It is guaranteed by securing the mounting mat that the mounting mat previously wound around the monolith will not separate or change its position at the monolith when the monolith with the mounting mat is being transported to the stuffing station.
[0027] To ensure that the arrangement comprising the monolith with the mounting mat wound around it have defined outside dimensions, it is, furthermore, advantageous for a pressing means to be provided at the stuffing station for pressing the mounting mat being held at the monolith on the outer circumferential surface, with which such pressing station the mounting mat can be pressed gently to desired outside dimensions before being stuffed into the catalytic converter housing.
[0028] Other features and advantages of the present invention will appear from the following description of a preferred exemplary embodiment with reference to the attached drawings. The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] [0029]FIG. 1 is a schematic top view of a winding station for winding a mounting mat around a monolith, which winding station is used in a plant for manufacturing a catalytic converter;
[0030] [0030]FIG. 2 is a schematic front view of the winding housing used in the plant according to FIG. 1; and
[0031] [0031]FIG. 3 is a schematic diagram showing the plant.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] [0032]FIG. 1 shows a schematic top view of a winding station 10 for winding a mounting mat 14 made of glass fibers around a monolith 12 .
[0033] The winding station 10 has a frame 16 , on which a first clamping unit 18 of a clamping means 20 , shown in the left-hand part of FIG. 1, a winding housing 22 , a securing means 24 as well as a second clamping unit 26 of the clamping means 20 are fastened. The clamping means 20 formed from the two clamping units 18 and 26 is used to hold, rotate and transport the monolith 12 through the station 10 , as will be explained in detail below.
[0034] A feed means 28 for tangentially feeding the mounting mat 14 is provided adjacent to the winding housing 22 . Furthermore, a handling means, not shown for the sake of clarity, is provided, with which the monolith 12 is inserted into and removed from the station 10 .
[0035] Both the clamping means 18 and the clamping unit 26 of the clamping means 20 are equipped with a respective stamp 30 and 32 each. The stamps 30 and 32 can be displaced to and fro axially in the longitudinal direction of the frame 16 along a common axis of displacement V. The axis of displacement V of the stamps 30 and 32 coincides here with the axis of symmetry of the winding housing 22 , which has an at least approximately round cross section, such that the monolith 12 to be held between the stamps 30 and 32 can be displaced from a receiving position, adjacent to the winding housing 22 , into a winding position in the winding housing 22 and from there into a securing position in the securing means 26 , from which the handling means will finally remove the monolith 12 wound around with the mounting mat 14 from the station 10 . Furthermore, at least one of the two stamps 30 and 32 is provided with a rotary drive, with which the approximately cylindrical monolith 12 being clamped between the stamps 30 and 32 is to be rotated around its axis of symmetry, wherein the other rotatably mounted stamp 32 or 30 is being carried. Both stamps 30 and 32 are driven synchronously with one another in one variant of the clamping means 20 .
[0036] As is shown in FIG. 2, which shows a front view of the winding housing 22 , the winding housing 22 passes over on its side shown in the left-hand part of FIG. 2 into an approximately horizontally extending support 34 for the feed means 28 . A feed gap 36 , which extends in parallel to the longitudinal direction of the winding housing 22 and is used to feed the mounting mat 14 into the winding housing 22 , is provided at the transition of the winding housing 22 into the support 34 . FIG. 2 also shows that the stamps 30 and 32 of the clamping means 20 hold and rotate the monolith 12 in relation to the winding housing 22 such that the axis of rotation R of the monolith 12 coincides with the axis of symmetry of the winding housing 22 . As a result, the monolith 12 with its outer circumferential surface 38 is maintained at an approximately constant distance a from the inner circumferential surface 40 of the winding housing 22 .
[0037] The securing means 24 has a housing 42 (drawn in broken lines), whose cross section is adapted to the cross section of the winding housing 22 and comprises two parts, so that the housing 42 can be opened. Two grooves 44 and 46 , which extend at right angles of the axis of displacement V and are used to receive a ring made of a heat resistant material each, are provided at the housing 42 . The internal diameter of the two rings acting as securing elements is adapted to the external diameter of the monolith 12 wound around with the mounting mat 14 . To secure the mounting mat 14 on the monolith 12 , the monolith 12 wound around with the mounting mat 14 is introduced by the stamps 30 and 32 into the rings, which are being held in the housing 42 of the securing means 24 , likewise extend at right angles to the axis of displacement V and hold the mounting mat 14 at the monolith 12 after the opening of the housing 42 .
[0038] The feed means 28 has a pusher 48 , which is movable to and fro in a direction of feed T in the longitudinal direction of the support 34 and is guided at a pair of guides 50 provided on the underside of the support 34 . Furthermore, a stacking means 52 , in which a larger number of mounting mats 14 are kept ready stacked up for the winding operation, is provided to the side of the support 34 . A separator 54 , with which the lowermost mounting mat 14 in the stacking means 52 is delivered onto the support 34 , is provided at the stacking means 52 .
[0039] At the beginning of the winding operation the station 10 is moved into its starting position, in which the two stamps 30 and 32 have been moved into the receiving position shown in the left-hand part of FIG. 1. The stamps 30 and 32 are now moved apart to the extent that the handling means, not shown, can position the monolith 12 to be wound around between the stamps 30 and 32 without problems. Furthermore, the separator 54 delivers a single mounting mat 14 onto the support 34 . The pusher 48 is then displaced to the extent that the front edge of the mounting mat 14 is arranged directly adjacent to the feed gap 36 .
[0040] After the station 10 has been moved into its starting position, the handling means, not shown, positions the monolith 12 between the stamps 30 and 32 , which are subsequently moved toward each other and clamp it between them. The clamped monolith 12 is then moved by the two stamps 30 and 32 into the winding position in the winding housing 22 . As soon as the monolith 12 is in the winding position, the pusher 48 is activated, and it introduces the mounting mat 14 in the direction of feed T into the winding housing 22 , and the monolith 12 is rotated by the clamping units 18 and 24 around the axis of rotation R. As soon as it has been introduced through the feed gap 36 into the area between the outer surface 38 of the monolith 12 and the inner surface 40 of the winding housing, the mounting mat 14 is then carried because of the relatively high roughness of the outer surface 38 of the monolith 12 , while it is sliding along the inner surface 40 of the winding housing 22 . The speed of rotation of the monolith 12 around the axis of rotation R and the velocity of feed of the mounting mat 14 in the direction of feed T are coordinated with one another such that the mounting mat 14 lies on the moving outer circumferential surface 38 of the monolith 12 . The pusher 48 is continuously feeding the mounting mat 14 in the process, and the tensile stress that acts on the mounting mat 14 in its longitudinal direction extending in the direction of feed T can be varied to a limited extent by changing the velocity of feed with which the mounting mat 14 is being introduced into the winding housing 22 by the pusher 48 .
[0041] As soon as the mounting mat 14 has been pulled completely into the winding housing 22 , the speed of rotation of the monolith 12 is slowed down, and the mounting mat 14 being held on the monolith 12 is turned into a position in which the mounting mat 14 with its lateral edges extending in parallel to the axis of rotation R meet or abut against each other.
[0042] After the mounting mat 14 has been properly wound on the monolith 12 , the clamping means 18 and 24 are stopped and moved in the direction of the securing means 26 . The stamps 30 and 32 deliver the monolith 12 wound around with the mounting mat 14 into the closed housing 42 of the securing means 26 . With the housing open 42 , rings, which are to be used to secure the mounting mat 14 in its position in relation to the monolith 12 , had been previously placed into the grooves 44 and 46 . For securing, the monolith 12 wound around with the mounting mat 14 is guided by the rings being held in the housing 42 in the grooves 44 and 46 , and the mounting mat 14 cannot separate from the monolith 12 during the stuffing into the housing 42 , because the size and the shape of the cross section of the closed housing 42 of the securing means 26 are at least approximately the same as those of the monolith 12 , as was explained before. As soon as the monolith 12 wound around with the mounting mat 14 has been completely stuffed into the housing 42 , i.e., it is in its secured position, the divided housing 42 of the securing means 26 is opened, and the handling device removes the completely wound monolith 12 with its mounting mat 14 being secured by the rings from the securing means 26 . The station 10 is then moved again into its starting position.
[0043] The monolith 12 thus wound around with the mounting mat 14 is subsequently fed to the pressing means 62 of a stuffing station 60 , in which the mounting mat 14 being held on the monolith 12 is pressed together to a predetermined size. Along with the mounting mat 14 , the monolith 12 , thus pretreated and pressed, is then stuffed into the catalytic converter housing being kept ready. The catalytic converter housing may be pretreated, before the stuffing by a radial expander 64 , wherein the catalytic converter housing is radially expanded in at least some sections before the monolith is stuffed in.
[0044] The station 10 is designed in the above-described exemplary embodiment as an independent process station, which is not directly integrated within a production line. However, it is also conceivable to integrate the station 10 within the process of a production line. The securing means 26 may be eliminated in this case, and the monolith 12 , wound completely around with a mounting mat 14 , is delivered directly into the pressing means 62 of the stuffing station 60 without securing.
[0045] Furthermore, it is conceivable to design the winding housing 22 as a divided housing in order to wind a common mounting mat 14 around a plurality of monoliths 12 in the winding housing 22 .
[0046] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
Appendix
[0047] List of Reference Numbers:
[0048] [0048] 10 Winding station
[0049] [0049] 12 Monolith
[0050] [0050] 14 Mounting mat
[0051] [0051] 16 Frame
[0052] [0052] 18 First clamping unit
[0053] [0053] 20 Clamping means
[0054] [0054] 22 Winding housing
[0055] [0055] 24 Securing means
[0056] [0056] 26 Second clamping unit
[0057] [0057] 28 Feed means
[0058] [0058] 30 Stamp
[0059] [0059] 32 Stamp
[0060] [0060] 34 Support
[0061] [0061] 36 Feed gap
[0062] [0062] 38 Outer circumferential surface
[0063] [0063] 40 Inner circumferential surface
[0064] [0064] 42 Housing
[0065] [0065] 44 Groove
[0066] [0066] 46 Groove
[0067] [0067] 48 Pusher
[0068] [0068] 50 Pair of guides
[0069] [0069] 52 Stacking means
[0070] [0070] 54 Separator
[0071] R Direction of rotation
[0072] T Direction of feed
[0073] V Axis of displacement
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A process is provided for manufacturing a catalytic converter formed from at least one monolith being held in a catalytic converter housing, especially a motor vehicle catalytic converter. A mounting mat ( 14 ) is placed on the outer circumferential surface ( 38 ) of the monolith ( 12 ) in the process, and the monolith ( 12 ) is subsequently stuffed together with the mounting mat ( 14 ) into the catalytic converter housing. To apply the mounting mat ( 14 ) on the monolith ( 12 ), the monolith ( 12 ) is set into rotation, while the mounting mat ( 14 ) is being fed tangentially and is carried by the monolith ( 12 ). A plant for carrying out the process is also provided as well as aan application device ( 10 ).
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FIELD OF THE INVENTION
The present invention relates to articles such as bags and related methods. More specifically, the present invention relates to articles for holding a particulate product and related methods.
BACKGROUND OF THE INVENTION
Dry particulate products such as bird seed, grass seed, water softener salt, and pet food are often sold by retailers in prefilled bags. Such bagged products can be quite heavy depending on their volume, sometimes weighing 50 pounds or more. It can be difficult to grip such bags because of their shape and because they are often made of a relatively slick plastic material. As such, because of both weight and difficulty in gripping, it can be difficult for consumers to manipulate such bagged products.
Such bagged products can also be problematic for retailers because of their propensity to rupture, leading to messy spills of the product contained therein. The shear weight of the product contained therein places unique demands on bag construction that are quite distinct from that of other types of bags such as grocery bags or common retailer bags.
Unfortunately, cost constraints make it difficult to solve these issues. Even adding pennies of additional cost to a bag design can render it unfeasible for use with near-commodity bagged products sold in mass-market retailers.
Accordingly, a need remains for articles for holding dry particulate products.
SUMMARY OF THE INVENTION
The present invention relates to articles for holding a product and related methods. In an embodiment, the invention includes an article including a first sheet, a second sheet coupled to the first sheet defining an interior volume between the first sheet and the second sheet, and a handle region defining an aperture passing through the first sheet and the second sheet. The handle region including a first flap and a second flap, the first flap coupled to the first sheet and the second sheet along a first axis, the second flap coupled to the first sheet and the second sheet along a second axis, the first axis and second axis perpendicular to one another, the first flap and the second flap configured to flex away from the handle region.
In an embodiment, the invention includes a bag including a first sidewall, a second sidewall coupled to the first sidewall defining an interior volume between the first sheet and the second sheet, and a die-cut handle. The die-cut handle including a first flap and a second flap, the first flap coupled to the first sidewall and the second sidewall along a first axis, the second flap coupled to the first sidewall and the second sidewall along a second axis, the first axis and second axis perpendicular to one another. The first and second flaps configured to flex between a closed position where the flaps are substantially planar with the first and second sidewall and an open position where the flaps are not-planar the first and second sidewall.
In an embodiment, the invention includes a method of forming a bag including coupling a first sidewall to a second sidewall to form a rectangular bag with four corners and forming a cut pattern through the first sidewall and the second sidewall to form a handle, the pattern outlining the shape of a plurality of flaps that can each flex along separate axes.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic view of an article in accordance with an embodiment of the invention.
FIG. 2 is an enlarged schematic view of the handle region of the article shown in FIG. 1 .
FIG. 3 is a schematic view of the hand of a user manipulating an article in accordance with an embodiment of the invention.
FIG. 4 is an opposite side view of the embodiment shown in FIG. 3 .
FIG. 5 is a cross-sectional schematic view of two flaps in a closed configuration.
FIG. 6 is a cross-sectional schematic view of a two flaps in an open configuration.
FIG. 7 is a schematic view of a handle region shown in accordance with another embodiment of the invention.
FIG. 8 is a cross-sectional view (not to scale) of an article as taken along line 8 - 8 of FIG. 1 .
FIG. 9 is a cross-sectional view (not to scale) of an article as taken along line 9 - 9 of FIG. 1 .
FIG. 10 is an exploded view of a support layer disposed between a first sheet and a second sheet in accordance with an embodiment of the invention.
FIG. 11 is an exploded view of a support layer disposed outside of a first sheet and a second sheet in accordance with an embodiment of the invention.
FIG. 12 is a schematic view of an article in accordance with another embodiment of the invention.
FIG. 13 is a schematic view of the handle region of an article in accordance with another embodiment of the invention.
While the invention is susceptible to various modifications and alternative forms, specifics thereof have been shown by way of example and drawings, and will be described in detail. It should be understood, however, that the invention is not limited to the particular embodiments described. On the contrary, the intention is to cover modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
DETAILED DESCRIPTION OF THE INVENTION
It can be difficult for customers to grip and manipulate bagged products, such as bagged bird seed or grass seed, because of the shape and weight of the filled bags, and also because the bags are often made of a relatively slick plastic material.
In some cases, handles have been attached to such bags in order to make them easier to manipulate for retail customers. However, because of the weight the bags, and because such handles generally result in concentrating the force of the bag weight over a small area of the hand, using handles can result in significant discomfort for bag users.
In addition, where bags have included handles, they are traditionally placed over the center of the bag. However, center placement is not an ideal placement of a handle for the purpose of pouring product, particularly a heavy product. A center-placed handle will increase the stress on the hand and wrist in the lifting and pouring of dry product, because the wrist must be cocked to approximately a 30 degree angle in order to elevate and handle packages with center-placed handles.
In some embodiments herein, a handle is formed in an article, such as a bag, in a manner so as to make the handle more comfortable for use. It has been observed that discomfort arises in an acute manner particularly where a cut edge of bag material is driven into the hand of the user by the overall weight of the bag and the product contained therein. In various embodiments herein, multiple flaps are used to make the handle more comfortable to use. Specifically, in various embodiments, the handle is formed such that flaps of bag material prevent a cut edge of bag material from contacting the hand of a user. The flaps of bag material can flex away from the plane of the package when a user inserts their hand into the handle, such that the edges of the flaps that are still connected to the rest of the package come in contact with the user's hand, instead of a cut edge of the bag. The use of flaps in this manner can lead to increased comfort on the part of the consumer picking up and/or carrying the bag, particularly in the context of bags loaded with a heavy product.
In some embodiments herein, two-layer laminate materials are used to construct articles, such as bags, that can be used to hold dry particulate products such as bird seed, grass seed, and the like. As such, some embodiments herein include an article as described herein in combination with a dry particulate product disposed within the article. Two-layer laminate materials can offer advantages in terms of product strength and/or product appearance. However, the use of such materials can be complicated by the varying properties each layer of the laminate. By way of example, a two-layer laminate of including a first layer of polyester, polyethylene, polypropylene or polyamide (e.g., nylon) and a second layer of polyethylene can be advantageous because it offers significant strength and can allow for an smooth and aesthetic outer surface while maintaining high strength. However, depending on the specific polymer or polymer alloy used in the laminate, the outer layer may not be conducive to heat-sealing. As such, use of such a laminate in a heat-sealed bag that has sufficient strength against rupture, particularly along seams or along tears or perforations in the structure, presents challenges.
However, embodiments of the invention herein include an article that incorporates a two-layer laminate into a heat-sealed bag in a manner that provides the advantages of two-layer laminates along with sufficient strength to resist ruptures along seams or along tears or perforations in the structure including in the area of the bag handle.
While not intending to be bound by theory, it is believed the bag can be made more ergonomic by placing the handle near a corner. Specifically, the placement of the handle near a corner of the package can make it easier to handle and pour the product. In some embodiments, the handle is positioned in a corner of the bag.
Various aspects of exemplary embodiments of the invention will now be described in greater detail. Referring now to FIG. 1 , a schematic view of an article in accordance with an embodiment of the invention is shown. The article 100 includes a body 102 having a top edge 160 , a bottom edge 162 , a first side edge 164 , and a second side edge 166 . The article 100 also include a first corner 168 , second corner 170 , third corner 172 , and fourth corner 174 . In this embodiment, the body 102 of the article 100 is rectangular in shape. However, it will be appreciated that the body 102 can also take on other shapes such as semi-rectangular, square, semi-square, oblong, semi-rounded or the like. The article can include a handle region 104 . The handle region 104 can facilitate gripping of the article 102 . In some embodiments, the article 102 can also include a pouring region 106 . In some embodiments, the pouring region 106 can be defined by a scored line. The pouring region 106 can be adjacent to one end of the top edge 160 , while the handle region 104 can be adjacent to the opposite end of the top edge 160 .
Referring now to FIG. 2 , an enlarged schematic view of the handle region 104 is shown. The handle region 104 can be configured to facilitate comfortable gripping of the article 102 . In some embodiments, the handle region 104 can include cut lines 138 , 140 , and 142 that allow multiple flaps of material to flex away when a person's hand is inserted into the handle, creating a tactile feeling of increased comfort for the bag user. Cut lines 138 , 140 , and 142 can allow flaps 122 , 126 , 130 , and 134 to move independently from one another. For example, when a person's hand is inserted, flap 122 can bend away from the plane of the body 102 along a first axis (line 124 ) and flap 126 can bend away from the body 102 along a second axis (line 128 ). In some embodiments, the first axis can be perpendicular to the second axis. Flap 130 can bend away from the body 102 along a third axis (line 132 ) and flap 134 can bend away from the body 102 along a fourth axis (line 136 ). In use, the weight of the bag will be supported by the user's hand through contact with the non-cut edge of the flaps that is still connected to the rest of the bag (e.g., the user's hand will support the weight by contact with the bag along one or more of the first axis, second axis, third axis, and fourth axis). In this manner, the flaps 122 , 126 , 130 , and 134 can serve to prevent the user's hand from supporting the weight of the bag through contact with a cut-edge of the material of the body 102 , thereby increasing comfort.
FIG. 3 is a schematic view of the hand 250 of a user manipulating an article in accordance with an embodiment of the invention. In this view, the article 200 includes a body 202 with a particulate product 252 disposed therein. The article 200 also includes a pouring region 206 that can include a perforation line to facilitate opening of the pouring region 206 . When a user's hand 250 is inserted into the handle region 204 , the article 200 is tilted with respect to the direction of gravity 254 because of the weight of the particulate product 252 . As such, when in a carrying position, the handle region 204 of the article 200 is disposed at the highest point of the article 200 .
FIG. 4 is an opposite side view of the embodiment shown in FIG. 3 . This view shows the flaps 222 , 226 , 230 and 234 bent backward because of the insertion of the user's hand 250 . In this manner, pressure on the user's hand 250 exerted by the force of gravity acting on the weight of the particulate material 252 contained in the article 200 is distributed across the portion of the flaps that contacts the rest of the article 200 and is bent. In this particular carrying position, the weight of particulate material 252 would mostly be supported by the user's hand as it contacts flap 224 and flap 230 . As such, this configuration of the handle region 204 prevents the entire load being supported against the user's hand 250 through contact with a cut-edge, leading to increased comfort for the user.
Referring now to FIG. 5 , a cross-sectional schematic view of a portion of a handle 260 is shown. The handle includes a first flap 262 and a second flap 264 . In this view, the first flap 262 and second flap 264 are in a closed configuration, substantially planar with the rest of the bag (not shown). As described above, the flaps can flex outwardly. Referring now to FIG. 6 , a cross-sectional schematic view of a portion of the handle 260 is shown in an open configuration. In the open configuration, the flaps have flexed such that the cut ends ( 270 and 272 ) of the first flap 262 and second flap 264 are now pointed away from the region 274 in between the two flaps 262 and 264 . This can occur, for example, in response to a user inserting their hand into the region 274 in between the two flaps 262 and 264 . In the open configuration, a user's hand can support the weight of a bag through contact with the portions 266 and 268 of the flaps 262 and 264 connected to the rest of the bag. As such, in the open configuration, the user need not support the weight of a bag through contact with cut edges, thereby increasing comfort for the user.
It will be appreciated that the cut lines in the handle region can be formed in various ways including die-cutting, laser-cutting, thermal-cutting, and the like. It will also be appreciated that the precise pattern of cut lines can take on many different forms. Referring now to FIG. 7 , a schematic view of a handle region is shown in accordance with another embodiment of the invention. In this embodiment, the handle region 304 includes a first flap 322 and a second flap 326 . The flaps 322 , 326 are formed in part through a first cut line 340 and a second cut line 342 . The cut lines 340 , 342 enable the flaps 322 , 326 to flex along lines 324 and 328 respectively. In use, a user's hand (not shown) would be inserted into the handle region 304 and the weight of the article would be supported by the user's hand along flex line 324 of the first flap 322 and along flex line 328 of the second flap 326 .
In some embodiments of the invention, a reinforcing material is disposed in between two separate laminate sheets in order to provide extra strength in the handle region. Referring now to FIG. 8 , a cross-sectional view (not to scale) of an article in accordance with an embodiment of the invention is shown as taken along line 8 - 8 of FIG. 1 . In this view, a first laminate 172 and a second laminate 174 are configured such that the edges of the laminates are coupled to one another. This coupling can be achieved using various techniques including the use of adhesives, heat-sealing, sonic welding, and the like. Each laminate can include multiple layers of material. By way of example, first laminate 172 can include a first layer 146 and a second layer 148 . The first layer 146 can include polyester, polyethylene, polypropylene, polyamide, and/or alloys including the same and the second layer 148 can include polyethylene or polyethylene alloys. Similarly, second laminate 174 can include a first layer 152 and a second layer 150 . The first layer 152 can include polyester, polyethylene, polypropylene, polyamide, and/or alloys including the same and the second layer 150 can include polyethylene or polyethylene alloys. Together, the first layer 146 and the second layer 148 can define an interior volume 154 . It is within the interior volume 154 that the article can contain a product, such as a dry particulate material (not shown).
However, in the handle region, the article may include an additional layer of material in some embodiments. Referring now to FIG. 9 , a cross-sectional view (not to scale) of an article is shown as taken along line 9 - 9 of FIG. 1 . Cut line 142 is also shown in this cross-sectional view. In this view, a support layer 156 is disposed in between the first laminate 172 and the second laminate 174 . In some embodiments the support layer 156 can be composed of a material that can be heat sealed to both the second layer of the 148 of the first laminate 172 and the second layer 150 of the second laminate 174 . In this configuration, the support layer 156 can strengthen and reinforce the handle region, making it less likely to tear or rupture. This can be particularly important in the context of articles that have multiple cut lines, such as that shown in FIG. 1 and FIG. 7 since additional cut lines create additional points where a tear can begin. Reinforcement can be important as in some embodiments the bag may be configured to carry an amount of a product exceeding 10 pounds in weight. In some embodiments, the bag may be configured to carry an amount of a product exceeding 20 pounds in weight. In some embodiments, the bag may be configured to carry an amount of a product exceeding 30 pounds in weight. In some embodiments, the bag may be configured to carry an amount of a product exceeding 40 pounds in weight.
FIG. 10 is an exploded view of a support layer 456 disposed between a first sheet 472 and a second sheet 474 . In some embodiments, the first sheet 472 and the second sheet 474 can comprise laminates. The first sheet 472 , the support layer 456 , and the second sheet 474 can all be bonded together in order to make an article such as a bag for particulate material.
However, a support layer can also be disposed on the outside of the first sheet and the second sheet. FIG. 11 is an exploded view of a support layer 556 disposed outside of a first sheet 572 and a second sheet 574 . The support layer 556 , the first sheet 572 , and the second sheet 574 can all be bonded together in order to make an article such as a bag for particulate material.
Embodiments of the invention can also include various other features in order to facilitate their use. By way of example referring now to FIG. 12 , an article 600 is shown including a handle region 604 . The article also includes an opening strip 606 disposed across the top edge of the article 600 . The opening strip 606 can be removed in order to facilitate the opening of the article 600 . In some embodiments, the opening strip 606 can include a perforation line in order to facilitate removal of the opening strip 606 . In some embodiments, the article can also include a reclosure mechanism (not shown) such as a compression seal in order to facilitate reclosure of the article after removal of the opening strip 606 . In some embodiments, the article 600 can also be configured to include one or more gussets 610 in order to facilitate expansion of the interior volume of the bag in order to hold dry particulate matter.
It will be appreciated that handle regions having multiple flaps in accordance with embodiments herein can take on many different configurations. While not intending to be bound by theory, it is believed that there can be various manufacturing advantages associated with configurations wherein the flaps can be formed by die-cutting along lines that are not curved. For example, it can be easier to maintain the sharpness of a die that only needs to cut along straight line segments as opposed to curved line segments. Referring now to FIG. 13 , an enlarged schematic view of the handle region 704 is shown in accordance with another embodiment herein. The handle region 704 can be configured to facilitate comfortable gripping of the article 702 . In some embodiments, the handle region 704 can include cut lines 738 , 740 , and 742 that allow multiple flaps of material to flex away when a person's hand is inserted into the handle, creating a tactile feeling of increased comfort for the bag user. Cut lines 738 , 740 , and 742 can allow flaps 722 , 726 , 730 , and 734 to move independently from one another. For example, when a person's hand is inserted, flap 722 can bend away from the plane of the body 702 along a first axis (line 724 ) and flap 726 can bend away from the body 702 along a second axis (line 728 ). In some embodiments, the first axis can be perpendicular to the second axis. Flap 730 can bend away from the body 702 along a third axis (line 732 ) and flap 734 can bend away from the body 702 along a fourth axis (line 736 ). In use, the weight of the bag will be supported by the user's hand through contact with the non-cut edge of the flaps that is still connected to the rest of the bag (e.g., the user's hand will support the weight by contact with the bag along one or more of the first axis, second axis, third axis, and fourth axis). In this manner, the flaps 722 , 726 , 730 , and 734 can serve to prevent the user's hand from supporting the weight of the bag through contact with a cut-edge of the material of the body 702 , thereby increasing comfort.
It should be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a composition containing “a compound” includes a mixture of two or more compounds. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
It should also be noted that, as used in this specification and the appended claims, the phrase “configured” describes a system, apparatus, or other structure that is constructed or configured to perform a particular task or adopt a particular configuration to. The phrase “configured” can be used interchangeably with other similar phrases such as arranged and configured, constructed and arranged, constructed, manufactured and arranged, and the like.
All publications and patent applications in this specification are indicative of the level of ordinary skill in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated by reference.
The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention.
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The present invention relates to articles such as bags and related methods. In an embodiment, the invention includes an article including a first sheet, a second sheet coupled to the first sheet defining an interior volume between the first sheet and the second sheet, and a handle region defining an aperture passing through the first sheet and the second sheet. The handle region including a first flap and a second flap, the first flap coupled to the first sheet and the second sheet along a first axis, the second flap coupled to the first sheet and the second sheet along a second axis, the first axis and second axis perpendicular to one another, the first flap and the second flap configured to flex away from the handle region. In an embodiment, the invention includes a method of forming a bag including coupling a first sidewall to a second sidewall to form a rectangular bag with four corners and forming a cut pattern through the first sidewall and the second sidewall to form a handle, the pattern outlining the shape of a plurality of flaps that can each flex along separate axes. Other embodiments are also included herein.
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This is a divisional of copending application Ser. No. 07/679,464, filed on Apr. 2, 1991, now U.S. Pat. No. 5,197,482.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to lesion localization needles and devices, for use in localizing or marking non-palpable lesions and tumors within the body, and more particularly, the present invention relates to a needle assembly which includes a wire marker having a helically wound wire tip for rotatingly anchoring a marker to a lesion within a human breast.
Localization or marking of lesions within the body, such as non-palpable lesions discovered within the body, and devices such as needles and wires for marking these lesions, are well known in the art. The devices generally comprise a hypodermic needle or cannula which is inserted into the body under local anesthesia to a position adjacent and in contact with the lesion. The wire marker is then passed through the cannula and is anchored into the lesion so that the lesion is marked for subsequent surgical procedures such as excision or biopsy. After marking the lesion with the wire marker, the cannula is usually removed from the body, leaving the wire in place and extending from the body. However, these markers tend to dislodge and migrate during transport of the patient for the surgical biopsy procedure.
Increasingly, ultrasonic imaging is being used as a preferred ancillary or adjunctive imaging method to evaluate breast masses which may be associated with positive or negative mammographic findings. Currently available localization and marking devices image poorly, if at all, ultrasonically, making it difficult to accurately pinpoint the tip of the localization wire with respect to the lesion. Consequently, a subsequent surgical biopsy procedure may result in an inaccurate incision causing unnecessary tissue damage, and may necessitate a second surgical procedure to properly biopsy the lesion, causing the patient unnecessary pain, suffering, and expense.
2. Discussion of the Prior Art
In the prior art, several types of lesion localization devices and lesion markers are disclosed. Currently, the method of detecting and performing a biopsy on a non-palpable occult lesion within the body, such as non-palpable breast lesions, has been to radiologically or ultrasonically locate the lesion and to mark the lesion using a localization needle assembly, prior to a biopsy procedure. These needle assemblies generally comprise a hypodermic needle or cannula which is inserted into the body to an area adjacent to and in contact with the lesion. A marking wire is then inserted through the cannula into the lesion and anchored in place so that the cannula may be removed.
Ultrasonic imaging is increasingly being used as the preferred method of detection and evaluation of lesions and masses within the body due to its accuracy, and in view of the fact that the patient is not exposed to potentially harmful radiation for extended periods of time. The prior art marking devices generally image very poorly ultrasonically, as the tip of the previous marker shows up as a small, hard to locate dot or spot on the viewing screen. Depth perception is very limited, and consequently, accurate, reliable placement of the previous marking device is not guaranteed.
Nicholson, et al., U.S. Pat. No 4,616,656, discloses a probe wire and sheath assembly in which the wire has a J-type memory hook for marking lesions. The wire probe has a soft flexibility so that when it is enclosed within the sheath it has a straight configuration. The sheath, or needle, is inserted into the body, for instance into the breast of a female patient, and positioned proximate to a lesion. The wire probe is then pushed further into the lesion so that the memory hook is reformed and anchors itself within the lesion. The sheath is then removed leaving the hook embedded in the lesion as a marker.
A similar device is disclosed in Hawkins, Jr , U.S. Pat. No. 4,230,123. Hawkins, Jr. discloses a needle sheath assembly which consists of a small gauge needle in which a stylus or wire is positioned within a cannula. A shorter outer sheath is slidably located over the cannula which is removable after insertion of the needle into the patient's body. The wire has a J-type hook which is passed through the cannula to stabilize the tip of the cannula during biopsy.
Nicholson, et al. and Hawkins, Jr. are subject to several disadvantages which effect the accuracy and performance of the device. Devices such as those disclosed in these references image very poorly and are inconsistently visualized ultrasonically, and consequently may not be accurately placed. Furthermore, in procedures involving lesions of the breast, the breast is compressed during the mammographic localization procedure so that after the needle is in place and compression discontinued, the needle marker may inadvertently dislodge or migrate to a different position than that set during the localization procedure. The needle may also deflect away from the lesion, or if the strength and resiliency of the wire is less than that required to penetrate the lesion, the hook may not reform, allowing the marker to migrate or dislodge. This can result in damaging the tissues of the breast, as well as an inaccurate surgical incision during the biopsy procedure, usually requiring a second surgical procedure to properly biopsy the lesion, causing the patient unnecessary pain, suffering and expense. Devices of this type also generally require that the breast be stabilized during transport of the patient from the radiology section of a hospital to the surgical section for the biopsy procedure in order to prevent dislodgement of the marker.
Simon, U.S. Pat. No. 4,790,329, discloses a biopsy localization device having a sheath or cannula through which a barbed rod passes. The cannula is provided with an open side port through which the barb extends upon positioning within a lesion. In use, the barb is compressed within the lumen of the cannula and the pointed end of the rod extends from the cannula. As the device penetrates the patient's body, and into a lesion, the rod is rotated 180° so that the end of the barb may pass through the open side port of the cannula. The rod is then drawn back so that barb and cannula anchor into the lesion to prevent removal. While the device is relocatable, such as by drawing back the cannula to enclose the barbed rod after anchoring, it is apparent that some tissue damage will result due to the barb puncturing the tissue once it is anchored. In addition, the cannula remains in place while the lesion is marked by the barb, which results in excessive weight applied to the tissue. The entire device must be stabilized in order to prevent tearing of tissue and dislodgement of the marker. As related to breast lesions, as discussed above, compression of the breast during the procedure provides accurate anchoring of the barb; however, during transport of the patient, the additional weight of the cannula as well as the barbed rod will require stabilization of the breast to prevent migration and dislodgement of the device. A similar device, facing the same disadvantages, is disclosed in Hawkins, et al , U.S. Pat. No. 4,799,495.
An additional type of prior art lesion localization and biopsy device is commonly referred to as the "Nordenstrom Screw Diagnostic Instrument", which was developed by Bjorn Nordenstrom (Radiology, November 1975, Volume 117, Page 474). The Nordenstrom screw is generally a biopsy device and not a lesion localization and marking device. A cannula is provided which is inserted into the body, having a screw-tipped rod within the lumen of the cannula. When the cannula is positioned proximate a lesion, the rod is rotated to screw the tip into the lesion. The screw tip is integral with the rod itself, and is a finely machined device in which the screw threads define grooves which taper to the tip of the device. After the screw tip is rotated into the lesion, the cannula is then rotated in an opposite direction using slight forward pressure to a position over the screw threads. Tissue from the lesion is captured in the grooves of the screw tip and the entire device is withdrawn so that the tissue may be examined. The Nordenstrom screw device, as stated above, is not a marking device, but instead allows the physician to immediately biopsy the lesion in question.
An additional marking device using a screw tip is disclosed in Hawkins, et al., U.S. Pat. No. 4,799,495. In this device, the cannula may be provided with a tapering screw tip to anchor the cannula in the tissue while the needle marker penetrates the lesion. The cannula and wire are used to mark the lesion, and Hawkins et al. also discloses the use of the cannula alone for marking the lesion. Furthermore, Hawkins et al. discusses a helical screw needle marker, similar to the Nordenstrom screw device, which may be inserted through the cannula to mark the lesion. However, the tapering screw tip of Hawkins et al is a finely machined device which is quite expensive to manufacture, and which also is subject to the disadvantage that the tapered end may result in the loosening or "backing off" of the screw tip which will dislodge the marker during transport of the patient, or upon discontinuation of compression of the breast during the marking procedure. Furthermore, the precise machining of the tip of this device, and in particular a hollow screw-tipped cannula, would be a difficult and very expensive procedure from a manufacturing standpoint, and would necessitate that the device be reusable due to these cost considerations. In view of this, and in light of current health risks and concerns for patient safety as related to blood products and invasive surgical procedures, sterilization procedures would be required prior to and after each use, thereby making the procedure more elaborate and expensive then normally necessary.
The novel, disposable lesion localization and marking device of the present invention obviates the problems associated with the prior art lesion localization devices by providing an inexpensive, simple to manufacture lesion marking device having a helically wound marking wire attached to a wire shaft which passes through a hypodermic needle comprising a cannula. The helically wound marking wire extends concentrically outward from the shaft and maintains a substantially uniform diameter so that once the wire is rotated or screwed into a lesion, it remains anchored in the tissue without the possibility of backing off and dislodging.
In a preferred embodiment, a second helically wound wire is provided on the shaft remote from the first helically wound wire at the tip which, in conjunction with a wire guide provided on a gripping knob of the cannula, assists in the forward advancement of the shaft so that excessive forward pressure is not required, and the second helix also acts as a depth guide to provide an accurate indication of the depth to which the first helix is embedded in a lesion. The helically wound wires are secured to the shaft by means such as soldering, or may be wound as part of the shaft itself, so that the entire device is simple to manufacture and relatively inexpensive, thereby making the device disposable following the biopsy procedure.
SUMMARY OF THE INVENTION
The present invention eliminates or substantially ameliorates the disadvantages encountered in the prior art through the provision of a lesion localization and marking device having a helically wound wire tip attached to a shaft which is inserted within the lumen of a cannula into the body and then rotated into a lesion to anchor the marker within the lesion tissue. The device is simple to manufacture and inexpensive thereby making it a disposable unit, which may be packaged in a sterile packaging unit for one time use.
The lesion localization and marking device of the present invention consists of a marker having a shaft constructed of stainless steel or other biocompatable material which has secured to its distal end, or formed integrally thereon, a stainless steel wire which is helically wound about the end of the shaft. The helically wound wire extends outwardly in a concentric manner from the end of the shaft and overhangs the shaft a predetermined distance. The end of the helix is sharpened to facilitate insertion into a lesion within the body. The helical wire is secured to the shaft by conventional means such as soldering.
The marking device, when used in conjuction with the needle assembly of the present invention, may be provided with a second helically wound wire which is secured to the shaft of the marker remote from the end having the first helically wound wire. The second helically wound wire is secured to the shaft by soldering, or integrally formed as part of the shaft, and is dimensioned to have the same number of turns per centimeter as the first helically wound wire, thus having the same pitch or angle for each turn of coil. The marking device is positioned within a hypodermic needle or cannula which essentially comprises a stainless steel tube having a cutting edge at one end and a thermoplastic gripping knob at its other end. The gripping knob has a hole bored through the center which preferably aligns with the lumen of the cannula, and a second hole is bored through the knob parallel to the first hole and offset from the center of the lumen. Through the second hole is positioned a wire guide which is bent perpendicular to the hole and placed to partially cover the first hole, leaving an opening which is substantially equal to the diameter of the shaft of the wire marker plus the diameter of the wire which forms the helix.
In use, the needle assembly is inserted into the body, such as into the breast of a female patient, until the tip of the cannula is proximate to a lesion which has been discovered during a mammogramphic or ultrasonic imaging procedure. The marking device is positioned within the cannula so that the sharpened tip of the first helical wire is adjacent to the cutting edge of the cannula, and the second helical wire is positioned a predetermined distance such that the end of the second helical wire closest to the first helical wire is adjacent to and engages the wire guide of the thermoplastic knob of the cannula. As the marking device is rotated, the second helical wire is guided along the wire guide so as to stabilize the shaft while drawing the marker into the cannula due to the interaction of the second helix and the wire guide during rotation, and the first helical wire is rotated into the lesion. The wire guide assists the forward advancement of the marker during rotation.
The length of the second helical wire is identical to the length of the first helical wire from the end of the shaft to the sharpened tip, and both helical wires have an identical number of turns per centimeter. As the first helical wire is embedded into the lesion, the physician can accurately gauge the depth to which the first wire enters the lesion by the distance the second helical wire extends outwardly from the gripping knob of the cannula. When the second helical wire is fully rotated within the cannula the physician will know that the first wire is fully extended outside the cannula and is in position with respect to the lesion. The cannula is then removed from the body leaving the marking device in place.
As ultrasonic imaging is increasingly being used as the preferred method of evaluation of breast lesions in localization procedures, it is very important the the marker used in the localization procedure provide consistent visualization and clean imaging with a recognizable acoustic pattern. Prior art markers do not provide adequate ultrasonic imaging and consequently do not contribute to accurate localization of a lesion The present invention, however, due to the helical tip, provides excellent imaging characteristics compared to prior art markers, such that each turn of the helix images distinctly, as opposed to the single spot or dot appearing from the prior art markers. As a result, the present marker provides an unambiguous ultrasonic image allowing for accurate marking of the discovered lesion under the same conditions as mammography, thus reducing the patient's exposure to X-rays as well as decreasing the number of repositions required to accurately mark the lesion.
Accordingly, it is a primary object of the present invention to provide an inexpensive, simple to manufacture, and disposable marking device for localizing lesions within the body, particularly breast lesions.
It is a further object of the present invention to provide a lesion localization device which substantially eliminates the possibility of dislodgement or migration of the needle marker after placement.
It is yet another object of the present invention to provide a lesion localization device which may be relocated or repositioned within the body which minimizes or substantially eliminates damage to tissue during repositioning.
A still further object of the present invention is to provide a lesion localization device which presents an unambiguous echo when exposed to ultrasonic sound waves, allowing placement of the device to be carried out without the need for the use of X-ray imaging.
A still further object of the present invention is to provide a lesion localization device in which the depth to which the lesion marker is placed with respect to a lesion is readily and accurately determined.
A still further object of the present invention is to provide a marking device for localizing non-palpable breast lesions which can be firmly anchored in the lesion and will not be dislodged regardless of the positioning or stability of the breast tissue.
Yet another object of the present invention is to provide an efficient and accurate method for marking non-palpable lesions within the body, particularly within the breast.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing objects and other features of the invention will become more readily apparent and may be understood by referring to the following detailed description of an illustrative embodiment of the lesion localization and marking device having a helically wound wire tip, taken in conjunction with the accompanying drawings; in which:
FIG. 1 illustrates a side elevational view of a marking device pursuant to the present invention;
FIG. 2 illustrates a side elevational view of a hypodermic needle or cannula pursuant to the present invention;
FIG. 3a illustrates an elevational end view of the gripping knob of the hypodermic needle of FIG. 2 along lines 3a-3a;
FIG. 3b illustrates an elevational end view of the cannula of the hypodermic needle of FIG. 2 along lines 3b-3b;
FIG. 4 illustrates a perspective, partially sectional view of the lesion localization needle assembly pursuant to the present invention after insertion into the body but prior to marking a lesion;
FIG. 5 illustrates a perspective, partially sectional view of the needle assembly of FIG. 4 during rotation of the marking device within the cannula and into a lesion;
FIG. 6 illustrates the needle assembly of FIG. 4 after rotation of the marking device into the cannula with the wire marker being fully embedded within a lesion;
FIG. 7 illustrates a side elevational view of an alternate embodiment of a marking device pursuant to the present invention; and
FIG. 8 illustrates a side elevational view of an alternate embodiment of a needle or cannula pursuant to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in specific detail to the drawings, in which identical reference numberals identify similar or identical elements throughout the several views, FIG. 1 shows marking device 10 according to the present invention. Marking device 10 is constructed of a biocompatable material, and is preferably constructed of stainless steel, although many metal alloys such as aluminum alloy, titanium alloy, ferrous alloy, and the like, as well as materials such as plastic and ceramic, may be employed. Marking device 10 essentially consists of a shaft 12 which is preferably type 18-8 stainless steel having a thickness of between 0.011 and 0.20 inches diameter, and is preferably 0.016 inches diameter. Marking device 10 is provided at one end with helical marking wire 14 which is helically wound about the end of shaft 12 and secured to the shaft as illustrated at 20. Preferably, helical marking wire 14 is constructed of the same material as shaft 12, and is secured to the shaft by soldering, preferably of a 98% tin and 2% silver solder. Helical marking wire 14 is wound about shaft 12 and extends outwardly away from the shaft to terminate in a sharpened tip 16. The diameter of the coil formed by helix 14 remains constant along its length Helix 14 extends from the end of shaft 12 a distance of between 0.5 centimeters and 2 centimeters, and preferably extends 1 centimeter from the end of shaft 12. The pitch of the coil is determined by the number of turns per centimeter, which along with the length of helix 14, is dependent upon the application for which the marker is to be used. Different tissues within the body have different degrees of strength and resiliency, some requiring more force to anchor the marker 10 in place, and thus some tissues require a device having more turns per centimeter than other tissues. Accordingly, helix 14 generally is provided with between 6 and 15 turns per centimeter, and preferably it is provided with 8 turns per centimeter for marking breast lesions.
Separated a distance "d" along shaft 12 from helical marking wire 14 is helical guide wire 18 which is also wound about shaft 12. Helix 18 is constructed of the same material as helix 14 and shaft 12, and helical wires 14 and 18 are the same gauge wire, preferably having a diameter of between 0.009 and 0.015 inches (0.02 and 0 04 cm). The preferred diameter for helical wires 14 and 18 is 0.011 inches (0.027 cm) for marking breast lesions. Helix 18 is secured to shaft 12 in a manner similar to helix 14. Helix is of the same length as the length that helix 14 extends from the end of shaft 12 to sharpened tip 16, and also has the identical amount of turns per centimeter as helix 14, and thus the same pitch to the coil formed by helix 18.
Distance "d" is dependent upon the length of the hypodermic needle or cannula with which marking device 10 is to be used. This will be described in greater detail below.
As can be seen in FIG. 2, hypodermic needle 30 comprises a cannula 32 having a sharpened cutting tip 34 and a gripping knob 36. Cannula 32, like marking device 10, is constructed of biocompatable material, and is preferably stainless steel. In a preferred embodiment, the cannula is 18-gauge thin wall stainless steel type 504, and has a length from tip 34 to knob end 36 of between 3 and 15 centimeters, depending upon the type and location of the lesion to be marked. Knob 36 is preferably constructed of thermoplastic material such as nylon and is secured to cannula 32 at end 38 by conventional means such as epoxy, adhesives, and the like. Knob 36 may have a ridged gripping surface 44 which aids the physician in handling the needle 30. Cannula 32 is of course hollow and defines a lumen 33, as best seen in FIG. 3B.
Gripping knob 36 has a hole 46 bored through the knob, which in the preferred embodiment aligns with lumen 33 of cannula 32 so that the cannula can extend through the hole to face 37 of knob 36. In addition to hole 46, a second hole 47 is bored through knob 36, which is offset and parallel to hole 46. A wire guide 40 passes through hole 47 and may be secured within the hole by conventional means such as epoxy, adhesives, and the like. Wire guide 40 passes through hole 47 and is bent at 41 along face 37 of knob 36 to form guide bar 42. Wire guide 40 may also loosely and pivotably rest within hole 47 so that guide bar 42 may be moved into and out of engagement with shaft 12 of marker 10. As seen in FIG. 3a, guide bar 42 partially covers hole 46 in knob 36 so as to reduce the opening of hole 46. The reason for this will be explained in greater detail below.
FIGS. 4, 5 and 6 show needle and marker assembly 50 in various positions during use of assembly 50 in marking a lesion within the body. Assembly 50 comprises marking device 10 as shown in FIG. 1 positioned within the lumen 33 of needle 30 as shown in FIG. 2. The location of the lesion within the body, such as non-palpable lesions found in the breast or organs deep within the body, is determined radiologically or ultrasonically in a non-invasive procedure. In order to biopsy the lesion or remove it, the surgeon must have an accurate location of the lesion prior to performing the surgical procedure to minimize damage to tissue. The accuracy of the location of the marker will obviate any need for additional incisions, as well as avoid unnecessary tissue removal, which benefits the patient both physically and cosmetically. The use of a marking device such as in the present invention is illustrated in FIGS. 4, 5 and 6.
As seen in FIG. 4, the needle and marker assembly 50 is inserted into the body through the skin surface 52 until cutting tip 34 of cannula 32 is positioned proximate a lesion or tumor 54. Marking device 10 is positioned within needle 30 such that sharpened tip 16 of helical marking wire 14 is positioned adjacent to cutting tip 34 of needle 30. The length of needle 30, as well as the length of shaft 12 and distance "d" between marking wire 14 and guide wire 18 is determined by the depth or distance lesion 54 is from the surface of the skin 52. Distance "d" is determined such that when marking device 10 is within the lumen 33 of needle 30, forward end 19 of helical guide wire 18 engages and rests against guide bar 42, resulting in sharpened tip 16 being adjacent to cutting tip 34.
Turning now to FIG. 5, after cutting tip 34 is positioned proximate to lesion 54, marking device 10 is rotated about shaft 12 to advance helical marking wire 14 into lesion 54. Sharpened tip 16 enters lesion 54 and the rotation about shaft 12 further advances marking wire 14 into the lesion to firmly anchor it in place. The depth to which helical marking wire 14 enters lesion 54 is determined by the distance helical guide wire 18 travels through hole 46 into cannula 32. As shaft 12 is rotated, guide bar 42 of wire guide 40 engages the shaft and helix 18 at end 19 of helix 18 and guides shaft 12 while allowing helical guide wire 18 to rotate into hole 46 in a screw-like fashion. Guide bar 42 is positioned between the individual coils of helical guide wire 18 to prevent slipping or pulling on the shaft. Wire guide 40 may be secured in hole 47 or may be pivotably secured so that guide bar 42 may rotated away from shaft 12 to disengage guide bar 42 from helix 18.
When helical marking wire 14 is embedded and anchored in lesion 54, that is when the end 23 of shaft 12 is proximate to the lesion 54, the rotation is ceased. This is best seen in FIG. 6 The surgeon may determine when marking wire 14 is in its desired position with respect to lesion 54 when guide wire 18 completely disappears into knob 36 past guide bar 42. The trailing end 21 of guide wire 18 is the same distance from the end 23 of shaft 20 as the distance between forward end 19 of guide wire 18 and sharpened tip 16 of marking wire 14. When the surgeon determines that the marking wire 14 in proper position, such as when it is completely embedded in the lesion, as evidenced by trailing end 21 of helix 18 turning into knob 36, the surgeon may then remove needle 30 from the body leaving marking device 10 firmly embedded in the lesion. Alternatively, when it is determined that the helix 14 is in a desired position with respect to lesion 54 without helix 18 being completely within cannula 32, such as when a lesion is located proximate the chest wall as determined by ultrasonic imaging, wire guide 40 may be pivoted to rotate guide bar 42 away from helix 18 to allow for removal of needle 30 without disturbing the position of helix 14. Marking device 10 remains firmly anchored due to the concentric nature of the coils of marking wire 14 and eliminates the possibility of inadvertent dislodgement due to relaxation of the tissues of the breast upon discontinuing the compression placed on the breast during the procedure.
FIG. 7 illustrates an alternate embodiment of the present invention showing marking device 10a, in which helix 14a and helix 18a are integrally wound as part of shaft 12a. FIG. 7 is identical to FIG. 1 in operation and function except that additional helical wires are not needed, since marking device 10a is of unitary construction in that shaft 12a and helixes 14a and 18a are constructed as a single unit. In a further embodiment, helix 14 and helix 18 may be joined so that the entire shaft 12 is in a helical coil.
In a further embodiment, cannula 32 may be provided with a notched portion 60, and knob 36 may be eliminated, as seen in FIG. 8. In this case, notch 60 engages helix 18, or alternately helix 14, dependent upon location of notch 60. Notch 60 will then guide marking device 10 in the same manner as wire guide 40 and guide bar 42.
While the invention has been particularly shown and described with reference to the preferred embodiments, it will be understood by those skilled in the art the various changes in form and detail may be made therein without departing from the spirit and scope of the invention. Accordingly, modifications and/or changes such as removing guide wire 18 or providing a longer or shorter marking wire, as well as increasing or decreasing the pitch of the coils as related to the number turns per centimeter, may be provided as desired, and are considered to be within the scope of the invention.
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A lesion localization and marking wire and needle assembly for marking non-palpable lesions within the body. A marking device having a helically wound coil of wire attached to an end of the shaft which is insertable into the body through a needle or cannula for rotatingly anchoring the marking device into a lesion or tumor is provided. The needle or cannula is inserted into the body with the marking device positioned therein so that when the cannula is positioned proximate to a lesion the shaft of the marker is rotated to advance the marker into the lesion to mark it for subsequent surgical procedures. A second helical wire may be provided on the shaft which cooperates with a wire guide device attached to the needle to enable the physician to determine the depth of the marking device as it anchors into the lesion. In particular, the device is provided for marking for biopsy lesions of the breast.
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The present invention concerns a furniture hinge comprising a fitment portion and a hinge cup hingedly connected thereto for fixing to furniture parts, and a damping device for damping a relative movement between the fitment portion and the hinge cup, wherein the damping device is arranged in or on the hinge cup.
The invention further concerns an article of furniture having at least one furniture hinge of the kind to be described.
Furniture hinges comprising a hinge cup and a damping device arranged in or on the hinge cup are already known in the state of the art. As an example in that respect mention is to be made of AT 6499 to the present applicant, DE 25 39 954 A1, DE 10 2007 047 287 A1, DE 10 2006 047 315 A1 or EP 1 469 153 A1. Damping devices having a piston which has a linear damping stroke usually have a travel-dependent damping function, that is to say the degree of damping is dependent on the available damping stroke of the piston. Therefore a sufficient damping travel is to be provided to achieve the desired soft cushioning of a relative movement of the two fitment portions. A particular requirement is therefore that of arranging the damping device in as space-saving a fashion as possible, but at the same time also ensuring an adequate damping stroke and thus a satisfactory damping action for the furniture hinge.
WO 2007/131933 A1 discloses a furniture hinge having a damping device, wherein the housing of the damping device is held within the hinge cup by way of co-operating fixing means (in the form of a tab and an abutment surface). As a consequence of a hinge lever of the hinge being connected to a slider of the damping device, the damping device already has to be fitted into and fixed in the hinge cup, as from the factory.
WO 2009/094272 A1 which is of earlier priority but published after the relevant date describes a furniture hinge having a damping device which is fitted into the hinge cup and fixed by way of snap-action holding means relative to the hinge cup bottom. That publication does not show a hinge in which the damping device can be inserted from above into the hinge cup, with the fitment portion and the hinge cup hingedly connected together. For retro-fitting of the damping device it is obviously necessary to dismantle the hinge.
The object of the present invention is to propose a furniture hinge of the general kind referred to in the opening part of this specification, wherein the damping device saves space, is efficient and can be fitted at a later stage.
According to the invention in an advantageous configuration that is achieved in that the damping device has a housing having first fixing means and second fixing means are arranged on the hinge cup, wherein the housing of the damping device can be inserted from above into the hinge cup and in the mounted position is arranged substantially completely within the hinge cup, wherein the housing of the damping device and the hinge cup can be connected together in said mounted position by way of the first and second fixing means.
The definition ‘can be inserted from above into the hinge cup’ is intended to mean insertion of the housing of the damping device in a direction of movement substantially perpendicular to the bottom of the hinge cup.
It is therefore possible with the proposed invention to arrange the housing of the damping device completely within the hinge cup, wherein the housing in that mounted condition preferably does not project beyond the hinge cup, that is to say the entire component unit of the damping device in the mounted condition is completely between the bottom of the hinge cup and the plane formed by the hinge cup opening. The housing of the damping device can be mounted relative to the hinge cup and removed therefrom by way of the first and second fixing means. In an embodiment of the invention it can be provided that the housing of the damping device can be releasably fixed on or in the hinge cup by the first and the second fixing means, preferably it can be fitted without the use of a tool and can preferably be dismantled without the use of a tool.
The damping device can include a slider movable relative to the housing, wherein the first fixing means are provided on the slider so that the housing of the damping device can be connected to the hinge cup releasably indirectly by way of the slider.
In a preferred embodiment of the invention it can be provided that the first and second fixing means are in the form of a self-latching latching connection. Such a latching connection permits automatic latching between the housing of the damping device and the hinge cup in the course of introducing the housing into the hinge cup without in that case the user having to actuate additional locking means for fixing purposes. The first and second fixing means can together form a snap-action connection so that the damping device can be clipped into the hinge cup in the form of a complete unit. In a possible embodiment of the invention, the first or second fixing means can include at least one movable or mobile arresting element by which the housing can be fixed relative to the hinge cup. A desirable configuration is characterised in that the arresting element is of a resilient nature, wherein the connection between the first and second fixing means is releasable by pressure against the resilient action of the arresting element.
In a possible embodiment it can be provided that the arresting element is arranged on the housing of the damping device and in the mounted position engages into an opening or at a latching edge of the hinge cup. In a kinematic reversal it is also possible that the arresting element is mounted on the hinge cup and in the mounted position engages into an opening or latching edge arranged on the housing of the damping device.
It can be provided that the first and second fixing means are operative between the housing of the damping device and a side wall of the hinge cup. Alternatively or supplemental thereto it may also be possible that the first and second fixing means are operative between the housing of the damping device and the bottom of the hinge cup or a support portion (in particular a fixing projection) associated with the hinge cup.
In that respect it is possible that the fixing projection is provided for mounting a spring which urges the hinge cup relative to the fitment portion into the completely closed position and/or into the completely open position. That fixing projection can thus also be used as a support element for the housing of the damping device. The fixing projection can extend at least portion-wise within the hinge cup, the fixing projection having a recess provided for receiving the housing of the damping device—in particular for receiving and guiding a linearly displaceable slider of the damping device.
In a preferred configuration of the invention it can be provided that the housing has a peripheral surface, the shape of which is adapted portion-wise to the inner shape of the hinge cup. In other words, the external shape and size of the housing of the damping device are adapted to the shape and size of the internal space in the hinge cup. That permits defined preliminary positioning of the housing, wherein after positioning has been effected the first and second fixing means can be connected together, wherein the housing of the damping device can be fixed relative to the hinge cup in positively locking relationship and/or force-locking relationship. Due to the contour of the housing of the damping device, that is adapted to the hinge cup, it bears in the mounted position for the greatest part directly against the inside wall of the hinge cup, wherein arranging it within the hinge cup is effected in a visually very inconspicuous fashion and the risk of dirt deposits between the housing of the damping device and the inside wall of the hinge cup is also reduced.
For easy dismantling of the damping device relative to the hinge cup there can be provided a release portion, by which the connection between the first and second fixing means is releasable, whereupon the housing of the damping device can be dismantled from the hinge cup. In that respect it may be advantageous if the release portion is arranged on the housing of the damping device. The release portion can be moved into a release position manually and/or by means of a tool whereby the housing of the damping device can be dismantled from the hinge cup.
Due to the first and second fixing means, hinge arrangements which already exist can be subsequently retro-fitted with a damping device, wherein the retro-fitting operation can already be effected in the factory. When the damping device is already fitted in the factory, production lines which are already there can be retained so that mounting the damping device only requires a very low level of complication and expenditure. It will be appreciated that subsequent fitting and/or dismantling of the damping device on already existing hinge arrangements can also be effected by a user. The damping device can also be inserted into the hinge cup and fixed relative to the hinge cup by way of the first and second fixing means when the hinge lever of the hinge is hingedly connected to the hinge cup.
To achieve a particularly compact structure it may be desirable if the damping device has a first and a second fluid chamber which are filled with damping fluid and which are connected together by way of a passage. In that case it may be desirable if a piston can be engaged in the first fluid chamber and thereby the volume of the first fluid chamber can be changed, and wherein arranged in the second fluid chamber is a device which is deformable or movable by a flow of damping fluid into and out of the second fluid chamber for changing the volume of the second fluid chamber.
The two fluid chambers are therefore connected in serial relationship and are in fluid-conducting communication by way of at least one passage. The damping fluid of the first fluid chamber, that is displaced during the damping stroke by the first piston, also has to flow through the passage into the second fluid chamber—apart from possible residual compressibility of the damping fluid—wherein the volume of the second fluid chamber can be changed by the fluid pressure. The second fluid chamber therefore forms a compensation space for the displaced damping fluid, that is variable during compression or decompression respectively. The second fluid chamber can be arranged in a very compact structure relative to the first fluid chamber whereby particularly small damping device constructions can be implemented.
In an embodiment of the invention the said device can have a deformable material portion arranged in the second fluid chamber or a piston displaceable in the second fluid chamber, whereby the volume of the second fluid chamber can be changed when damping fluid flows in or out. Thus instead of the second piston in the second fluid chamber, it is also possible to employ a deformable material portion made from a compressible material such as for example foam rubber. The arrangement of the second piston can—but does not have to—be omitted as the return movement of the first piston produces a reduced pressure and thus a suction effect so that the damping fluid present in the second fluid chamber is at least partially caused to flow back into the first fluid chamber again after damping has taken place.
In an embodiment of the invention the first fluid chamber has a first longitudinal axis and the second fluid chamber has a second longitudinal axis, wherein the first longitudinal axis and the second longitudinal axis of the fluid chambers extend parallel to each other or can also extend transversely relative to each other. The passage connecting the two fluid chambers can in principle also be of a very short length (for example in the form of a hole in the function as an overflow opening). It is preferably provided that the passage connecting the two fluid chambers extends from the bottom region of the first fluid chamber to the inlet region of the second fluid chamber.
In a possible embodiment of the invention it can be provided that the damping device has a first piston and at least one second piston with a linear damping stroke, wherein the direction of the linear damping stroke of the first piston extends substantially parallel or transversely relative to the linear damping stroke of the second piston.
The first and second pistons can each be guided displaceably in a fluid chamber, wherein the two fluid chambers are connected in serial relationship and are in flow communication by way of the at least one passage. In that way it is possible to reduce the damping stroke of the first piston and therewith the structural size of the damping device. The damping medium of the first fluid chamber, that is displaced during the damping stroke of the first piston, flows through the narrowed passage into the second fluid chamber whereby the flow resistance of the damping fluid present in the first fluid chamber is increased. By virtue of the resulting small structure for the damping device, it can be particularly easily accommodated within the hinge cup.
In a possible embodiment of the invention it can be provided that the direction of the linear damping stroke of the first piston relative to the linear damping stroke of the second piston includes an angle α, wherein the angle α is between 70 and 110°. In a preferred configuration of the invention it can also be provided that the direction of the linear damping stroke of the first piston relative to the linear damping stroke of the second piston extends at a right angle.
In a possible embodiment the two fluid chambers can be respectively formed by the internal space of a fluid cylinder. It is however particularly preferred for the fluid chambers to be provided in a housing of the damping device so that the additional provision of fluid cylinders is not absolutely necessary. In that way the damping device can be implemented with a reduced number of components to be employed.
The damping device can have an actuating element, by which the force can be applied to the damping device, wherein the actuating element can be acted upon by one of the fitment portions or by a hinge lever arranged between the fitment portions, during the hinge movement. The hinge lever which is pivotable during the hinge movement can be caused to immerse into the hinge cup towards the end of the closing movement of the furniture hinge. In that respect a possible configuration provides that at least one of the two pistons is integrally connected to the actuating element. The integral configuration of the actuating element with one of the pistons reduces the number of components, while in addition force can be applied directly to the damping device.
In a possible embodiment the actuating element can have a linearly displaceable slider which can be acted upon by one of the fitment portions or by a hinge lever arranged between the fitment portions as from a predetermined relative position of the fitment portions with respect to each other. The slider can be in the form of a sliding wedge having an inclined surface which can be acted upon by one of the fitment portions or by the hinge lever towards the end of the closing movement and/or the end of the opening movement.
To avoid unwanted tilting of the sliding slider during the damping operation it may be advantageous if the slider has a guide—preferably in the form of a slot—, whereby the slider is displaceable relative to a fixing projection arranged on the hinge cup. The fixing projection can be provided at the same time for mounting a spring device which urges the two fitment portions into an end position. In that case the spring device can urge the fitment portions in the direction of the completely open position and/or in the direction of the completely closed position, wherein the spring action begins only towards the end of the closing process and/or towards the end of the opening process. The proposed damping device is therefore desirably provided to damp an opening movement and/or a closing movement over a portion of the total opening angle range of the two fitment portions relative to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details and advantages of the present invention will be described by means of the specific description hereinafter. In the drawings:
FIG. 1 shows a perspective view of an article of furniture having a movable furniture part which is pivotally mounted to the furniture carcass by way of furniture hinges according to the invention,
FIG. 2 shows a perspective view of a furniture hinge having a damping device integrated in the hinge cup,
FIGS. 3 a , 3 b show a side view of the furniture hinge mounted to the furniture parts in an open position and a cross-sectional view thereof,
FIGS. 4 a , 4 b show a side view of the furniture hinge mounted to the furniture parts in an intermediate position and a cross-sectional view thereof,
FIGS. 5 a , 5 b show a side view of the furniture hinge mounted to the furniture parts in a closed position and a cross-sectional view thereof,
FIG. 6 shows a perspective view of the damping device,
FIGS. 7 a - 7 c show views in horizontal section illustrating positions of the two pistons during the damping stroke and during the return stroke,
FIGS. 8 a , 8 b show an alternative embodiment of a damping device, wherein a deformable material portion is arranged in the second fluid chamber for changing the volume of the second fluid chamber,
FIGS. 9 a , 9 b show a possible embodiment of a damping device which can be mounted and/or removed on the hinge cup without a tool, having a fixing device for fixing to the furniture hinge,
FIGS. 10 a , 10 b show a further embodiment of a damping device which can be releasably fixed within the hinge cup,
FIGS. 11 a - 11 d show various views of a further embodiment of a damping device having a release portion for dismantling purposes,
FIGS. 12 a - 12 d show a damping device having various configurations of a release portion for dismantling the damping device,
FIG. 13 shows a highly diagrammatic view of a hinge cup countersunk in a standard bore, wherein the fixing means for fixing the damping device are operative between the housing of the damping device and the bottom and/or a side wall of the hinge cup, and
FIGS. 14 a - 14 c show the damping device to be inserted into the hinge cup in a dismantled position and in the mounted position and a slider of the damping device with fixing means provided thereon.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a perspective view of an article of furniture 1 having a furniture carcass 2 , wherein a movable furniture part 3 in the form of a pivotable door is fixed by way of furniture hinges 4 according to the invention to a frame 2 a provided or arranged on the furniture carcass 2 . The movable furniture part 3 is mounted pivotably between a closed position of closing the furniture carcass 2 and an open position.
FIG. 2 shows a possible embodiment of a furniture hinge 4 , wherein a first fitment portion 5 is associated with the furniture carcass 2 and a second fitment portion 6 is associated with the movable furniture part 3 . As shown in the Figure, the carcass fitment portion 5 can be L-shaped or U-shaped and in the mounted position can at least partially embrace the frame 2 a shown in FIG. 1 . It will be appreciated that the fitment portion 5 may also be in the form of a hinge arm. The second fitment portion 6 has a hinge cup 6 a which can be sunk in a bore on the movable furniture part 3 . The hinge cup 6 a has a flange 6 b which in the mounted position bears against the inside of the movable furniture part 3 . Arranged between the fitment portion 5 and the hinge cup 6 a is a hinge lever 7 which is mounted displaceably and/or tiltably relative to the first fitment portion 5 by way of an adjusting device 8 . The hinge lever 7 is mounted pivotably to the hinge cup 6 a at an axis of rotation on the other side. In the illustrated embodiment therefore the furniture hinge 4 is in the form of a single-axis hinge. It is possible to see a spring device 9 which urges the two fitment portions 5 , 6 in the direction of the closed position or holds the fitment portions 5 , 6 in a closed position. A damping device 10 is arranged substantially completely within the hinge cup 6 a , wherein the damping device 10 is provided for damping a relative movement of the two fitment portions 5 , 6 relative to each other over a part of the movement through the maximum opening angle of the two fitment portions 5 , 6 . The damping device 10 has an actuating element 11 in the form of a linearly displaceable slider 11 a which is acted upon by the hinge lever 7 towards the end of the closing movement of the furniture hinge 6 and thereby applies the force to the damping device 10 .
FIG. 3 a shows a side view of the open furniture hinge 4 in the mounted condition. The first fitment portion 5 is fixed to the frame 2 a of the furniture carcass 2 while the second fitment portion 6 is mounted with the hinge cup 6 a to the movable furniture part 3 . It is possible to see the damping device 10 whose arcuate peripheral edge is at least partially adapted to the contour of the inside wall of the hinge cup 6 a . The housing of the damping device 10 can be for example at least approximately of a mushroom-shaped configuration in plan view. The hinge lever 7 which is pivoted during the hinge movement acts on the linearly displaceable slider 11 a towards the end of the closing movement whereby the damping process is initiated. The Figure also shows the spring device 9 which in the illustrated embodiment performs the function of a closing spring.
FIG. 3 b shows a vertical section along the arrows shown in FIG. 3 a . The carcass fitment portion 5 is fixed to the frame 2 a by way of a screw 12 . The hinge cup 6 a is sunk in the movable furniture part 3 , the damping device 10 with the slider 11 a being completely integrated in the hinge cup 6 a . The slider 11 a has an inclined surface 15 which is acted upon by the hinge lever 7 as from a predetermined relative position of the fitment portions 5 and 6 with respect to each other. The slider 11 a has a slot 13 so that the slider 11 a is displaceable guidedly during the damping process relative to a fixing projection 14 arranged stationarily on the hinge cup. In the illustrated Figure the hinge lever 7 is in a position of being spaced from the inclined surface 15 of the slider 11 a.
FIG. 4 a shows a view similar to FIG. 3 a , with the difference that the movable furniture part 3 has been further moved in the closing direction and the hinge lever 7 now encounters the slider 11 a of the damping device 10 , which can be particularly clearly seen from the sectional view in FIG. 4 b . The cranked hinge lever 7 now abuts against the inclined surface 15 of the slider 11 a whereby the damping process is initiated.
FIG. 5 a shows the completely closed position of the movable furniture part 3 relative to the frame 2 a , the damping process already being concluded. It can be seen from the sectional view in FIG. 5 b that the hinge lever 7 has displaced the slider 11 a by way of the inclined surface 15 thereof so that the stationary fixing projection 14 , in comparison with FIG. 4 b , bears against the opposite end of the slot 13 . The movement to be damped has been applied to the damping device 14 by the movement of the slider 11 a.
FIG. 6 shows the damping device 10 which can be completely integrated into the hinge cup 6 a and the housing 10 a of which is at least portion-wise adapted to the inside shape of the hinge cup 6 a . The housing 10 a has an arcuate peripheral edge which in the mounted position bears at least region-wise against the inside wall of the hinge cup 6 a . The slider 11 a with its inclined surface 15 and its slot 13 is mounted displaceably relative to the housing 10 a during the damping stroke and during the return stroke.
FIG. 7 a shows a perspective view in horizontal section of the damping device 10 , with reference to which the operating principle of the damping device 10 is to be described. The Figure shows a first fluid chamber 16 in which a first piston 16 a is linearly displaceably guided. The damping device 10 is in the form of a fluid damper, the first fluid chamber 16 being filled with a damping fluid (for example a liquid, an oil or, with a suitable structural size, also with air). A seal 17 a seals the first piston 16 a with respect to the inside wall of the first fluid chamber 16 . Associated with the first fluid chamber 16 is a return mechanism 18 a in the form of a spring which, after the damping stroke has been effected, moves the piston 16 a back into a position for the next damping stroke again. The return mechanism 18 a can also be arranged outside the fluid chamber 16 . The slider 11 a is preferably integrally connected to the first piston 16 a so that a movement of the slider 11 a at the same time also leads to movement of the first piston 16 a into the first fluid chamber 16 . The device 25 arranged in the second fluid chamber 21 for altering the volume in that second fluid chamber, in the illustrated embodiment, includes a displaceable piston 21 a , by which the volume of the second chamber 21 can be changed when damping fluid flows in or out.
The damping fluid is pressed through the passage 19 and through a through opening 20 a in a switching blade 20 into the second fluid chamber 21 by the first piston 16 a being pushed into the fluid chamber 16 . The seal 17 b seals the piston 21 a with respect to the second fluid chamber 21 a . The second piston 21 a is also displaced into a rearward end position by the damping fluid being pressed from the first fluid chamber 16 into the second fluid chamber 21 . The damping fluid is exclusively between the first piston 16 a and the second piston 21 a . It can be seen that the direction of movement A of the first piston 16 a extends transversely relative to the direction of movement B of the second piston 21 a . The direction of movement A of the first piston 16 a includes an angle α which is preferably between 70° and 110° with the direction of movement B of the second piston 21 a . Preferably the directions of movement A and B of the first piston 16 a and the second piston 21 a are at a right angle to each other. The directions of movement A, B can also extend in mutually parallel spaced relationship.
FIG. 7 b shows the first piston 16 a pushed completely into the first fluid chamber 16 , that is to say the damping process is already concluded. The fact that the piston 16 a was pushed into the first fluid chamber 16 provided that the damping fluid in the first fluid chamber 16 was pressed through the passage 19 , the opening 20 a in the switching blade 20 and the through-flow opening 22 a into the second fluid chamber 21 , whereupon the second piston 21 a was displaced within the second fluid chamber 21 into the rearward end position shown. The size of the through opening 20 a in the switching blade 20 increases with increasing pressure actuation by the damping fluid, whereby the flow cross-section of the through opening 20 a can be increased. The switching blade 20 is preferably made from rubber-elastic material.
In FIG. 7 c the two pistons 16 a , 21 a have been partially returned again by the two return mechanisms 18 a , 18 b so that the pistons 16 a , 21 a are moved in the direction of the readiness position shown in FIG. 7 a again. The return mechanism 18 b therefore moves the second piston 21 a in the opposite direction again, in which case the damping fluid in the second fluid chamber 21 can flow back through the two through-flow openings 21 a and 21 b . Starting from the first position shown in FIG. 7 b (in which the damping fluid flows exclusively through the through opening 20 a into the second fluid chamber 21 ) the switching blade 20 was moved into a second position as shown in FIG. 7 c in which the switching blade 20 lifts off the through-flow openings 22 a , 22 b so that, in the return stroke, the damping fluid can also flow back around the switching blade 20 in the direction of the first fluid chamber 16 . In that way the damping device 10 can be very quickly moved into a readiness position for the next damping stroke again. At the same time the first piston 16 a of the first fluid chamber 16 is also moved back by the return mechanism 18 a and can again assume the readiness position. It can also be provided that the arrangement of the second return mechanism 18 b can be omitted and only the first return mechanism 18 a is provided. In that way the return movement of the first piston 16 a results in a reduced pressure being produced in the first fluid chamber 16 , by which the damping fluid coming from the second fluid chamber 21 due to a suction effect passes into the first fluid chamber 16 again. Starting from FIG. 7 c the two pistons 16 a , 21 a can again be moved back into the starting position shown in FIG. 7 a.
The switching blade 20 therefore performs a triple function, more specifically a) for building up the pressure of the damping medium in the first fluid chamber 16 , b) overload safeguard by radial expansion of the through opening 20 so that the flow cross-section can be increased, and c) damping return by lifting the switching blade 20 off the through-flow openings 22 a and 22 b.
In an embodiment of the invention it is provided that the piston surface of the first piston 60 and the piston surface of the second piston 21 have an operative piston surface of the same size. It is however also possible for the effective piston surface of the first piston 16 a and that of the second piston 21 a to be of differing sizes so that it is possible to provide a travel step-down effect in respect of the second piston 21 . When therefore the effective piston surface of the second piston 21 is larger than that of the first piston 16 , a damping stroke of the first piston 16 a also leads to a reduced damping stroke of the second piston 21 a . The length of the second fluid chamber 21 and thus the size of the housing 10 a can possibly also be reduced by virtue of the reduced damping stroke of the second piston 21 a.
FIG. 8 a shows an alternative embodiment of a damping device 10 . Similarly to the embodiment of FIGS. 7 a - 7 c , there is provided a slider 11 a which is integrally connected to the first piston 16 a so that the first piston 16 a engages into the first fluid chamber 16 in the damping stroke. A seal 17 a seals off the first piston 16 a relative to the first fluid chamber 16 . In the damping stroke the damping fluid displaced by the first piston 16 a can flow by way of the through opening 20 a in the switching blade 20 and through the through-flow opening 22 a into the second fluid chamber 21 . In the illustrated embodiment the device 25 arranged in the second fluid chamber 21 includes a compressible deformable material portion, by which the volume of the second fluid chamber 21 can be altered when damping fluid flows in or out. FIG. 8 a shows the first piston 16 a in a readiness position for the damping stroke. In FIG. 8 b the fact of the first piston 16 a being pushed into the first fluid chamber 16 provided that the damping fluid was urged into the second fluid chamber 25 by way of the above-described common paths, whereby the device 25 was deformed and the volume of the second fluid chamber 21 increased. When the slider 11 a is no longer acted upon by the hinge lever 17 of the furniture hinge 4 then the first piston 16 a of the first fluid chamber 16 is moved back into the position shown in FIG. 8 a again by the return mechanism 18 a . As a result, a reduced pressure is produced in the first fluid chamber 16 , whereby the suction effect causes the fluid in the second fluid chamber 21 to be drawn back through the through-flow openings 22 a , 22 b and around the switching blade 20 into the first fluid chamber 16 again, whereupon the device 25 of the second fluid chamber 21 also expands again and again assumes the FIG. 8 a position. It is therefore not absolutely necessary for a displaceable second piston 21 a having its own return mechanism 18 b also to be provided in the second fluid chamber 21 . The device 25 can have a compressible material portion (for example a TPU plastic portion or a foam rubber). It will be appreciated that the device 25 can also include a second piston 21 a as described hereinbefore, which is supported displaceably within the second fluid chamber 21 .
FIGS. 9 a and 9 b show a possible embodiment illustrating how the furniture hinge 4 can also be fitted with a damping device 10 subsequently (that is to say retro-fitted either at the factory or also by a user). FIG. 9 a shows the carcass fitment portion 5 and the door fitment portion 6 with the hinge cup 6 a connected pivotably to the carcass fitment portion 5 by way of the hinge lever 7 . The hinge lever 7 is mounted to the hinge cup 6 a at the axis of rotation S. Provided on the hinge cup 6 a are diagrammatically shown fixing means 23 (for example in the form of a recess, a latching edge or an opening 23 a ) while the housing 10 a of the damping device 10 is provided with corresponding fixing means 24 (for example in the form of a resilient arresting element 24 a ). The housing 10 a of the damping device 10 can therefore be releasably connected to the hinge cup in the illustrated mounting position by way of the first and second fixing means 23 , 24 , preferably being automatically latchable.
FIG. 9 b shows the damping device 10 with the housing 10 a and the slider 11 a displaceable relative thereto. For fixing to the furniture hinge 4 the housing 10 a has fixing means 24 with at least one arresting element 24 a which is in engagement in the mounted position with the opening 23 a , shown in FIG. 9 a , of the hinge cup 6 a . In that way the housing 10 a of the damping device 10 can be fixed relative to the hinge cup 6 a . In contrast to the slot 13 shown in FIG. 6 the slot 13 in FIG. 9 b is open downwardly in order thereby to fit the slider 11 a and therewith the damping device 10 subsequently to the fixing projection 14 shown in FIGS. 3 b , 4 b and 5 b respectively. In the mounted condition of the housing 10 a the arcuate peripheral surface thereof bears against the inside wall of the hinge cup 6 a and does not project beyond the hinge cup 6 a . The arresting element 24 a is resilient, is acted upon by a spring or is formed directly by a spring and can be moved from the mounted position on the hinge cup 6 a into a release position by applying pressure in opposition to the spring force of the arresting element 24 a so that the housing 10 a of the damping device 10 can be removed again from the hinge cup 6 a . The fixing means 24 with the arresting element 24 a and the opening 23 a on or in the hinge cup 6 a is only shown by way of example, it will be appreciated that other possible forms of mounting and removal are also possible. In a kinematic reversal it is also possible for the resilient arresting element to be arranged on the hinge cup 6 a and for the opening 23 a or latching edge also to be arranged on the housing 10 a of the damping device 10 .
FIG. 10 a shows a further possible way of fixing a damping device 10 which can be arranged in the mounted position entirely within a hinge cup 6 a . The damping device 10 includes a housing 10 a which can be fitted into the hinge cup 6 a from above (therefore substantially at a right angle to the bottom of the hinge cup). The housing 10 a of the damping device 10 has a first fixing means 24 in the form of a clip-like or circlip-like spring while the hinge cup 6 a is provided with second fixing means 23 in the form of an elongate recess 23 a , wherein the housing 10 a of the damping device 10 and the hinge cup 6 a can be releasably connected together in the mounted position by way of the first and second fixing means 23 , 24 . It is also possible to see a fixing projection 14 arranged within the hinge cup 6 a and extending substantially parallel to an axis of rotation S of the furniture hinge 4 . In the interior of the hinge cup 6 a the fixing projection 14 has a recess 40 provided for receiving and guiding the linearly displaceable slider 11 a . The flattening afforded by the recess 40 , or the lower position of the fixing projection 14 , permits an enlarged structural space for the housing 10 a of the damping device 10 .
FIG. 10 b shows the mounted position of the damping device 10 within the hinge cup 6 a . In that position the damping device 10 does not project beyond the plane of the opening of the hinge cup 6 a . The housing 10 a has a shoulder-shaped abutment 25 a which in the mounted position is supported against a corresponding counterpart abutment 25 b of the hinge cup 6 a . The peripheral surface of the damping device 10 is adapted to the contour of the internal space in the hinge cup 6 a . Towards the end of the closing movement of the movable furniture part 3 relative to the stationary furniture carcass 2 the hinge lever 7 bears against the slider 11 a of the damping device 10 , whereby the damping process is initiated.
FIG. 11 a shows a possible way of removing the damping device 10 fixed in the hinge cup 6 a . The housing 10 a of the damping device 10 has at least one release portion 26 , by which the connection between the first and second fixing means 23 , 24 is releasable so that the housing 10 a can be completely removed. The housing 10 a can be levered out of the hinge cup 6 a by applying a screwdriver 27 to the release portion 26 and the carcass abutment portion 5 . Removal is of relevance in that respect as a damping effect for the mobile hinge 4 is sometimes not wanted at all. If for example the movable furniture part 3 is pivotably mounted to the furniture carcass 2 by way of a plurality of furniture hinges 4 , it may be sufficient for only one furniture hinge 4 to be fitted with a damping device 10 , while the other furniture hinges 4 do not have any damping device in order thereby to ensure reliable closure of lighter movable furniture parts 3 . FIG. 11 b shows a perspective view from the front of the damping device 10 , from which it is possible to see the housing 10 a with the shoulder-shaped abutment 25 a and the linearly displaceable slider 11 a . In the illustrated embodiment the release portion 26 for dismantling of the damping device 10 is provided in one piece on the housing 10 a . FIG. 11 c shows a perspective view from the front of the damping device 10 while FIG. 11 d shows a perspective view from the front of the damping device 10 .
FIG. 12 a shows a further possible way of dismantling the damping device 10 by means of a slot-type screwdriver 27 which in the illustrated embodiment can engage the linearly displaceable slider 11 a . Various configurations of the release portion 26 are shown in FIGS. 12 through 12 d . In FIG. 12 b the release portion 26 is in the form of a bar projecting upwardly from the housing 10 a . In FIG. 12 c the release portion 26 is in the form of a recess in the displaceable slider 11 a , the release portion 26 being adapted to receive a cross-head screwdriver. In FIG. 12 d the release portion 26 is also provided on the slider 11 a and the release portion 26 with the slider 11 a jointly provide a slot-shaped recess in which a slot-type screwdriver can engage for dismantling of the damping device 10 .
FIG. 13 shows a highly diagrammatic view of a hinge cup 6 a sunk in a provided standard bore 30 in the movable furniture part 3 . The hinge cup 6 a has a bottom 31 and a side wall 29 extending therearound. The damping device 10 with the housing 10 a and the linearly displaceable slider 11 a includes first fixing means 24 while second fixing means 23 are associated with the hinge cup 6 a , wherein the housing 10 a of the damping device 10 can be releasably connected together in the intended mounted position by way of the first and second fixing means 23 , 24 . The second fixing means 24 of the housing 10 a can therefore be releasably connected to the bottom 31 of the hinge cup 6 a and/or to a side wall 29 thereof. The hinge lever 7 mounted at the axis of rotation S acts on the linearly displaceable slider 11 a as from a predetermined relative position of the hinge cup 6 a whereby the slider is pushed into the housing 10 a and initiates the damping process.
FIG. 14 a shows a perspective view of the furniture hinge 4 , wherein the fitment portion 5 in the form of the hinge arm is hingedly connected to the hinge cup 6 a by way of at least one hinge lever 7 . The housing 10 a of the damping device 10 can be fitted into the hinge cup 6 a from above when the hinge levers 7 and the hinge arm 5 are mounted, and can be releasably fixed therein. The damping device 10 has a slider 11 a movable relative to the housing 10 a , wherein the first fixing means 24 are provided on the slider 11 a so that the housing 10 a of the damping device 10 can be releasably connected to the hinge cup 6 a indirectly by way of the slider 11 a . In the illustrated Figure the second fixing means 23 of the hinge cup 6 a are formed by a fixing projection 14 which projects laterally inwardly from an inside wall of the hinge cup 6 a and is provided for connection to the slider 11 a . The fixing projection 14 can pass through the side wall of the hinge cup 6 a and in so doing also serve to receive the spring device 9 , by which the furniture hinge 4 is movable into the completely closed position.
FIG. 14 b shows the damping device 10 when subsequently fitted into the hinge cup 6 a . The housing 10 a of the damping device 10 has an arcuate peripheral edge adapted to the inside shape of the hinge cup 6 a . The housing 10 a of the damping device 10 has at least one preferably shoulder-shaped abutment 25 a which is additionally supported at an inside wall of the hinge cup 6 a so that the housing 10 a is held at least partially in positively locking relationship within the hinge cup 6 a . Towards the end of the closing movement of the hinge 4 the hinge lever 7 encounters the slider 11 a , whereupon it is pushed into the housing 10 a and the closing movement of the hinge 4 is thus damped.
FIG. 14 c shows a highly diagrammatic perspective view of a possible embodiment of a slider 11 a . The slider 11 a is provided with an inclined surface 15 provided for contact with the hinge lever 7 . The first fixing means 24 arranged on the slider 11 a include at least one guide groove 43 , extending in the longitudinal direction of the slider, for the second fixing means 23 arranged on the hinge cup 6 a , preferably for the fixing projection 14 arranged in the hinge cup 6 a (see FIG. 14 a ) for fixing the slider 11 a . In addition there is an introduction opening 41 , through which the fixing projection 14 can be arranged in the guide groove 43 . The slider 11 a can thus be moved relative to the fixing projection 14 in such a way that the fixing projection 14 can be passed through the introduction opening 41 and positioned in the guide groove 43 . In the damping stroke therefore the slider 11 a can be displaced relative to the fixing projection 14 mounted in the guide groove 43 . To remove the damping device 10 the fixing projection 14 is again threaded through the introduction opening so that the housing 10 can again be moved out of the hinge cup 6 a . In the illustrated embodiment the slider 11 a has on both longitudinal sides guide grooves 43 provided for receiving two fixing projections 14 disposed in mutually opposite relationship in the hinge cup 6 a.
The present invention is not limited to the illustrated embodiments but includes or extends to all variants and technical equivalents which can fall within the scope of the appended claims. The positional references adopted in the description such as for example up, down, lateral and so forth are also related to the directly described and illustrated Figure and are to be appropriately transferred to the new position upon a change in position.
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A furniture hinge, comprising a fitting part, a hinge cup that is articulated thereto for fastening to furniture parts, and a cushioning apparatus for cushioning a relative movement between the fitting part and the hinge cup, wherein the cushioning apparatus is disposed in or on the hinge cup, wherein the cushioning apparatus comprises a housing having first fastening means, and second fastening means are disposed on the hinge cup, wherein the housing of the cushioning apparatus can be inserted from above into the hinge cup and in the installed position is disposed substantially completely inside the hinge cup, wherein the housing of the cushioning apparatus and the hinge cup can be connected to each other in said installed position by the first and second fastening means.
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FIELD OF THE INVENTION
[0001] This application claims a benefit of priority from U.S. Provisional Application No. 60/575,319, filed May 28, 2004, the entire disclosure of which is herein incorporated by reference.
[0002] The present invention relates to a coated tablet formulation which includes a tablet core coated with a medicament such as a DPP4-inhibitor, such as saxagliptin, and to a method for preparing such coated tablet formulation.
BACKGROUND OF THE INVENTION
[0003] The compound of the structure
or its HCl salt, (hereinafter the above DPP4-inhibitor or saxaglipitin) is an orally active reversible dipeptidyl peptidase-4 (DPP4) inhibitor, which is a therapeutic agent for treatment of Type-2 diabetes mellitus which is disclosed in U.S. Pat. No. 6,395,767.
[0004] After a meal intake, insulinotropic hormone GLP-1 is released which in turn induces insulin release from the pancreas. Some of the GLP-1 is inactivated by the DPP4 present in plasma and intestinal capillary endothelium. Therefore, if the DPP4 is inhibited, more GLP-1 will be available to activate insulin release from the pancreas. The advantage of this mechanism of insulin release is that insulin is secreted only in response to a meal. Therefore, problems of hypoglycemia associated with other diabetes drugs will be less likely with a DPP4 inhibitor.
[0005] The above DPP4 inhibitor is a labile compound which is prone to an intra-molecular cyclization as shown below.
[0006] The resultant degradant, cyclic amidine (mainly cis-cyclic amidine (CA)), is not therapeutically active and therefore, its formation is not desirable. This cyclization reaction can occur both in solid state and solution state. The rate of intra-molecular cyclization is accelerated when formulations are subject to commonly used processing activities such as wet granulation, roller compaction, or tabletting. In addition, most commonly used excipients, when mixed with this compound, can accelerate the rate of cyclization. Moreover, the level of cis-cyclic amidine increases when the drug to excipient ratio increases posing more challenges for low strength dosage forms. Given these properties of the molecule, manufacture of a conventional tablet dosage form for the DPP4-inhibitor, which is a preferred dosage form, is not a viable option.
[0007] Currently, capsule formulations containing a dry mix of the DPP4-inhibitor and commonly used excipients are manufactured at a small scale and used for clinical studies. The scale up of capsule formulations containing the DPP4-inhibitor will also be problematic since it will involve milling to control the particle size of the DPP4-inhibitor so that capsules of lower strengths are manufactured without content unifomity problems.
[0008] Additionally, most of the therapeutic agents as a single entity or as a combination product for diabetes treatments are available in a tablet dosage form. Since a tablet dosage form using traditional manufacturing process is not feasible for the DPP4-inhibitor, its manufacturing with other therapeutic agents, as a combination tablet will be even more problematic.
[0009] Thus, it is seen that there is clearly a need for stable pharmaceutical formulations containing medicaments which are subject to intra-molecular cyclization which results in formation of degradants such as cyclic amidines which are not therapeutically active.
[0010] U.S. Pat. No. 6,395,767 to Robl et al. (hereinafter Robl et al.) discloses cyclopropyl-fused pyrrolidine-based dipeptidyl peptidase IV inhibitors (DPP4 inhibitors) which include compounds having the structure
or a pharmaceutically acceptable salt thereof, wherein the pharmaceutically acceptable salt can be the hydrochloride salt or the trifluoroacetic acid salt.
[0011] Robl et al. discloses that the DPP4 inhibitors including those set out above may be formulated as tablets, capsules, granules or powders.
BRIEF DESCRIPTION OF THE INVENTION
[0012] In accordance with the present invention a coated tablet is provided which may include a medicament which is subject to intra-molecular cyclization, but is surprisingly stable under normal storage conditions, that is at 30° C. and 60% relative humidity.
[0013] The coated tablet of the invention includes a tablet core (also referred to as a “core”, “tablet core”, “placebo”, “placebo core tablet”, “tablet core composition” or “core composition”) and
a) a coating layer coated on the core, which coating layer is an inner seal coat formed of at least one coating polymer; b) a second coating layer, disposed over the inner seal coat, formed of a medicament and at least one coating polymer which preferably is the same coating polymer in the inner seal coat; and optionally c) an outer protective coating layer, disposed over the second coating layer, formed of at least one coating polymer, which preferably is the same coating polymer in the second coating layer and inner seal coat, but need not necessarily include the same amounts of such polymer.
[0017] The medicament will preferably be the DPP4-inhibitor of the structure
or a pharmaceutically acceptable salt thereof, such as the HCl salt, also referred to as Compound A.
[0018] In a preferred embodiment, the coated tablet of the invention will include a tablet core which is formed of one or more bulking agents or fillers, optionally one or more binders, optionally one or more disintegrants, and optionally one or more tableting lubricants,
a) an inner seal coating layer which includes at least one coating polymer which preferably is a polyvinyl alcohol (PVA) based polymer; b) a second coating layer disposed over the seal coating layer a) which includes at least one medicament and at least one coating polymer which is preferably a PVA based polymer, and preferably the same as the coating polymer of the inner seal coating layer.
[0021] The above coating layers are applied to the tablet core preferably by spray coating on to the tablet core.
[0022] In a more preferred embodiment of the invention, an outer protective or third coating layer will be coated over the second coating layer (containing the medicament) and will function as a protective layer. The third or protective coating layer may preferably include similar components as in the second coating layer except that it will not include a medicament, but may optionally include one or more colorants, and may not necessarily include the same amounts of such components. Optionally, a fourth layer (which includes similar components as in the third layer) containing colorants and a coating polymer can also be applied to differentiate tablets of various strengths. The first, second, third and fourth coating layers may be formed of the same or different coating polymers.
[0023] It has been found that the coated tablets of the invention exhibit superior chemical stability as compared to traditional tablets manufactured using conventional dry granulation or wet granulation techniques.
[0024] The coating approach will also facilitate preparation of a combination formulation of a problematic medicament with another drug by using the other drug tablet as a starting tablet (instead of the tablet core or placebo mentioned above) and applying the inner seal coating and the second coating containing the problematic medicament and coating polymer, and optionally but preferably, the outer protective coating over the other drug tablet.
[0025] The coated tablets of the invention may be prepared preferably using perforated pan coaters. Fluid bed coating and spray coating may be used as well.
[0026] In addition, in accordance with the present invention, a method is provided for preparing the coated tablet of the invention, which method includes the steps of
a) providing a tablet core; b) coating the tablet with an inner seal coating layer formulation which includes at least one coating polymer; c) drying the coated tablet to form an inner seal coating thereon; d) coating the so-coated tablet with a second coating layer formulation which includes medicament and at least one coating polymer; e) drying the so-coated tablet to form a second coating layer (containing medicament) thereon; f) optionally, but preferably, coating the so-coated tablet with a third outer protective coating layer formulation which includes at least one coating polymer; and g) optionally, coating the so-coated tablet with a fourth outer protective coating layer which includes at least one coating polymer and colorant, and h) drying the so-coated tablet to form the coated tablet of the invention.
[0035] In a preferred embodiment of the method of the invention the inner seal coating layer formulation, the second coating layer formulation and the outer protective coating layer(s) formulation(s) each will be applied as a suspension of the coating polymer in a coating solvent.
[0036] The third and fourth outer protective coating layers need not include a medicament (although it may, if desired), and may be formed of the other components of the first coating layer and/or second coating layer. The second coating layer may be formed of the components of the first coating layer and/or third/and or fourth coating layer, but not necessarily the same amounts of such components.
[0037] In preparing the coated tablet of the invention, coating suspensions which include coating polymer in water are prepared. Other coating solvents which may be employed include ethanol, methanol, and isopropyl alcohol, with water being preferred. Tablets which are placebos (contain no medicament) and form tablet cores are coated with the inner seal coating suspension and are dried. The second coating layer suspension containing medicament and coating polymer is applied over the so-coated tablets which are then dried.
[0038] Where the coated tablet of the invention is to include an outer protective layer, a coating suspension is prepared as in the case of the inner seal coating suspension but without medicament. The coating suspension will then be coated onto the previously coated tablets as described for the inner seal coating and second coating to form a protective coating layer thereon.
[0039] The coated tablets of the invention are useful in the treatment of mammals such as humans, dogs and cats for Type II diabetes.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The tablet core or placebo employed in the coated tablet of the invention will include conventional pharmaceutical excipients to enable formation of a pharmaceutically acceptable solid tablet core. The tablet core may be in the form of a tablet, bead, beadlet, or pill, all of the above being collectively referred to as a tablet core.
[0041] The coated tablet of the invention will contain medicament, such as the above DPP4-inhibitor, saxaglipitin, in an amount within the range from about 0.1 to about 70% by weight and preferably from about 1 to about 50% by weight of the tablet core.
[0042] The tablet core employed in the coated tablet of the invention will preferably contain
a) at least one bulking agent or filler; b) optionally at least one binder; c) optionally at least one disintegrant; and d) preferably but optionally at least one lubricant.
wherein
a) the bulking agent or filler is present in an amount within the range from about 1 to about 95% by weight, preferably from about 10 to about 85% by weight; b) the binder is present in an amount within the range from about 0 to about 20% by weight, preferably from about 1 to about 10% by weight; c) the disintegrant is present in an amount within the range from about 0 to about 20% by weight, and preferably from about 0.25 to about 10% by weight; and d) the lubricant is present in an amount within the range from about 0 to about 5% by weight, preferably from about 0.2 to about 2% by weight, all of the above % by weight being based on the weight of the tablet core.
[0051] It is preferred that the bulking agents are microcrystalline cellulose and lactose monohydrate;
the disintegrant is croscarmellose sodium; and the lubricant is magnesium stearate.
[0054] The tablet cores present in the coated tablets of this invention can be prepared by a variety of processes and order of addition of excipients. The utility of these formulations is not limited to a specific dosage form or manufacturing process. Tablet cores may be manufactured by wet granulation, dry granulation, direct blending or any other pharmaceutically acceptable process.
[0055] In accordance with the present invention, a preferred method is provided for preparing the tablet cores employed in the coated tablets of the invention which includes the steps of blending the one or more excipients such as bulking agent, optionally binder and optionally disintegrant. A lubricant will be preferably added to the blend to facilitate tablet formation.
[0056] The bulking agents or fillers will be present in the tablet core compositions of the invention in an amount within the range from about 1 to about 95% by weight and preferably from about 10 to about 85% by weight of the core composition. Examples of bulking agents or fillers suitable for use herein include, but are not limited to, cellulose derivatives such as microcrystalline cellulose or wood cellulose, lactose, sucrose, starch, pregelatinized starch, dextrose, mannitol, fructose, xylitol, sorbitol, corn starch, modified corn starch, inorganic salts such as calcium carbonate, calcium phosphate, dicalcium phosphate, calcium sulfate, dextrin/dextrates, maltodextrin, compressible sugars, and other known bulking agents or fillers, and/or mixtures of two or more thereof, preferably microcrystalline cellulose.
[0057] The binder will be optionally present in the pharmaceutical compositions of the invention in an amount within the range from about 0 to about 20% weight, preferably from about 1 to about 10% by weight of the core composition. Examples of binders suitable for use herein include, but are not limited to, hydroxypropyl cellulose, corn starch, pregelatinized starch, modified corn starch, polyvinyl pyrrolidone (PVP) (molecular weight ranging from about 5,000 to about 1,000,000, preferably about 40,000), hydroxypropyl methylcellulose (HPMC), lactose, gum acacia, ethyl cellulose, cellulose acetate, as well as a wax binder such as carnauba wax, paraffin, spermaceti, polyethylenes or microcrystalline wax, as well as other conventional binding agent and/or mixtures by two or more thereof, preferably hydroxypropyl cellulose.
[0058] The disintegrant will be optionally present in the pharmaceutical composition of the invention in an amount within the range from about 0 to about 20% by weight, preferably from about 0.25 to about 10% by weight of the core composition. Examples of disintegrants suitable for use herein include, but are not limited to, croscarmellose sodium, crospovidone, starch, potato starch, pregelatinized starch, corn starch, sodium starch glycolate, microcrystalline cellulose, low substituted hydroxypropyl cellulose or other known disintegrant, preferably croscarmellose sodium.
[0059] The lubricant will be optimally present in the pharmaceutical composition of the invention in an amount within the range from about 0.1 to about 5% by weight, preferably from about 0.2 to about 2% by weight of the core composition. Examples of tableting lubricants suitable for use herein include, but are not limited to, magnesium stearate, zinc stearate, calcium stearate, talc, carnauba wax, stearic acid, palmitic acid, sodium stearyl fumarate or hydrogenated vegetable oils and fats, or other known tableting lubricants, and/or mixtures of two or more thereof, preferably magnesium stearate.
[0060] The inner seal coating layer formulation (also referred to as the first coating layer) will include up to 95% of polymer based on the weight of the inner seal coating layer, and may be prepared as described hereinbefore. The formulation will contain at least one coating layer polymer and a coating solvent as described above, which preferably is water, which is used for processing and removed by drying. The coating layer polymer may be hydroxypropyl methylcellulose, polyvinyl alcohol (PVA), ethyl cellulose, methacrylic polymers or hydroxypropyl cellulose, preferably PVA. The coating layer may also optionally include a plasticizer such as triacetin, diethyl phthalate, tributyl sebacate or polyethylene glycol (PEG), preferably PEG; and an anti-adherent or glidant such as talc, fumed silica or magnesium stearate, opacifying agent such as titanium dioxide. The coating layer may also include iron oxide based colorants. The coating material is commercially available under the trade name Opadry® HP or Opadry® II white.
[0061] The second coating layer formulation will preferably be similar in composition to the first coating layer formulation although it will include medicament, preferably the DPP4-inhibitor in an amount within the range from about 0.5 to about 70%, preferably from about 30 to about 50% by weight, based on the weight of the second coating layer.
[0062] The third outer protective coating layer will preferably be similar in composition to the first coating layer.
[0063] The fourth coating layer where present will preferably be similar in composition to the third outer protective coating layer and will include colorant as desired, such as within the range from about 0.5 to about 5.0% by weight, based on the weight of the fourth coating layer.
[0064] The inner seal coating layer will preferably be formed of coating layer polymer in an amount within the range from about 10 to about 95%, preferably from about 20 to about 90% by weight of the inner seal coating layer, optionally plasticizer in an amount within the range from about 10 to about 30%, preferably from about 15 to about 20% by weight of the coating layer, and anti-adherent or glidant in an amount within the range for about 15 to about 30%, preferably from about 10 to about 15% by weight of the inner seal coating layer.
[0065] The second coating layer will be preferably formed of coating layer polymer in an amount within the range from about 30 to about 99.5%, preferably from about 40 to about 60% by weight of the second coating layer and medicament in an amount within the range from about 0.25% to about 70%, preferably from about 20 to about 50% by weight of the second coating layer.
[0066] The coating layer polymer in the second coating layer will be at least about 5 mg with a 200 mg tablet core, and the medicament will be at least about 0.5 mg.
[0067] The third outer protective coating layer will preferably be of similar composition to the first coating layer.
[0068] The inner seal coating layer will be present in an amount within the range from about 1 to about 5%, preferably from about 1 to about 3% by weight of the finished coated tablet; the second coating layer (containing medicament) will be present in an amount within the range from about 0.25 to about 70%, preferably from about 1 to about 50% by weight of the finished coated tablet, depending on potency; and the third outer protective coating layer and fourth layer where present will each be present in an amount within the range from about 1 to about 10%, preferably from about 1 to about 5% by weight of the finished coated tablet.
[0069] Preferred coated tablet formulations in accordance with the invention are set out below.
Possible Range Preferred Range Material %/mg by weight of 200 mg %/mg by weight of 200 mg Tablet Placebo placebo core tablet placebo core tablet Bulking Agent 2 to 95%/4 to 190 mg 10 to 85%/20 to 170 mg Lactose 0 to 95%/0 to 190 mg 20 to 75%/40 to 150 mg Microcrystalline cellulose 0 to 95%/0 to 190 mg 20 to 75%/40 to 150 mg Disintegrant 0 to 20%/0 to 40 mg 0.25 to 10%/0.5 to 20 mg Croscarmellose sodium 0 to 20%/0 to 40 mg 2 to 10%/4 to 20 mg Lubricant 0.1 to 5%/0.2 to 10 mg 0.2 to 2%/0.4 to 4 mg Magnesium Stearate 0.1 to 5%/0.2 to 10 mg 0.2 to 2%/0.4 to 4 mg
[0070]
%/mg by weight of 200 mg
%/mg by weight of 200 mg
First Inner Seal Coating Layer
placebo core tablet
placebo core tablet
Coating polymer, and optional
0.5 to 50%/1 to 100 mg
1 to 3%/2 to 6 mg
plasticizer and glidants
[0071]
%/mg by weight of 200 mg
%/mg by weight of 200 mg
Second Coating Layer
placebo core tablet
placebo core tablet
DPP4-inhibitor (free base or
0.1 to 70%/0.2 to 140 mg
1 to 50%/2 to 100 mg
HCl salt)
Coating polymer, and optional
1 to 70%/2 to 140 mg
1 to 50%/2 to 100 mg
plasticizer and glidants
[0072]
Third Outer Protective Coating
%/mg by weight of 200 mg
%/mg by weight of 200 mg
Layer
placebo core tablet
placebo core tablet
Coating polymer, and optional
0.5 to 50%/1 to 100 mg
1 to 5%/2 to 10 mg
plasticizer, glidants and color
[0073] The following working Example represents a preferred embodiment of the invention.
EXAMPLE
[0074] A 500 g batch of 2.5 mg DPP4 coated tablets having the following composition were prepared as described below
Weight (mg) % by weight of Tablet Core a 200 mg placebo core tablet Lactose Monohydrate NF 99 mg (49.5%) Microcrystalline Cellulose NF 90 mg (45%) Croscarmellose Sodium NF 10 mg (5%) Magnesium Stearate NF 1 mg (0.5%) Total 200 mg (100.0%) Inner Seal Coating Layer 4 mg (2%) Opadry ® HP which contains the following ingredients Polyvinyl Alcohol 40% PEG 20% Talc 15% Titanium dioxide 25% Middle Layer DPP4-inhibitor, Saxaglipitin 2.5 mg (1.25%) Opadry ® HP 20 mg (10%) Outer Protective Layer Opadry ® HP 4 mg (2%)
[0075] The 500 g of tablet cores were prepared as follows.
[0076] Lactose monohydrate, croscarmellose sodium, and microcrystalline cellulose were blended in a planetary mixer. The blend was then lubricated by blending with pre-screened magnesium stearate using a Turbula mixer. The lubricated blend was compressed using a single station press or using a rotary press into 200 mg placebo tablets.
[0000] Inner Seal Coating Layer
[0077] The inner seal coating suspension was prepared as follows.
[0078] 0.1 N HCl (about 226.7 g) in a metal container was continuously stirred with a lightening mixer. 40 g Opadry® HP powder was quickly added into the vortex. After the powder addition was completed, mixing was continued at a low speed until a uniform mixture was visually evident. pH of the resulting suspension was measured and pH was adjusted to 2 using concentrated HCl or NaOH.
[0079] A Glatt coater was set up according to the following parameters
Glatt Coater Parameter Pump rate 3.5-5 ml/min Pan speed 20 rpm Air pressure 1.5 bar Inlet air temperature 50° C. Exhaust air temperature about 38° C. Air flow 80 m 3 /hour Gun to bed distance 6.5 inch Nozzle size 0.8 mm
[0080] The tablet cores were preheated in a coating pan for about 10 to 15 minutes. 30 heated tablets were weighed. Drying of the tablets was continued until the moisture was driven out of the tablet and tablet weight became constant. The final weight of 30 tablets was designed as A.
[0081] The 30 tablets were coated with the inner seal coating suspension as prepared above employing the Glatt coater.
[0082] The 30 tablets were weighed every 10 minutes (and the weight recorded) until the tablet weight reached the targeted weight (Equation 1). The coated tablets were dried by heating until the tablet weight became constant. The final weight of the so-coated tablets was designated as B.
Targeted weight= A× 1.02 =B Equation 1:
Middle (Drug) Coating Layer
[0083] The middle drug-containing coating layer suspension was prepared as follows.
[0084] 12.5 g of the DPP4-inhibitor (free base) was added to 1000 ml of 0.1 N HCl in a metal container. The pH was measured and adjusted to 2. The HCl was continuously stirred and 100 g Opadry® HP was quickly added into the vortex. The mixture was then stirred at low speed until a uniform mixture was visually evident. The pH of the suspension was maintained at 2 using either concentrated HCl or 1N HCl as necessary.
[0085] The seal coated tablet cores prepared above were coated with the coating suspension containing the DPP4-inhibitor prepared above employing the Glatt coater. The 30 seal coated tablets were weighed, initially every 30 minutes, then every 15 minutes and the weight recorded until the targeted weight was reached (Equation 2). The so-coated tablets were dried by heating until the tablet weight became constant. The final weight of 30 tablets was designated as C.
Targeted weight= B+ 30×(2.925(equivalent to 2.5 mg free base)+20 mg)= B+ 687.75 mg= C Equation 2:
[0086] The amount of drug coated onto the tablets was determined using HPLC, fiber optic probe, or NIR or other suitable means. Coating was stopped when the targeted amount of drug was deposited.
[0000] Outer Protective Coating Layer
[0087] The so-coated tablets were then coated with a suspension of Opadry® HP as used in forming the inner seal coating. The 30 tablets were weighed every 10 minutes and the weight recorded until tablet weight reached the targeted weight (Equation 3). The tablets were dried by heating until the tablet weight became constant.
[0088] The final weight of 30 tablets was designed as D.
Targeted weight= C+ 30×4 mg= C+ 120 mg= D Equation 3:
[0089] The so-coated tablets were transferred to a suitable container.
[0090] The tablets of the invention so-prepared had superior stability to conventional tablet formulations (wherein the drug was in the core) and capsule formulations.
[0091] The above 2.5 mg potency coated tablets of the invention were stored at various storage conditions up to and including 41 weeks and stability data related to presence of the degradant cyclic anidine (mainly cis-cyclic amidine (Cis-CA)) were collected. As shown in Table 1 set out below, no cis-CA was detected at 25° C./60% RH storage condition. The cis-CA levels were 0.22% and 0.32% at 30° C./60% RH and 40° C./75% RH storage conditions, respectively. These levels are significantly lower than those observed in the 5 mg and 20 mg potency capsule formulations shown in Table 2.
TABLE 1 Twenty-six weeks stability data on 2.5 mg potency tablets coated with Opadry ® HP, free base as starting material, and three coating layers. For stability evaluation, tablets were packaged in HDPE bottles. 4 wks for all closed 8 wks for all closed conditions conditions 2 wks for all closed 1 wk for two open 5 wks for two open conditions conditions conditions Cis- Trans- Cis- Trans- Cis- Trans- Storage Condition Amide % CA % CA % Amide % CA % CA % Amide % CA % CA % 5° C.-closed 0 0 0 0 0 0 0 0 0 25° C./60% RH-closed 0 0 0 0 0 0 0 0 0 30° C./60% RH-closed 0 0 0 0 0 0 0 0 0 40° C./75% RH-closed 0 0 0 0 0.05 0 0 0.09 0 50° C.-closed 0 0.17 0 0 0.33 0.15 0 0.52 0.12 30° C./60% RH-open NA NA NA 0 0 0 0 0.20 0.06 40° C./75% RH-open NA NA NA 0 0.68 0.15 0 3.22 0.42 12 wks for all closed 26 wks for all closed 41 wks for all closed conditions conditions conditions Cis- Trans- Cis- Trans- Cis- Trans- Storage Condition Amide % CA % CA % Amide % CA % CA % Amide % CA % CA % 5° C.-closed 0 0 0 0 0 0 0 0 0 25° C./60% RH-closed 0 0 0 0 0 0 0.03 0 0 30° C./60% RH-closed 0 0 0 0 0.22 0 0.03 0.17 0 40° C./75% RH-closed 0 0.20 0.05 0 0.32 0 0.03 0.90 0 50° C.-closed 0 0.75 0.15 0 1.00 0 0 1.62 0 30° C./60% RH-open NA NA NA NA NA NA NA NA NA 40° C./75% RH-open NA NA NA NA NA NA NA NA NA NA denotes “data not available”
[0092]
TABLE 2
Stability data for capsule formulations (benzoate salt of DPP4 4.8%, Anhydrous lactose 50.2%,
lactose hydrous 40%, croscarmellose sodium 2%, and sodium stearyl fumarate 3%,
fill weights for 5 mg and 20 mg capsules are 150 mg and 350 mg, respectively.)
5 mg capsule
20 mg capsule
2 wks
4 wks
13 wks
26 wks
2 wks
4 wks
13 wks
26 wks
Conditions
Cis-CA %
Cis-CA %
Cis-CA %
Cis-CA %
Cis-CA %
Cis-CA %
Cis-CA %
Cis-CA %
25° C./60% RH-closed
0.11
0.13
0.20
0.31
0.08
0.05
0.14
0.26
40° C./75% RH-closed
0.23
0.35
0.61
0.95
0.22
0.26
0.46
0.62
50° C.-closed
NA
0.73
1.72
NA
NA
0.43
1.19
NA
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A coated tablet formulation is provided which includes a medicament such as the DPP4-inhibitor, saxaglipitin
or its HCl salt, which is subject to intra-molecular cyclization, which formulation includes a tablet core containing one or more fillers, and other conventional excipients, which tablet core includes a coating thereon which may include two or more layers, at least one layer of which is an inner seal coat layer which is formed of one or more coating polymers, a second layer of which is formed of medicament which is the DPP4-inhibitor and one or more coating polymers, and an optional, but preferable third outer protective layer which is formed of one or more coating polymers. A method for forming the coated tablet is also provided.
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BACKGROUND OF THE INVENTION
This invention relates to novel continuous filament cabled yarn which after heatsetting is useful for making cut pile carpet which shows reduced foot traffic patterns, i.e., trackless carpet consists of two singles carpet yarns, both of which are tangled and contain substantially no twist (i.e. less than one turn of twist per 2.54 cm of singles yarn length) and. Presently, cabled continuous filament yarn that is used for making cut pile trackless carpet differs from that used for making saxony cut pile carpet in that it contains more cable twist and is textured in cabled yarn form. In commercial practice, the texturing of this yarn is accomplished by stuffer box and is coupled in-line with continuous heatsetting of the yarn using Superba® heatsetting equipment and conditions. More specifically, the yarn is fed through a stuffer box crimper with or without steam to compress the yarn. The yarn upon exiting the crimper is permitted to fall onto the endless stainless steel, perforated belt of the Suberba heatsetting machine in a wadded up, crimped form. The belt passes slowly and continuously through a long chamber filled with saturated steam, which in the case of nylon yarn, is maintained at a temperature of about 136° C. The yarn, after passing through the chamber, is cooled in its wadded-up, crimped form and removed from the belt. The resulting textured yarn is ready for tufting of trackless carpet.
It would be highly desirable to reduce the cost of trackless carpet by providing a continuous filament cabled yarn which will develop texture during heatsetting without being first subjected to stuffer box crimping or other special mechanical crimping means.
SUMMARY OF THE INVENTION
In accordance with the present invention a continuous filament cabled yarn is provided which will develop texture during heatsetting of the yarn without first being subjected to stuffer box crimping or other special mechanical crimping means. The cabled yarn of the present invention differs from conventional continuous filament cabled carpet yarn in that the singles yarns in addition to containing crimped carpet filaments also contain high shrinkage filaments having no crimp and carpet filaments having crimp. The filaments are in the form of two singles yarns (plies) cabled together. The Shrinkage Value of the high shrinkage filaments is at least 5 units higher than the Contraction Value (i.e. the sum of the Bulk Value and Shrinkage Value) of the crimped carpet filaments. The Shrinkage Values and quantities of the high shrinkage filaments are selected such that after heatsetting of the cabled yarn the tracklessness of a cut pile test carpet having tufts made therefrom is better, as determined by Test A, hereinafter defined, than if the cabled yarn consisted entirely of the crimped carpet filaments. (The procedure for determining Shrinkage Values and Bulk Values are given hereinafter.) When the cabled yarn of the invention is subjected to heatsetting treatment, a torque is generated which imparts a random texture of the yarn that is desirable for trackless carpet constructions. The amount of texture imparted to the yarn is believed to be affected by the amount of high shrinkage filaments in the yarn and the difference between the Shrinkage Value of the high shrinkage filaments and the Contraction Value of the carpet filaments.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic representation of a continuous filament yarn of the present invention. The yarn is composed of two single yarns, each consisting of high shrinkage filaments and carpet filaments, cabled together.
FIG. 2 is a schematic representation of the cabled yarn shown in FIG. 1 after the yarn is heatset with a portion broken away to show the arrangement of the high shrinkage and carpet filaments.
FIG. 3 is a schematic representation of a section of the cabled yarn shown in FIG. 2 with a portion broken away to show a slightly different arrangement of the filaments.
The invention will be understood from the following detailed description of the preferred embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Crimped carpet filaments useful in making the plied yarn of the present invention have deniers of at least 10 (e.g. 12 to 25) and Shrinkage Values of less than 5. In present commercial practice, almost all continuous filament cabled yarns used in the construction of trackless carpets are composed of either crimped nylon 66 or crimped nylon 6 carpet filaments with the remainder of such cabled yarns being composed of crimped polypropylene carpet filaments. However, other crimped carpet filaments, such as, crimped polyester or acrylic carpet filaments are also contemplated as being useful in practicing the invention.
Normally, the Shrinkage Value of the crimped carpet filaments is 3 or less and the Bulk Value, for example, is about 17 but may be as high as 30 or more depending on the type of crimp imparted to the filaments, for example, conventional air jet texturing or gearcrimping methods provide filaments having a Bulk Value in the range of 15 to 22 while false twist texturing would provide higher Bulk Values.
The high shrinkage filaments of the cabled yarn have Shrinkage Values at least 5 units higher than the sum of the Bulk and Shrinkage Values of the crimped nylon carpet filaments. The denier of the high shrinkage filaments may be the same or different from that of the crimped carpet filaments. In general, as either the weight percentage or Shrinkage Value of the high shrinkage filament component of the cabled yarn increases while all other variables remain the same, more texture is imparted to the plied yarn. One or both plies of the plied yarn may contain high shrinkage filaments. Preferably, each ply contains the same amount by weight of the high shrinkage filaments. Representative high shrinkage filaments having the requisite Shrinkage Values include filaments made from polyester (e.g. polyethylene terephthalate); nylon copolymers, such as copolymers containing hexamethylene adipamide (66) units, hexamethylene terephthalamide (6TA) units and hexamethylene azelamide (69) units where the amounts are selected to provide a copolymer having a melting point approximately that of the crimped carpet filaments; and acrylic polymer. The cabled yarn of the invention usually contains from 4% to 30% by weight of the high shrinkage filaments, and, preferable, each singles yarn contain less than 25% by weight and most preferable less than 15% by weight of high shrinkage filaments.
Referring to FIG. 1, where a preferred yarn of the present invention is illustrated, yarn 1 consists of two identical singles yarns 2 and 3 having little or no twist and being cabled together with, for example, 3.5 to 6.0 turns per inch (1.4 to 2.4 turns per cm) of twist. Yarns 2 and 3 are each conveniently prepared by inserting, respectively, bundles 6 and 7 of high shrinkage filaments (e.g. a 50 denier bundle consisting of 5 filaments) into conventional bulked (i.e. crimped) continuous filament singles carpet yarns 4 and 5 (e.g. 1250 denier yarn consisting of 60 filaments) by means of an air tangler. Yarn 1 is then heatset. During heatsetting of yarn 1, bundles 6 and 7 shrink causing yarns 4 and 5 to buckle as shown in FIGS. 2 and 3. Some breakage of high shrinkage acrylic filaments may occur by this method because the acrylic filaments are fragile. Of course, the high shrinkage filaments can be inserted into the singles carpet yarn by hand or other appropriate method if desired. Conventional bulked continuous filament nylon carpet yarns have a denier in the range of 1000 to 2000. In FIGS. 2 and 3 a portion of yarns 4 and 5 is broken away to expose filament bundles 6 and 7 which otherwise would be hidden.
High shrinkage filaments, such as polyester filaments, useful for practicing the present invention can be made by known techniques selected to provide the desired shrinkages. The plied yarns may also contain other components such as antistatic filaments and additives such as delustrants and antisoiling agents conventionally employed from time-to-time in the manufacture of carpet yarns.
According to one embodiment of the invention, special styling effects are achieved by subjecting yarns of the present invention to stuffer box crimping just prior to heatsetting. In this instance, while there is no cost advantage over conventional trackless cabled carpet yarns, there are aesthetic advantages that are not achievable with the conventional yarns.
MEASUREMENTS
Bulk and Shrinkage Values of filaments are determined by the following procedures. A yarn consisting of the filaments is conditioned at 23° C. and 72% relative humidity for one day prior to testing. Using a Suter denier reel or the equivalent and a winding tension of 0.033 grams per yarn denier, the yarn is wound into a skein having a 1.125 meter circumference and a skein denier of approximately (but not to exceed) 55,000 skein denier. For example, if the yarn denier is 520, 52 revolutions of the denier reel will provide a skein denier of 54,080 while 53 revolutions would provide a skein denier of 55,120. In this instance 52 revolutions Would be used. The ends of the skein are tied together While maintaining the 0.033 grams per denier tension, and the skein having a length of 56.25 cm is removed from the denier reel and suspended from a 1/2 inch (12.7 mm) diameter rod. A number 1 paper clip, bent into an "S" shape is suspended from the skein. The rod with skein and paper clip attached is placed in a 180° C. forced hot air oven sufficiently large that the skein hangs freely. (In the case of polypropylene, instead of using a temperature of 180° C., a temperature of 120° C. is used.) After 5 minutes in the oven, the rod with skein and paper clip is removed from the oven and hung in an atmosphere of 23° C. and 72% relative humidity for one minute. Then, a weight equal to 0.0009 grams per skein denier is then gently suspended from the paper clip and after an additional 30 seconds, the skein length in centimeters is again measured and recorded this time as L . The small weight is then replaced with a weight to give 0.0834 grams per skein denier and after an additional 30 seconds, the skein length in centimeters is once again measured, and recorded this time as L 1 . The Bulk Value is determined by the following formula: ##EQU1## The Shrinkage Value is determined by the following formula: ##EQU2## The Contraction Value is the sum of the Bulk Value and Shrinkage Value.
TEST A
The following procedure provides a means for testing a cabled yarn (Test Yarn) comprising high shrinkage filaments and crimped nylon carpet filaments to determine if cut pile carpet having tufts made therefrom is better with respect to trackless than cabled yarn of comparable denier (Control Yarn) consisting entirely of the crimped nylon carpet filaments. By comparable denier is meant a denier that will permit the same gauge to be used in step (c) for both the Test and Control Yarns.
(1) A cabled yarn (Control Yarn) is made entirely of the crimped carpet filament present in the Test Yarn;
(2) The Test and Control Yarns are heatset using Superba® equipment in a conventional manner under conditions that are suitable for the carpet filaments of the yarn and that minimize restriction of the shrinkages of any of the filaments of the yarn.
(3) Two cut pile carpet samples of saxony construction are made. One of the samples (Control Carpet) is made using the Control Yarn and the other sample (Test Carpet) is made using the Test Yarn. Both carpet samples are made using the following construction:
(a) gauge (spacing between rows of tufts)--the choice of gauge depends on the denier of the single yarn defined as follows:
______________________________________Single Yarn Denier Gauge______________________________________800-999 1/101000-1299 1/81300-1499 5/321500 and higher 3/16______________________________________
(b) face weight--34 ounces (963.9 grams) of yarn per square yard of carpet with the spacings between stitches being selected to provide the 34 ounces (963.9 grams) face weight.
(c) pile height--5/8 inches (1.59 cm)
(d) backing--the primary backing is a polypropylene backing, such as Polybac® backing (style 2477) and the secondary backing is also a polypropylene backing, such as Actionbac® backing (style 3801).
4. The carpet samples are dyed to the same shade of color using conventional Otting dyeing equipment and dyeing conditions.
5. Each sample of carpet (Test Carpet and Control Carpet) is subjected to the following test procedure.
(a) place the carpet samples side-by-side on a firm flat surface.
(b) place a metal block (simulating a shoe) having a width of 6.35 cm, a length of 25.4 cm and a height of 3.81 cm on each carpet sample. Then, place sufficient weight on each block so that the total weight on each carpet sample is 22.7 kg.
(c) after 15 seconds, remove the weights and the metal blocks from the carpet samples.
(d) after an additional 90 seconds, visually compare the "foot prints" made in the carpets by the metal blocks and weights with the pile direction of both carpets being oriented in the same direction. The carpet having the least visually noticeable foot print has better tracklessness. If the foot prints appear visually the same, then the carpet samples have the same tracklessness.
The following example is given to further illustrate the invention. In the examples percentages are by weight.
EXAMPLE
A polyester (PET) 50 denier/5 filament yarn having a Shrinkage Value of 67 was inserted by air-jet into a bulked continuous filament 1250 denier/60 filament nylon 66 yarn having a Contraction Value of 20 to form a high shrink/carpet blend yarn. Two of the blend yarns were cabled with 3.5 turns per inch (2.54 cm) of twist in the S-direction to provide a cabled yarn. Two additional heatset cabled yarns were similarly made as described above except that instead of using the polyester yarn described above, a 50 denier-5 filament polyester yarn having a Shrinkage Value of 46 was used in making one of the yarns and a 108 denier-33 filament polyester yarn having a Shrinkage Value of 67 was used in making the other yarn. Also, a cabled yarn consisting entirely of above-mentioned nylon yarn was made (Control). Each yarn was heatset using Superba equipment and heatsetting conditions. Each cabled yarn was made into a trackless carpet and tested for tracklessness in accordance with Test A hereinbefore described. The results of Test A are given below.
TABLE______________________________________Carpet High Shrinkage Yarn Tracklessness______________________________________1 None (Control) Poor (None)2 50-5-PET (46% shrinkage) Good3 50-5-PET (67% shrinkage) Very Good4 108-33-PET (67% shrinkage) Excellent______________________________________
The results given in the Table show that carpet having good tracklessness characteristics are provided with the cabled yarns containing either of the PET (67% shrinkage yarns). The results further show the effect of Shrinkage Value on tracklessness. (Compare the tracklessness of Carpet 2 and 3.) The tracklessness of Carpet 2 could be improved by inserting more of the PET (46% shrinkage) yarn into the cabled yarn.
In related experiments, the yarns instead of being heatset using Superba equipment and conditions were heatset using Suessen equipment and conditions. The results with regard to tracklessness were the same as given in the above Table.
In other related experiments, a 50 denier/5 filament polyester yarn having a Shrinkage Value of 67 was parallel fed into one of two 1250 denier-60 filament bulked continuous filament nylon 66 yarns (each having a Contraction Value of 20) during the cabling of the two nylon yarns. The yarns were cabled with 3.5 turns of twist per inch (2.54 cm) in the S-direction. In this instance, the cabled yarn contained polyester filaments in only one of the two plies. The cabled yarn after being heatset using Superba equipment and conditions was made into a trackless carpet and was tested for tracklessness as described above. The carpet was found to have good tracklessness characteristics.
It is expected that similar results will also be obtained when the cabled yarn of the invention comprises crimped carpet filaments other than crimped nylon carpet filaments, for example, crimped polypropylene carpet filaments.
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Yarn suitable for use in making cut pile trackless carpet is disclosed. The yarn is composed of two continuous filament singles yarn cabled together with from 3.5 to 5.0 turns per inch (2.54 cm) of twist. Each singles yarn is tangled and contains substantially no twist. The yarn is characterized, in that, each singles yarn comprises, in addition to crimped carpet filaments, filaments having no crimp and a high degree of shrinkage. The yarn develops texture during conventional heatsetting of the yarn without the use of mechanical crimping.
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FIELD OF THE INVENTION
The invention relates to a hermetically sealed dry accumulator that is suitable for use as a direct current source of everyday and industrial application.
BACKGROUND OF THE INVENTION
Lead acid accumulators are widely used to convert chemical energy into electrical energy and conversely, to store electrical energy. The lead acid accumulators generally consist of positive and negative electrodes and electrolyte--sulfuric acid, housed in a hard rubber or plastic case.
The disadvantages of standard lead acid accumulators are well known. Lead acid accumulators require routine filling of their cells with water. The lead acid accumulators are relatively large and heavy for the amount of electrical energy, which they accumulate.
Electrical accumulators having a negative electrode made of iron, cadmium, magnesium, indium or zinc, a positive electrode made of lead dioxide, and electrolyte, which includes an aqueous solution of an alkaline hydroxide and a metallic sulfate, are also known. The alkaline accumulator is inherently limited because its operation depends on an alkaline electrochemical reaction with a salt that forms a weak electrical linkage with the positive electrode.
Consequently, the alkaline accumulator has a relatively small specific power output and must be made relatively large and heavy to produce a given amount of electrical energy.
Thus, there is a need for a hermetically sealed dry accumulator, having a significantly larger power output per unit of mass and a proportionately smaller volume. Ideally, the improved accumulator would contain relatively less lead, would weigh considerably less than conventional accumulators and would demonstrate a longer service life. An accumulator that contains less lead would be simpler to make and would involve the production of less environmentally damaging byproducts.
SUMMARY OF THE INVENTION
A hermetically sealed dry accumulator in accordance with the present invention comprises a case having a negative electrode coated with copper, cadmium, zinc, nickel or iron and a porous lead dioxide positive electrode. Between and in contact with the positive and negative electrodes is an electrolyte comprising a silica gel which is infused with a solution containing concentrated sulfuric acid saturated with a metallic sulfate, corresponding to the selected metal coating the negative electrode. For example, in one form of the invention, the coating of the negative electrode is copper and the solution contains copper sulfate. The case which contains the silica gel and the electrolyte may be hermetically sealed.
The present invention provides a method for making a hermetically sealed dry accumulator which comprises installing a negative electrode composed of a metal selected from the group consisting of copper, cadmium, zinc, nickel, iron, and a porous lead dioxide positive electrode in an acid resistant case adapted to hold a liquid; placing finely ground silica gel in the case and around the electrodes in an amount sufficient to surround the electrodes and form a bed of silica gel; injecting into the bed a volume of saturated solution containing concentrated sulfuric acid and an amount of metallic sulfate of the metal of the negative electrode, sufficient to thoroughly wet the silica gel; and hermetically sealing the case.
Further objects, features and advantages of the present invention will be apparent from the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a hermetically sealed dry accumulator constructed in accordance with the present invention;
FIG. 2 is a perspective view of a negative electrode;
FIG. 2A is an enlarged. cross-sectional view of the negative electrode of FIG. 2 taken along line 2A--2A of FIG. 2;
FIG. 3 is a perspective view of a positive electrode;
FIG. 3A is an enlarged cross-sectional view of the positive electrode of FIG. 3 taken along line 3A--3A of FIG. 3;
FIG. 4 is a cut-away perspective view of a hermetically sealed dry accumulator constructed in accordance with this invention;
FIG. 5 is a cross-sectional view of an accumulator taken along line 5--5 of FIG. 4; and
FIG. 6 is an exploded perspective view of the accumulator of FIG. 4, with the silica gel omitted for clarity.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, a hermetically sealed dry accumulator 10 in accordance with the present invention includes a case 20 having a top, a bottom and four sides. Case 20 may be constructed of any of the conventionally used, acid-resistant plastic materials. Synthetic resins are preferred in the case construction. The main features of suitable plastics are: structural strength, impact strength, wear resistance when contacting and sliding on hard objects, low specific weight, chemical stability when contacting sulfuric acid and minimal aging when contacting the environment (air, moisture, atmosphere). Materials such as polyvinyl-chloride and polyethylene are preferred. The case may be also constructed of hard rubber.
A negative electrode 30 is mounted in the case 20. Electrode 30 is made of a metal selected from the group consisting of copper, cadmium, zinc, nickel and iron and may include several physically separated plates which are electrically connected. The selected metal may be present in the form of a coating 32. A grid is embedded in electrode 30 which provides structural support but which does not actually take part in the chemical reaction. The grid may be composed of plastic or ceramic material and optionally may be reinforced with an aluminum mesh armature.
For example, the grid may be an assembly of aluminum rod-like elements having diameters in the range of about 0.8 to about 1.5 mm which intersect in a plane to define a plurality of substantially square apertures each about 1.5 mm wide. Cadmium and copper, although more expensive than aluminum, can also be used as grid materials.
Alternatively, as shown on FIG. 2A, the negative electrode may include a non-metallic grid, such as a plastic grid 36, having a thin layer of nickel 34 and a coating 32 of the selected metal. The grid 36 is formed by rod-like elements, which have cross sections generally circular, polygonal or square with flat areas extending lengthwise on the rod-like elements. Preferably, the plastic rod-like elements are about 1.5 mm in thickness and intersect to define substantially square apertures about 1.5 mm wide. It is necessary to coat the plastic grid 36 with an initial layer 34 of nickel about 5 microns in thickness even though an outmost coating is composed of a selected metal other than nickel.
If the selected metal is copper, the coating 32 preferably has a thickness in the range of about 5 to about 10 microns. The thickness of the coating 32 is preferably about 20 microns for cadmium and zinc, about 5 to 10 microns for nickel, and about 20 to 30 microns for iron.
The coating and the thin layer 34 of nickel may be applied by well-known metallizing processes. Vacuum deposition processes, such as sputtering and chemical vapor deposition are preferred.
The hermetically sealed dry accumulator 10 also employs a lead dioxide positive electrode 40 which preferably is a porous lead dioxide electrode. A porous lead dioxide layer 42 constitutes the active mass for the positive electrode.
A much preferred lead dioxide electrode and the method by which it is made are described in our concurrently filed patent application entitled "Method For Making Porous Lead Electrodes." That porous lead electrode preferably comprises a plastic grid 40 surrounded by a layer of nickel 45, having a thickness of about 5 microns and covered by coating 44 of lead having a thickness of about 200 microns and then covered with the porous lead dioxide layer 42. The plastic grid 46 is constructed of a synthetic plastic material such as polyethylene chloride, polypropylene or polyvinyl-chloride. Polyethylene chloride is the preferred grid material.
That electrode is preferably made by a process including the steps comprising providing a plastic or ceramic grid, coating the grid by a thin layer of nickel, such as a 5 micron layer which is covered by a thin layer of lead, such as 200 microns thick, molding a paste containing water and a halogenated lead compound, such as lead chloride, upon the lead layer, submerging the paste covered grid in an electrolyte solution in which an aluminum or magnesium electrode is also submerged, electrically reducing the halogenated lead compound to form a highly porous lead layer, and electrically oxidizing the porous lead layer in an aqueous hydrochloric acid solution to produce a porous lead dioxide electrode. The paste is preferably a mixture of powdered lead chloride and water, and is applied in a thickness of about 200 microns to occlude the metal-covered plastic grid holes.
Electrolyte 50 is dispersed in the case 20 between and in contact with the negative electrode 30 and the positive electrode 40. The electrodes are preferably immersed in the electrolyte. The upper ends of the electrodes extend out of the electrolyte and are either connected to electrical conduit terminals or are utilized as terminals themselves. The electrodes or the electric conduit terminals extend outwardly through the top of the case.
The electrolyte includes a porous and highly absorbent silica gel, the pores of which are infused with a liquid solution. It is preferred that the silica gel be sufficiently absorbent to allow the accumulator of the present invention to function in any position rather than being limited to operation in an upright position, as are accumulators containing a free electrolyte. Additionally, it is especially preferred that the silica gel be highly absorbent so as to be capable of absorbing any gases that might generate while the accumulator discharges or is charged with electricity. Preferably, the silica gel has a microgranulate structure and an active surface area in the range of about 600 to about 800 square meters per gram as measured by the Brunauer, Emmett Teller (B.E.T.) method.
A suitable silica gel may be the product of a chemical reaction between sodium silicate, also called water glass, and sulfuric acid. Alternatively, the silica gel may be produced by contacting a finely divided silicon dioxide with concentrated sulfuric acid. The silica gel may be also produced by the method described below, which furnishes a relatively high yield of silica gel having a microgranular structure as contrasted with methods which produce substantial amounts of particles that necessitate regrinding and subsequent chemical purification.
In the preferred method of making silica gel especially useful in the electrochemical cell of the present invention, a chemically pure solution of water-glass (Na 2 O n ·SiO 2 ) with a specific gravity of about 1.10 and a chemically pure solution of sulfuric acid having a specific gravity of about 1.20 are contacted in a proportion of about 100 to 15 parts by volume. The water-glass is poured onto the surface of the sulfuric acid while it is gently and continuously stirred in a glass vessel. A chemical reaction takes place between the water-glass and the sulfuric acid which produces water, sodium sulfate, and silica. Small particles of silica are produced in the aqueous solution and form a colloid.
The colloid is removed and placed on specially perforated dishes to hasten coagulation. The colloid is held at a temperature in the range of about 20° C. to about 25° C. for a period of about 24 hours during which the colloid, which had the appearance of a gelled mass, coagulates into a solid. The solid then is crushed between rollers to produce particles having a size distribution such that at least about 90% of the particles can pass through a 1 mm mesh sieve. The particles are maintained at a temperature of about 30° C. to 40° C., such as by infra-red lamps, with constant stirring until the particles of silica gel contain relatively little moisture.
The dried particles of silica gel are next treated with a 3 weight percent sulfuric acid solution and then washed with distilled water separately, as necessary, until essentially no sodium sulfate or sulfuric acid can be detected by conventional laboratory means in the wash water. The washed particles are separated from the wash water by filtration, preferably vacuum filtration, and dried again, as in ovens fitted with infra-red lamps, at a temperature of about 100° C. for a period of from about 6 to about 10 hours. After the second drying, the silica gel particles are placed in air-tight plastic or glass vessels until use.
During operation the silica gel is infused with an oversaturated solution of metallic sulphate in concentrated sulfuric acid. It is preferred that the solution be chemically oversaturated with the metallic sulphate. If the hermetically sealed dry accumulator of the present invention is operated with a liquid solution that contains less than a saturating amount of the metallic sulphate the cell will exhibit relatively shorter service life. The liquid solution is prepared by adding concentrated sulfuric acid to metal sulphate at 90° C. while stirring. The resulting slurry is then cooled to room temperature and the supernatant liquid is drawn and employed as electrolyte.
To assemble the hermetically sealed dry accumulator, the case is partially filled with silica gel so that the surfaces of the electrodes are below the surface of the silica gel bed. The surface of the silica gel bed is maintained about 5 mm below the top in relatively small accumulators.
The liquid electrolyte is then injected below the surface of the silica gel with a syringe and the case is filled from the bottom up smoothly displacing air from the bead without agitating the silica gel until the surface of the bed begins to look wet, at which time the silica gel is suitably thoroughly wetted and at which time the silica gel is suitably thoroughly wetted and saturated. The case is left in this condition for about 6-12 hours to equilibrate. After essentially all of the air in the silica gel has been-displaced and the chemical reaction has ceased, the case may be hermetically sealed.
Prior to placing the hermetically sealed dry accumulator in operation, the accumulator is charged by a external surface of current.
Each of the selected metals and the associated metallic sulphate will produce a different voltage in a hermetically sealed dry accumulator as shown in Table 1. The tabulated voltages may be used as a guide in selecting electrode material combinations appropriate for a particular application.
TABLE 1______________________________________Negative PositiveElectrode Electrode Electrolyte ElectromotiveMaterial Material Solution Force (Volts)______________________________________Copper Lead dioxide Copper sulfate 1.5 and sulfuric acidCadmium Lead dioxide Cadmium sulphate 2.2-2.4 and sulfuric acidNickel Lead dioxide Nickel sulphate 1.6-1.7 and sulfuric acidZinc Lead dioxide Zinc sulphate 2.4-2.5 and sulfuric acidIron Lead dioxide Iron sulphate about 1.0 and sulfuric acid______________________________________
FIG. 6 is an exploded view of an accumulator 60 made in accordance with the present invention having a cylindrical case 62 that encloses a negative electrode formed by five copper plates 64 which are electrically connected. The case 62 is about 60 mm long and about 30 mm in diameter. The plates 64 are composed of solid copper foil having a thickness in the range of about 0.2 mm and are shaped generally as rectangles, about 45 mm long and 20 mm wide.
Preferably, the plates 64 are supported at their edges by the case 62 and are held approximately parallel about 6 mm from each other.
The plates 64 have a plurality of holes, each having a diameter of about 2 mm, so as to facilitate movement of particles and fluids within the case 62. The holes may be formed by a punching method.
Each of the plates 64 comprising the negative electrode is generally rectangular and has a bendable, integral extension 63. The extensions are threaded through apertures made in the lower washer 66 which is disposed across one end of the case 62, are bent into proximity with each other on one side of the lower washer 66, and are soldered together, so as to electrically join all five of the plates 64. A lower cap 70, constructed of or coated by an electrically conducting material and provided with sealing means 68 contacts the soldered extensions 63 of the plates 64 and mates with the case 62 to create a hermetic seal.
Between the plates 64 are disposed four gratings 72 which are electrically connected to act as a single positive electrode. The grating 72 is generally rectangular and has a rigid integral extension 73, suitable for making electrical contact. The grating 72 may define rectangular apertures having a width of about 5 mm and a length of about 19 mm. Each grating 72 includes a plastic frame covered by a thin layer of nickel, coated by a thin layer of lead which is surrounded by a porous lead dioxide layer. The layer of nickel and is preferably, about 5 microns in thickness and the thin layer of lead is about 200 microns in thickness.
A bed of silica gel 74 thoroughly wetted with an electrolyte and, preferably, made in accordance with the process described herein is disposed around and between the plates 64 and gratings 72. The silica gel 74 covers substantially all of the rectangular portion of the plates 64 and gratings 72.
An upper washer 76 extends across one end of the case 62 and retains the silica gel 74 in proximity with the plates 64 and the gratings 72. Extensions 73 of the gratings 72 pass through apertures defined by the upper washer 76 and are joined to conductive soldering bridges (78 and 80). The bridges are in physical contact with an electrically conductive insert 82 which is press-fitted into and extends through an aperture in an upper cap 84 and may be provided with sealing means, such as an O-ring. The cap 84 fits across and hermetically seals the upper end of the case 62.
It will be apparent to those skilled in the art from the foregoing that modifications may be made in the embodiments described without departing from the spirit and scope of the invention. Accordingly, the invention is not intended to be limited except as may be necessary in light of the following claims.
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The invention is related to hermetically sealed dry accumulators having significantly larger power output per units of mass in a proportionately smaller volume. The accumulator includes one electrode comprising copper, cadmium, zinc, nickel, or iron, and another electrode of lead dioxide. An immobilized electrolyte containing a silica gel and sulfuric acid is in contact with the electrodes. A method for producing a novel silica gel which is especially suited for use in the immobilized electrolyte is also described.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for producing superconducting thick films, and more particularly, to a method for producing a superconducting thick film used, for example, for a dielectric resonator.
2. Description of the Related Art
Because of the recent rapid propagation of mobile communication, a shortage of radio-wave frequencies used for communication is anticipated in the near future. Therefore, in order to effectively use the limited frequencies, the development of a microwave filter used in base stations, having low loss and steep attenuation characteristics, has been desired. As such a filter, for example, a dielectric resonator is used. An example of such a dielectric resonator is a TE 011 -mode dielectric resonator as shown in FIG. 1. The dielectric resonator 10 includes a copper plate 12. A dielectric 14 is placed on the copper plate 12. A substrate 18 provided with a superconducting film 16 is further placed on the dielectric 14. Therefore, the dielectric 14 is sandwiched between the copper plate 12 and the superconducting film 16. Excitation cables 20 and 22 are disposed so as to be opposed to each other on both sides of the dielectric 14 between the copper plate 12 and the superconducting film 16.
Another example is a TM 010 -mode dielectric resonator as shown in FIG. 2. A dielectric resonator 10 includes a dielectric substrate 30 and superconducting films 32 and 34 formed on both sides of the dielectric substrate 30. The dielectric substrate 30 is fixed within a metallic case 38 with a Teflon sheet 36 therebetween. The metallic case 38 is provided with an excitation cable 40 on one end and an excitation cable 42 on another end.
Such a dielectric resonator 10 uses a phenomenon in which an electromagnetic wavelength is shortened to 1/(εr) 1/2 (where εr is the relative dielectric constant) in the dielectric in comparison with that in free-space, and is used in various resonant modes such as a TE mode, TM mode or TEM mode. In such a dielectric resonator 10, its unloaded Q (Qu) depends on both dielectric Q (Qd=1/tan δ) and Q (Qc) due to conductor loss resulting from an electric current on the surface of the metal, and Qu is expressed by the following equation:
1/Qu=(1/Qd)+(1/Qc)
Thus, in order to obtain a resonator having high unloaded Q (Qu), a dielectric material having high Qd as well as electrodes having high Qc, i.e., a low conductor loss, must be used. Accordingly, as shown in FIG. 1 or FIG. 2, superconducting films 18, 32 and 34, having smaller surface resistance than that of a conductive metal such as copper, are used, whereby conductor loss can be reduced. with respect to such superconducting films 18, 32 and 34, various investigations and developments have been made mainly on yttrium-based thin films.
However, in view of implementing the industrial use in the case of thin films, production costs are significantly high, and it is difficult to form thin films having large areas. On the other hand, in the case of thick films formed by screen-printing or the like, although production costs are significantly low in comparison with the thin film process and it is easy to form large areas, the surface resistance is large because the surface state and the grain orientation of thick films are inferior to thin films. In particular, with respect to a Bi-based 2223 phase which has a high critical temperature Tc (110° K) among oxide high temperature superconductors and the implementation of use of which is expected, the surface state deteriorates because flaky grains grow in a disorderly way, and improvement of the grain orientation and the surface state has been required.
SUMMARY OF THE INVENTION
To overcome the above described problems, preferred embodiments of the present invention provide a method for producing a superconducting thick film which has satisfactory grain orientation and surface state, and low surface resistance.
One preferred embodiment of the present invention provides a method for producing a superconducting thick film comprising the steps of: forming a thick layer comprising a superconducting material on a substrate; firing the thick layer formed on the substrate; subjecting the fired thick layer to cold isostatic pressing; and refiring the thick layer subjected to cold isostatic pressing.
The above described method may further comprise the step of repeating at least once the steps of subjecting the thick layer to cold isostatic pressing and of firing the thick layer after the step of refiring the thick layer is ended.
Preferably, the cold isostatic pressing is performed while a sheet having a release agent is placed between the thick layer and a jig plate in associated with the thick layer.
Preferably, the thick layer is a Bi-based 2223 phase.
In the above described method, the substrate may be a dielectric substrate. In this case, the substrate may be a dielectric substrate selected from the group consisting of an MgO substrate, a Ba(Sn, Mg, Ta)O 3 -based substrate, and a Ba(Mg, Sb, Ta)O 3 -based substrate. Alternatively, the substrate may be an Ag substrate.
By cold isostatic pressing, uniform pressure is applied to the substrate and to the surface of the thick film. By performing such cold isostatic pressing and firing, the surface roughness of the thick film is significantly improved, resulting in satisfactory surface state and grain orientation. Particularly in a superconducting thick film of the Bi-based 2223 phase, a satisfactory surface state is obtained.
In a TE 011 -mode dielectric resonator, a dielectric is sandwiched between electrodes and in such a case, a silver substrate or a dielectric substrate may be used as the substrate for forming a superconducting thick film used as an electrode.
When both surfaces of the dielectric must be provided with a superconducting thick film, as in a TM 010 -mode dielectric resonator, a dielectric substrate is used as a substrate.
When a dielectric substrate is used as the substrate, the dielectric substrate is preferably selected from the group consisting of an Mgo substrate, a Ba(Sn, Mg, Ta)O 3 -based substrate and a Ba(Mg, Sb, Ta)O 3 -based substrate.
Other features and advantages of the present invention will become apparent from the following description of the invention which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing a conventional TE 011 -mode dielectric resonator.
FIG. 2 is a schematic diagram showing a conventional TM 010 -mode dielectric resonator.
FIG. 3 is a schematic diagram which shows steps in a method for producing superconducting thick films in one preferred embodiment of the present invention.
FIG. 4 is a schematic diagram which shows steps when superconducting thick films are formed on both sides of a substrate.
FIG. 5 shows the surface of a thick film in sample No. 3 in Table 1.
FIG. 6 shows the surface of a thick film in sample No. 6 in Table 1.
FIG. 7 shows a sectional view of a thick film in sample No. 3 in Table 1.
FIG. 8 shows a sectional view of a thick film in sample No. 6 in Table 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to obtain a superconducting thick film, superconducting material powder is prepared. The superconducting material powder and an organic vehicle are mixed. The resultant mixture is adjusted so as to have an appropriate viscosity and a thick film is formed on a substrate by screen-printing or the like. The resultant thick film is dried in an oven, organic components are removed, and then the substrate provided with the thick film is fired. There are no specific conditions with respect to the powder or vehicle or firing atmosphere. For example, firing may be performed in the air or in a mixed gases having different oxygen partial pressure.
After the substrate provided with the thick film is fired, cold isostatic pressing (CIP) is performed. Subsequent to CIP, the substrate provided with the thick film is fired again. After repeated CIP and firing, a superconducting thick film is formed. The pressure of CIP is preferably about 1,000 (kg/cm 2 ) or more. Additionally, after the superconducting material is screen-printed on the substrate, if CIP is performed before firing, film density is of course improved.
The reason for selecting CIP instead of general pressing as the pressing method is that uniform pressure is applied entirely and damage to the substrate or the superconducting thick film can be prevented during pressing. In particular, when a dielectric substrate is used as a substrate, cracking may occur on the substrate during pressing, resulting in a serious problem, and thus the advantage of CIP is obvious.
When a superconducting thick film used for a TE 011 -mode dielectric resonator as shown in FIG. 1 is produced, as shown in FIG. 3, a thick film 52 is formed on a substrate 50, a jig plate 54 is placed on the thick film 52, and the thick film 52 is sandwiched between the substrate 50 and the jig plate 54. They are then vacuum sealed in a rubber case, a vinyl bag, or the like, and CIP is performed. Although any material such as a metal, resin, or ceramic may be used as the jig plate 54, preferably the surface thereof is mirror finished. Additionally, as shown in FIG. 1, if a sheet 56 a release agent is sandwiched between the jig plate 54 and the thick film 52, damage to the superconducting film can be reduced. As the substrate 50, an Ag substrate or dielectric substrate may be used.
In the case of a superconducting thick film used for a TM 010 -mode dielectric resonator as shown in FIG. 2, as shown in FIG. 4, thick films 52 are formed on both sides of a substrate 50, and jig plates 54 are placed on both thick films 52 with sheets 56 therebetween. In such a state, the substrate 50 provided with thick films 52 is pressed by CIP. A dielectric substrate must be used in such a case, as the substrate 50, and for example, a dielectric substrate selected from the group consisting of an MgO substrate, a Ba(Sn, Mg, Ta)O 3 -based substrate, and a Ba(Mg, Sb, Ta)O 3 -based substrate is used.
In the method described above, the surface roughness of a superconducting thick film is significantly improved by repeating CIP and firing, and consequently, the surface resistance is also decreased. Therefore, by using a superconducting thick film formed by such a method for a dielectric resonator, a resonator having high unloaded Q can be obtained.
EXAMPLE
Powder having a composition of a Bi-based 2223 phase and an organic vehicle were mixed, and the resultant mixture was adjusted so as to have an appropriate viscosity, and then was screen-printed on an MgO ceramic substrate to obtain a thick film. The resultant thick film was dried in an oven at 100 to 150° C., and organic components were removed at 300 to 400° C., and then firing was performed at 840 to 860° C. After the substrate provided with the thick film was fired, in the method shown in FIG. 3, CIP was performed at a pressure of 2,000 kg/cm 2 . The substrate provided with the thick film was then fired again under the conditions described above. Such CIP and firing were repeated again in some instances. In such a method, a plurality of thick films were formed under different conditions of firing and pressing shown in Table 1. In Table 1, sample Nos. 1 to 3 are out of the range of the present invention, and sample Nos. 4 to 7 are within the range of the present invention.
TABLE 1__________________________________________________________________________Sample No. 1 2 3 4 5 6 7__________________________________________________________________________Firing temperature (° C.) 850 850 850 850 850 850 850First firing time (hour) 100 200 250 50 50 50 50From second onward firing time 0 0 0 50 × 1 50 × 2 50 × 3 150 × 1(hour)Cycle(times) 0 0 0 1 2 3 1Surface roughness Ra(μm) 0.8 0.9 0.9 0.6 0.4 0.4 0.5Surface resistance Rs(20 K) (mΩ) 6.1 5.7 6.0 3.5 1.1 1.0 3.1Surface resistance Rs(70 K) (mΩ) 57.8 13.4 14.5 50.1 6.1 5.6 8.6__________________________________________________________________________
In Table 1, "First firing time" indicates firing time in which firing was performed for the first time after a thick film had been formed on a substrate by screen-printing. "From second onward firing time" indicates firing time in which firing was performed again after first firing and first pressing had been performed. Herein, from second onward firing time as well as the number of firings are shown. "Cycle" indicates the number of cycles, where each cycle consists of a pressing step and a firing step. Therefore, the number of firings in the "from second onward firing time" agrees with the value in the "Cycle" row. "Surface resistance" indicates the surface resistance of a thick film formed, and the surface resistances at absolute temperatures of 20° K and 70° K are shown.
The measurement of the surface resistance was carried out by a dielectric resonator method (Hakki & Colemann) using a dielectric resonator having a structure shown in FIG. 1. The dielectric resonator method is generally used as a method for evaluating dielectric characteristics of a dielectric material within the microwave band, and also as a method for measuring surface resistance of a superconductor. In FIG. 1, the dielectric 14 is composed of a Ba(Sn, Mg, Ta)O 3 -based material, and in the measuring temperature region, the relative dielectric constant εr and the dielectric loss tangent tan δ thereof are already known. The dielectric 14 has a diameter of 8.5 mm, a thickness of 3.8 mm, and a resonant frequency f o of 10.7 GHz.
With respect to thick films formed under the conditions of sample Nos. 3 and 6, FIGS. 3 and 4 show the surface states of the thick films formed and FIGS. 5 and 6 are sectional views of the thick films formed. As is obvious from Table 1, with respect to the thick film of sample No. 3, first firing only was performed at a temperature of 850° C. for 250 hours. With respect to the thick film of sample No. 6, first firing was performed at a temperature of 850° C. for 50 hours, and then, three cycles were performed, each cycle consisting of firing at 850° C. for 50 hours and CIP at a pressure of 2,000 kg/cm 2 .
As is clear from Table 1, in sample Nos. 1 to 3 (in which CIP was not performed), the resultant thick films have large surface roughness Ra and also have large values of surface resistance Rs. In contrast, in sample Nos. 4 to 7 (in which CIP was performed), the surface roughness Ra of the resultant thick films is decreased, and the values of surface resistance Rs are also decreased. With respect to the thick film of sample No. 4 in which one cycle of CIP and firing was performed, although the surface resistance Rs at an absolute temperature of 70° K has a large value, the surface resistance Rs at an absolute temperature of 20° K has a smaller value than that of thick films of sample Nos. 1 to 3. With respect to the thick films of sample Nos. 5 and 6 in which a plurality of cycles of CIP and firing were performed, the surface roughness Ra is decreased and the surface resistance Rs is also decreased in comparison with thick films of sample Nos. 4 and 7 in which only one cycle was performed.
From FIGS. 3 to 6, it is also clear that the surface state of sample No. 6 is better than that of sample 3. As described above, by repeating CIP and firing a plurality of times, the surface state and the grain orientation of a superconducting thick film are improved, enabling reduction in surface resistance.
In accordance with the present invention, by forming a thick film composed of a superconducting material on a substrate, and after firing, by performing cold isostatic pressing (CIP) and firing, a satisfactory surface state of the thick film can be achieved and surface resistance can be reduced. Therefore, if a superconducting thick film obtained as described above is used for a dielectric resonator, a resonator having a large unloaded Q can be obtained. Additionally, since the thick film can be formed by screen-printing or the like, there will be no difficulties which might occur in a thin film formation, and production costs are low, and also, large areas can be formed easily.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the forgoing and other changes in form and details may be made therein without departing from the spirit of the invention.
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A method for producing a superconducting thick film involves the steps of forming a thick layer comprising a superconducting material on a substrate; firing the thick layer formed on the substrate; subjecting the fired thick layer to cold isostatic pressing; and refiring the thick layer subjected to cold isostatic pressing.
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FIELD OF THE INVENTION
This invention relates to a method and apparatus for manipulating and sewing flexible fabric panels, and more particularly to a method and apparatus for sewing flange material to the edges of panels of mattress sacks.
BACKGROUND OF THE INVENTION
Mattresses typically include an inner construction covered by a mattress sack. The mattress sack generally includes top and bottom panels which are interconnected by side panels. The sack usually is secured to the inner construction by a flange which is secured to the periphery of one of the top and bottom panels and which is connected to the inner construction using hog rings or the like. The inner construction typically includes springs of known configurations. The top and bottom panels may be sewn directly to the side panel, or joined with border tape or the like.
The flange material is usually affixed to the edges of a top or bottom panel at the same time as the edges of the panel are cut and stitched. This process utilizes a sewing machine adjacent a table upon which the mattress panel rests. While in the past, this process was primarily a manual operation, efforts have been made in more recent times to automate this process. Early attempts held the mattress panel stationary while propelling the sewing machine around the circumference of the mattress panel. More recent efforts in this regard have held the sewing machine stationary while manipulating the mattress panel on an air table. Examples of such apparatus are found in U.S. Pat. Nos. 5,529,004 (assigned to the Assignee of the present application), Publication No. W095/25194 (assigned to the Assignee of the present application), U.S. Pat. No. 5,560,308 and U.S. Pat. No. 5,367,968.
Problems encountered in all of these systems, and partially solved in some of the foregoing patents, include proper alignment of the edge of the mattress panel with the sewing needle, and proper rotation of the mattress panel around a corner to produce a rounded, evenly cut corner with the desired radius and stitching, and proper alignment of the flange material.
It is highly desirable to automate as much of the process as possible and to minimize the amount of manual labor required for sewing the mattress panels. Automation saves labor costs and minimizes injury to workers, produces a higher level of accuracy and provides reproducibility to render a more uniform look to the finished product.
Despite efforts to improve accuracy and to minimize worker participation, there is still room for improvement in both areas. In particular, some of the foregoing existing apparatus still require manual guidance of the sewn edge of the panel as it passes through the sewing machine, particularly at the end of the sewing cycle. In addition, the foregoing existing apparatus still require that the panel be manually removed from the table or sewing area at the end of the stitching cycle.
Therefore, it is one object of the present invention to more fully automate the process of stitching the edges of a mattress panel and attaching the flange.
It is another object of the present invention to further increase the accuracy and reproducibility of the stitching of the edges of the top and bottom panels of a mattress sack, and the attachment of the flange.
SUMMARY OF THE INVENTION
These and other objects are achieved in accordance with the present invention which relates to a method and apparatus for manipulating and sewing edges of fabric panels, such as the top or bottom panel of a mattress sack. This invention also relates to a method and apparatus for attaching a flange to the edges of a mattress panel. A conventional sewing machine and a conventional air table for supporting the fabric panel are employed.
One aspect of this invention is an improved edge guide which not only aligns and guides the edge of the panel as it is fed to the sewing machine, but also assists in preventing the panel from bunching up or folding over or expanding along the edge to prevent it from being too thick to be fed through the sewing mechanism of the sewing machine and to permit accurate location of the trailing edge. The edge guide includes top and bottom plates. The top plate drops down until it engages the top surface of the panel, and then backs off a predetermined distance to allow smooth feeding of the panel through the edge guide to the sewing apparatus. This operation also provides information to the controller on the vertical thickness of the panel. The edge guide also includes sensors that trigger the slow-down of the sewing machine and rotation of the panel about a corner.
In another aspect of the invention, a wheel is provided which drops down and engages the panel as the final edge is being sewn. The wheel can either be an idler wheel which freely rotates or it can be driven. If an idler wheel is provided, the wheel is disposed so that it rotates in a direction parallel to the feed direction about an axis perpendicular to the feed direction. In one embodiment, as the sewing machine is backed away from the panel along the final edge, the idler wheel prevents the panel from being pulled along with the machine in a direction transverse to the feed direction. In another embodiment, the wheel may be powered and disposed at a slight angle with respect to the feed direction to push the panel away from the sewing machine along the final edge of the panel.
In yet another aspect of the invention, apparatus is provided to remove the panel from the table after the sewing operation is completed. This apparatus includes an arm which is oriented generally parallel to the feed direction and which includes a plurality of wheels rotating about an axis generally parallel to the feed direction. When the wheels are pivoted into position so that they engage a fabric panel, the fabric panel is driven in a direction generally transverse of the feed direction off the table.
In a further aspect of the invention, an edge flattener is provided which is driven by a servo motor at varying speeds. The speed of the edge flattener is increased as the panel is rotated around a corner to feed the top layer faster at the corner to prevent bunching. Moreover, the desired rotation rate of the flattener can be set by the operator to produce optimal feed and flattening.
In another further aspect of the invention, when the apparatus of this invention is used to attach a flange to the edge of a top or bottom panel of a mattress sack, a flange guidance system is provided on a dolly which supports the sewing machine and which is movable with the sewing machine toward and away from the sewing table. A reel of the flange material is rotatably mounted the dolly. The flange material extends from the roll upwardly through a flange guide and out a slot at the top of the guide to be precisely aligned so that an outside edge of the flange material is disposed between the sewing needle and the edge cutter on the sewing machine. Moreover, since the flange material and guide are mounted on the moveable dolly carrying the sewing machine, as the final edge of a panel is sewn and the sewing machine is retracted away from the table, the flange material also is retracted from the panel. A cutting wheel mounted on a pneumatically actuated arm cuts the flange material and sewing threads after completion of the sewing process.
Another aspect of the present invention includes an elongated sled utilized to pull the panel through the sewing zone of the sewing machine. This sled extends generally transversely of the feed direction of the panel and is sufficiently long to extend substantially across the width of the panel being pulled. The sled includes at least two clamps for grasping a forward edge of the panel at two different points. A slip clutch allows the sled to maintain tension on the panel without ripping the panel, and without pulling the panel through the sewing zone faster than the feed mechanism of the sewing machine will allow.
In accordance with the forgoing apparatus, an improved method is also disclosed for sewing flange material to the top or bottom panel of a mattress sack and for sewing and cutting the edge of the panel. In this improved method, operator participation is minimized. The operator manually places a panel onto the table so that a forward edge is adjacent the clamps of the sled in its home position and so that a side edge is aligned with the edge guide. The automatic process is then commenced by the pressing of a button or the like. Both sled clamps close and the sled pulls the panel to a position in which the sewing head is a predetermined distance from the first corner. The edge guide measures the panel thickness and then is backed away from the table and away from the panel, while the sewing head of the sewing machine is advanced towards the panel into a sew position. The clamp spaced farthest from the sewing machine then opens. The operator manually loads the panel into the sewing machine. Thereafter, automatic sewing is commenced by the activation of another button or the like on the control panel. The edge guide is then advanced toward the panel into the desired orientation, and the top plate of the edge guide drops down to its programmed spacing from the bottom plate. The sewing machine then stitches a predetermined distance, for example 6", to determine the stitch rate for this particular panel. Thereafter, the panel is sewn and cut until the corner is reached. Flange material is fed to the sewing machine and stitched to the panel edge. The panel is pivoted at the corner and stitched and cut while the panel is pivoted to produce a rounded corner.
After four edges are sewn and cut in a similar manner, the panel returns to its initial edge after it rounds the fourth corner. A wheel then drops down to engage the top surface of the panel. In one embodiment, the wheel is free-wheeling and rotates in a direction generally parallel to the feed direction about an axis perpendicular to the feed direction. As the start location is approached along the initial edge, the sewing machine backs away from the panel to taper the amount of material cut from the edge so as to blend the newly cut edge with the originally cut and sewn edge. In another embodiment, the wheel is angled with respect to the feed direction, and rotates at an angle away from the sewing machine. In this embodiment, the sewing machine remains stationary and the wheel begins pushing the panel away from the sewing machine until the panel is completely removed from the sewing machine at the start point. In either embodiment, the flange material stays aligned with the sewing machine and the sewing machine sews off onto the flange material. Thereafter, the flange material is cut and the panel is carried by the sleds to an unload point. The unload apparatus then propels the panel off the table.
The foregoing method and apparatus substantially fully automate the process of affixing flange material to a top or bottom panel of a mattress sack. In addition, a precisely and reproducibly cut and sewn edge is provided all the way around the perimeter of the panel. Rounded corners are also produced.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully appreciated from the following detailed description when taken in conjunction with the accompanying drawings, in which:
FIG. 1A is a top, perspective view of the apparatus of this invention;
FIG. 1B is a top, partially cutaway perspective view of the apparatus of FIG. 1A;
FIG. 1C is a side, schematic view of the sewing elements of the sewing machine of FIG. 1A;
FIG. 2 is a partial, side perspective view of the apparatus of FIG. 1A;
FIG. 3 is a partial, side perspective view illustrating the edge guide of the apparatus of FIG. 1A;
FIG. 4 is a partial, side perspective view illustrating one operating position of the edge guide of FIG. 3;
FIG. 5 is a partial, side perspective view illustrating another operating position of the edge guide of FIG. 3;
FIG. 6 is a partial, side perspective view illustrating the sled and driving system therefor of the apparatus of FIG. 1A;
FIG. 7 is a partial, side perspective view illustrating the flange cutter of the apparatus of FIG. 1A;
FIG. 8 is a top, schematic plan view of the apparatus of FIG. 1A illustrating an initial operating position;
FIG. 9 is a top, schematic plan view of the apparatus of FIG. 1A illustrating another operating position;
FIG. 10 is a top, schematic plan view of the apparatus of FIG. 1A illustrating rotation of the fabric panel;
FIG. 11 is a top, schematic plan view of the apparatus of FIG. 1A illustrating a further operating position; and
FIG. 12 is a top, schematic plan view of the apparatus of FIG. 1A illustrating a final operating position in which the fabric panel is removed from the apparatus.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a method and apparatus for manipulating and sewing a panel formed of a flexible material, such as a top panel or bottom panel of a mattress sack. This method and apparatus may also be used to attach a flange to the edges of a mattress panel. This invention permits a high level of automated manipulating and sewing and minimizes the need for human intervention. This system includes improvements to that described in publication WO 95/25194, and U.S. application Ser. No. 08/656,345, assigned to the Assignee of the present application, each of which is specifically incorporated herein by reference.
One embodiment of the method and apparatus of the present invention will now be described with particular reference to FIGS. 1A-1C. Apparatus 10 includes sewing machine 20, pivot arm 30, sled 40, edge guide 50, edge flattener 60, cutter 70 (FIG. 7), wheel 80, dolly 120 and flange guidance system 150. Fabric panels 100 (FIG. 8) or the like are supported by and manipulated on a work table 110 such as a conventional air table which includes a plurality of small holes 111 through which compressed air is forced.
The operation of all of the components of apparatus 10 is controlled by controller 90 which is a programmable microprocessor or the like and is conventional in nature. Controller 90 sends appropriate signals to each of the components to perform their desired function at the desired time, and coordinates the supply of pneumatic pressure where required to allow components to perform desired operations. A typical example of controller 90 is a microprocessor sold by Control Technology Corp. Controller 90 includes either a central panel or a conventional touch screen 91.
Sewing machine 20 is conventional, and may be, for example, a machine such as the Porter 1000 or Porter 518, sold by Porter Sewing Machines, Inc. of Beverly, Mass. Sewing machine 20 includes the usual feed dogs and/or walking feet 21 for feeding a work piece to a conventional stitching needle or needles 22 in a feed direction identified in FIG. 1A by arrow 24. If two needles 22 are provided, one needle typically produces an overedge stitch while the other needle produces a chain stitch. The needle disposed most closely adjacent the outer edge of the fabric produces the overedge stitch. Machine 20 also includes a conventional edge cutter 25 for cutting a strip of material from the edge of a panel 100 (FIG. 8) as it is being sewn. A preferred sewing machine 20 includes a Wilcox and Gibbs-type cutter 25 which cuts material in the feed direction 24 as the material is being stitched and moved in feed direction 24. Cutter 25 moves up and down in synchronization with needles 22 of sewing machine 20. As such, cutter 25 permits cutting of the edges of the panel to provide rounded corners and smooth edges.
Sewing machine 20 is carried by a moveable dolly 120 which rides on rails 122 which are oriented in a direction generally perpendicular to the feed direction 24. Rails 122 rest on rollers 123. Dolly 120 is moved toward and away from table 110 in a direction generally perpendicular to the feed direction 24 by a drive such as a conventional screw drive 124 which is operated by a servo motor 126 and controlled by controller 90. Drive 124 may, for example, include a threaded screw shaft which rotates and extends through a mating, stationary threaded block (not shown) which is affixed to dolly 120. Typically, dolly 120 has a range of travel of about 6", although the range of travel could be any amount desired. Servo motor 126 locks dolly 120 into a desired position. The location of dolly 120 may be monitored by a conventional position sensor or shaft encoder (not shown).
Pivot arm 30 rotates a fabric panel 100 around a corner during the stitching operation. Arm 30 is pivoted by motor 31. Pivot arm 30 is raised and lowered by stepper motor 32 in response to commands received from controller 90. Arm 30 includes a generally horizontal beam 34, generally vertical post 36 and a connecting leg 38 which extends from the top of post 36 to beam 34. Disposed on the lower surface of beam 34 are projections 35 which preferably have pointed tips and are somewhat resilient. Rubber is a preferred material for projections 35, although other materials could be used which would not tear panels 100. Projections 35 are designed to engage the upper surface of a fabric panel 100 for rotation thereof. Pivot point 37 is disposed on the bottom end of post 36. Point 37 rests on a panel 100 on table 110 when lowered by motor 32 and provides a point about which arm 30 rotates. Point 37 is formed of the same material as projections 35. When rotating a panel 100, projections 35 and point 37 are spaced a small distance above table 110 to prevent damage to panel 100. Typically, projections 35 and point 37 are positioned one half the thickness of a panel above table 110. This distance was previously calculated by edge guide 50, as will be discussed.
Sled 40 includes an arm 42 that extends in a direction generally transverse to the feed direction 24. Mounted on arm 42 are at least two clamps 43 and 44. Clamp 43 is spaced from the sewing machine 20 downstream of or after the sewing machine 20 in the feed direction 24. Clamp 43 also is generally aligned with the sewing needles 22 in a direction transverse to the feed direction 24, although clamp 43 may also be offset from the sewing needles 22 toward clamp 44 in a direction transverse to the feed direction 24. Clamp 44 is spaced from clamp 43 in a direction transverse to the feed direction 24. Clamps 43 and 44 are spaced sufficiently to provide a stable pull on a panel 100 along a forward edge 102, yet are not spaced so far that clamp 44 is disposed beyond the other side edge 107 of a panel 100.
Clamps 43 and 44 are preferably the same and are preferably pneumatically actuated, although they need not be. Clamps 43 and 44 each include a lower plate 45 and an upper, pivotally mounted clamp arm 46. Each arm 46 is operated by an associated pneumatic cylinder 47. Plates 45 travel or slide along table 10 and are sufficiently thin that they each slide between a panel 100 and table 110, preferably without producing any movement of panel I 00. In operation, a signal from controller 90 actuates cylinder 47 to drive clamp arm 46 downwardly to clamp an edge of panel 100 between clamp arm 46 and lower plate 45.
Arm 42 and associated clamps 43 and 44 arc driven along table 10 by a drive system 121, as shown in FIG. 6. Drive system 121 may be any conventional belt drive and includes a belt 123 formed of a chain or a flexible rubber or plastic material which is affixed to arm 42 by fixture 125. Fixture 125 extends up through a slot 127 disposed on the surface of table 110. Belt 123 is driven by servo motor 129 which responds to signals received from controller 90. A slip clutch 131 is disposed in the drive train between motor 129 and belt 123. Slip clutch 130 may be, for example, a pneumatic pressure clutch which allows slippage of motor 128 with respect to belt 123 and provides an upper limit to the force applied to the forward edge 102 of fabric panel 100. Slip clutch 131 allows sled 40 to apply tension to panel 100 along edge 102 without tearing panel 100 or without overriding the feed mechanism of sewing machine 20. As a result, sled 40 moves only as fast as sewing machine 20 will allow. Typically, clutch 131 is coupled to motor 129 by a belt 133, although other known connections may be used. Preferably clutch 130 is connected to belt 123 by means of a pulley 137, although a gear chain or other known connections may be used.
A known shaft encoder 135 tracks the position of sled 40 in a known manner. Shaft encoder 135 is a slave shaft encoder coupled to the shaft of clutch 131, such as by a belt (not shown). The belt coupling the shaft encoder to the clutch 131 moves only when and as much as belt 123 and thus precisely tracks the location of sled 40.
Pneumatic lines (not shown) couple both cylinders 47 to a source of compressed air and extend along belt 122. Preferably, a known mechanism is provided for gathering the pneumatic lines and for providing a flexible casing for allowing the lines to pay out with movement of sled 40 and for preventing the pneumatic lines from becoming entangled in the sled. A typical mechanism is an articulated, semi-rigid chain through which the pneumatic lines pass. Such a chain is sold by Igus Company of Rhode Island under the trademark NYLATRAK.
Edge flattener 60 will now be described with reference to FIGS. 1A and 3. Flattener 60 is designed to flatten an edge of a panel 100 before the edge is sewn by sewing machine 20. Moreover, edge flattener 60 urges any protruding fill outwardly towards the edge of the panel. Edge flattener 60 is disposed prior to the sewing needles 22 in the feed direction 24. A preferred edge flattener includes a central shaft 67 and a helical ridge 62 disposed on the outer surface of shaft 67. Shaft 67 of flattener 60 is pivotally mounted and uses a spring mount 64 to absorb vibrations. A pneumatic cylinder 66 raises the flattener 60 upwardly off table 110 during loading of a panel 100. Alternatively, the cylinder 66 may be used to replace the spring mount by acting as an air spring. Flattener 60 is held against an upper surface of a panel 100 by mount 64 and/or cylinder 66. While shaft 67 of flattener 60 may be attached to the main drive shaft of the sewing machine 20 with a flexible drive (not shown) so that it may sychronously rotate with the sewing machine, preferably flattener 60 is rotated by a separate dedicated servo motor 68 controlled by controller 90. Flattener 60 is rotated about its central axis preferably in a direction counter to the feeding direction 24 of the materials. In other words, the bottom surface of flattener 60 engaging the top surface of panel 100 moves in a direction opposite of feed direction 24. Servo motor 68 allows the edge flattener to be rotated at a speed which varies under different operating conditions. This feature is particularly valuable when rotating a panel around its corner, since the speed of the edge flattener preferably is increased to accommodate a somewhat increased speed of movement of the sewing surface of panel 100 as the panel is being rotated to prevent the formation of radially extending wrinkles or an undulating surface at the corners.
Cutter 70 will now be described with particular reference to FIG. 7. Cutter 70 includes a wheel 71 rotatably mounted on the distal end of an arm 72 which is extended and retracted by a pneumatic cylinder 74. Wheel 71 includes a sharpened edge 76 around its perimeter which is adapted to cut fabric material. Edge 76 rides in recessed slot 77 on table 110 and on cutting surface 78 within slot 77. Cylinder 74 propels arm 72 and wheel 71 in a direction transverse to the feed direction 24 and is controlled by controller 90. Wheel 71 is typically used to automatically cut flange material and the sewing thread along trailing edge 104 of a fabric panel 100 after completion of a sewing operation attaching flange material to the edges of a fabric panel 100. FIG. 7 shows wheel 71 in its nested position adjacent cylinder 74. Upon completion of a sewing operation, and upon receiving a command from controller 90, arm 72 propels wheel 71 to the left as shown in FIG. 7 and returns it to nested position in FIG. 7 after completion of a cutting operation.
Wheel 80 will now be described with particular reference to FIG. 2. Wheel 80 is rotatably mounted at the end of an extensible arm 82. Arm 82 is pivotally mounted at its opposite end to a support structure 84. Arm 82 may be extended by operation of a pneumatic cylinder (not shown). Pivoting of arm 82 about support 84 is also accomplished through the use of a pneumatic cylinder (not shown). Both the pivoting of arm 82 and its extension are controlled by controller 90. Preferably, wheel 80 is an idler wheel, and is allowed to rotate freely about its central axis. Typically wheel 80 is actuated at the conclusion of a sewing operation on a panel and is pivoted downwardly at the same time as arm 82 is extended outwardly to place wheel 80 in contact with the top surface of a panel 100. Wheel 80 is designed to permit panel 100 to pass beneath it in the feed direction 24, and therefore is aligned such that it rotates freely about an axis that is generally transverse to the feed direction 24. Wheel 80 prevents panel 100 from moving in a direction transverse to the feed direction as sewing machine 20 is withdrawn from the edge 106 of panel 100, or away from table 110 during the final stages of a sewing operation, as will be described.
Alternatively, wheel 80 may be coupled to a servo motor (not shown) and positively driven. If positively driven, wheel 80 is disposed such that its axis of rotation forms an acute angle with respect to a line transverse to the feed direction 24. In this configuration, when wheel 80 is rotated wheel 80 pushes panel 100 generally in feed direction 24 but away from sewing machine 20 at an acute angle with respect to the feed direction. This feature allows panel 100 to be pushed away from the sewing machine while the sewing machine remains stationary with respect to table 110 at the end of a sewing operation, thus also allowing the panel to be completed without continuing to cut the panel edge beyond the starting point of the sewing operation.
Edge guide 50 will now be described with particular reference to FIGS. 3, 4 and 5. Edge guide 50 serves three functions. First, edge guide 50 provides guidance to the inside edge 106 of a panel 100 being sewn to properly align it with sewing machine 20. The second function is to sense the position of the trailing edge 104 of a panel 100. The third function is to determine the thickness of the panel and to prevent the panel from rising up off the surface of table 110 or folding over onto itself prior to sewing. Such a folded or rising panel could impede the sewing process, provide an undesirable stitch, or cause an inaccurate determination of the location of trailing edge 104 of panel 100.
Edge guide 50 includes an upper plate 52 having a generally horizontal lower surface, a lower plate 53 having a generally horizontal upper surface parallel to the lower surface of plate 52 and a generally vertical back registration plate surface 51 which is perpendicular to the lower surface of plate 52 and the upper surface of 53. The edge of plate 52 facing away from sewing machine 20 in the feed direction 24 is generally curved upwardly away from plate 53 to facilitate the advance of a panel 100 between plates 52 and 53.
Edge guide 50 also includes sensors 56 and 57. Sensors 56 and 57 detect the location of trailing edge 104. In a preferred embodiment, sensors 56 and 57 are each conventional diffused infrared sensors which emit infrared radiation from a dedicated emitter portion and receive reflected infrared radiation at a receiver portion. If a panel 100 is present, sensors 56 and 57 are covered by panel 100 and infrared radiation emitted by the emitter is reflected by the panel back to the receiver. If the panel does not cover the emitter, the infrared radiation escapes through openings 59 in plate 52 and is not returned to the receiver. A low intensity beam is preferred to provide a finer beam width to give a more accurate reading of the position of edge 104 since a low intensity beam is relatively unaffected by panel thickness. As trailing edge 104 passes sensor 57, no infrared radiation strikes sensor 57, controller 90 is signaled accordingly, and the speed of sewing machine 20 is reduced. As the trailing edge 104 passes sensor 56, the sewing machine stops, and the controller initiates the process of rotating panel 100 about a corner, which will be discussed in more detail hereinafter. Sensors 56 and 57 could also be conventional photocells which are receptive to light of other wavelengths, and which are designed to detect the absence or presence of light or the interruption of light.
Lower plate 53 preferably is vertically stationary, while upper plate 52 is movable vertically, or in a direction generally perpendicular to plate 53 toward and away from plate 53 by a servo motor 54. It is to be understood, however, that upper plate 52 could be stationary while lower plate 53 is movable in a direction perpendicular to upper plate 52, or that both plates 52 and 53 could be moveable with respect to one another in a direction generally perpendicular to their horizontal extent. Motor 54 rotates shaft 61 and includes a shaft encoder 192, or any other sensor capable of measuring the spacing between the lower surface of plate 52 and the upper surface of plate 53. One end of shaft 61 is attached to the rotor of motor 54 while the other end is rotatably mounted in non-rotating support 63 for upper plate 52. Preferably, nonrotatable support rods 65 are disposed on either side of shaft 61 to provide stability to support 63 and to provide smooth vertical movement of upper plate 52. Edge (guide 50 is mounted on horizontal rails 174 which allow a motor 176 with a conventional screw drive to move edge guide 50 toward and away from table 110.
Extending downwardly from generally horizontal support 63 are two generally vertical support posts 163. Extending outwardly away from each support post 163 and overlying upper plate 52 is a support arm 165. Each support arm 165 is coupled to plate 52 by a connector 167 which may be screw, rivet, bolt or the like. Disposed between the lower surface of each support arm 165 and an upper surface of plate 52 is a spring 169, or some other similar sort of biasing system. Typically, springs 169 are disposed about connectors 167. Springs 169 preferably are helical compression springs, foam, or the like. Disposed on a cross-support 171 which extends between posts 163 is a plate 173 upon which is mounted a proximity sensor 175. Disposed directly below sensor 175 on an upper surface of plate 52 is a pad 177. Sensor 175 is programmed to send a signal to controller 90 when it gets within a predetermined distance from pad 177, typically 1 to 1.5 mm.
In operation, as a panel 100 passes through edge (guide 50, the inner edge 106 of panel 100 is aligned in registration with back registration plate surface 51. Initially, controller 90 moves upper plate 52 downwardly toward the upper surface of panel 100 until the bottom of plate 52 encounters the upper surface of panel 100. Any further advance of plate 52 compresses springs 169 until proximity sensor 175 detects the presence of pad 177. Upon detection of pad 177, controller 90 backs upper plate 52 away form lower plate 53 a predetermined distance, such as 1/8 to 1/4", to prevent plates 52 and 53 from providing an undesirable drag on the movement of panel 100. During this process, controller 90 measures the thickness of the panel 100. This measurement, and the movement of upper plate 52 away loom lower plate 53 is monitored and controlled by the shaft encoder 192. Plates 52 away 53 prevent a panel 100 from expanding vertically, or folding over onto itself which could foul the sewing process and also which could provide an inaccurate measurement of the position of the trailing edge 104 of the panel. Vertical expansion of the panel would shorten the length of panel 100 accordingly and could also unduly reflect infrared light back to sensor 56 or 57 after edge 104 had already passed. If properly flattened along edge 106, the position of trailing edge 104 is properly determined and the panel is smoothed out in preparation for sewing.
Flange guidance system 150 will now be described with particular reference to FIGS. 1A and 1B. System 150 includes a rotatable reel 152 which carries flange material 154 on a roll. Reel 152 is mounted on an axle 156 on dolly 120, and moves with dolly 120 toward and away from table 110. Reel 152 rotates about axle 156, or axle 156 is journalled at its ends in dolly 120. Axle 156 is oriented in a direction generally perpendicular to feed direction 24. System 150 includes a feed passage 158 which extends front adjacent reel 152 and to a slot 160 in a surface 163 parallel to table 110 and inserted into a recess in table 110. Surface 163 is mounted onto dolly 120. Slot 160 is disposed between edge guide 50 and sewing machine 20. Passage 158 and slot 160 are sufficiently wide to accommodate and guide typical flange material used in conjunction with a mattress panel. The outside edge of passage 158 and slot 160 facing away from table 110 is oriented such that an edge of flange material 154 exiting slot 160 in registration with the outer edge of slot 160 will pass through the sewing, machine 20 in precisely the desired location. Preferably, the outer edge of the flange material 154 passes between edge cutter 25 and needles 22 of the sewing machine 20 so that the flange material is sewn to the panel 100, but is not cut by cutter 25 during the sewing operation. As a result, after the cutting operation has been completed, the outer edge of the flange material 154 is roughly aligned with the cut edge of the finished panel 100. As dolly 120 is backed away from table 110, as will be described, the flange material 154 travels with dolly 120 to remain properly aligned at all lines with needles 22 and cutter 25 at the completion of the sewing operation. When withdrawn, sewing machine 20 sews off onto flange material 154, and cutter 70 cuts both the material 154 and the sewing threads.
Unload apparatus 130 will now be described with reference to FIG. 8. Apparatus 130 is mounted on table 110 at a position downstream or beyond sewing machine 20 in feed direction 24 and is also preferably, although not necessarily, spaced from sewing machine 20 in a direction perpendicular to the feed direction 24. Ideally, apparatus 130 is disposed such that after panel 100 is completely sewn and is pulled by sled 40 to a position where trailing edge 104 is roughly aligned with sewing machine 20, an outer edge 107 opposite inner edge 106 is disposed beneath apparatus 130.
Apparatus 130 includes a support arm 132 which preferably extends in a direction generally parallel to the feed direction 24. Arm 132 carries a plurality of wheels 134 which rotate about an axle 136 which typically extends generally parallel to the feed direction 24. Wheels 134 are driven by belts 138 which in turn are driven by motor 140. Arm 130 is spaced above table 110 a distance sufficient to allow a panel 100 to pass between arm 130 and table 110. Arm 130 is supported in this position by mount 142. Arm 130 typically is rotatably mounted in mount 142 such that arm 130 may pivot about an axis which extends along its direction of elongation in the feed direction 24 to either raise wheels 134 off table 110 or to rotate them downwardly toward table 110 and into engagement with an upper surface of panel 100. This rotation is controlled by a pneumatic cylinder 144 which in turn is controlled by controller 90.
In operation, at the appropriate time, cylinder 144 pivots arm 130 such that wheels 134 are urged downwardly into engagement with an upper surface of panel 100 when the panel has been fully sewn. At this point, wheels 134 are rotated in such a manner as to push panel 100 in a direction perpendicular to feed direction 24 off table 110 and away from sewing machine 20, as shown in FIG. 14.
A photocell sensor 190 (FIG. 12) or the like is positioned on table 110 at a predetermined distance from sewing machine 20 upstream thereof or before sewing machine 20 in the feed direction 24. A typical predetermined distance is 14". Sensor 190 detects when the trailing edge 104 of panel 100 passes and alerts controller 90, for reasons to be discussed. Sensor 190 typically is aligned with sensors 56 and 57 in a direction transverse to feed direction 24 but is spaced upstream of sensors 56 and 57 in the feed direction 24.
The operation of apparatus 10 and the method of this invention will now be described with particular reference to FIGS. 8-12.
The process is initiated by the manual placement of a panel 100 on table 110. At this point, the edge guide 50 is advanced toward table 110 in its normal sewing position and plates 52 and 53 are separated. Also, at this point, sled 40 is in its programmed home position, or in its position that is normally closest to sewing machine 20 in the feed direction 24, but downstream thereof as shown in FIG. 8. Clamps 43 and 44 are in their open position. Flange material 154 is either already present and properly aligned in sewing machine 20, or the operator has pulled a leading edge of the material off reel 152 and through passage 158. The operator places edge 106 of panel 100 in registration with edge 51 and edge 102 is aligned with clamps 43 and 44. The operator then activates a button, or a location on a touch screen. This initial button or location on a touch screen is called a "panel advance" button. Controller 90 responds by closing both clamps 43 and 44 to grasp forward edge 102 of panel 100. Controller 90 then prompts sled 40 to pull panel 100 until edge 104 is a predetermined distance away from needle 22, as detected by sensor 190 as edge 104 passes beyond sensor 190. A preferred distance is about 14", although other distances could be used. Upper plate 52 of edge guide 50 then drops down until it touches an upper surface of panel 100. Further movement of plate 52 compresses springs 169, until sensor 175 detects pad 177. Thereafter, upper plate 52 is raised upwardly away from lower plate 53 a predetermined distance, such as 1/8" to 1/4" to a fixed position. This process permits edge guide 50 to measure the panel thickness and this value is stored in controller 90. Thereafter, edge guide 50 is backed outwardly away from table 110 a predetermined distance by motor 176. Controller 90 advances dolly 120 and sewing machine 20 toward table 110 and into a sew position in which the needles 22 are disposed in the desired stitching position. Clamp 44 is then opened to release edge 102.
By only using one clamp 43, the clamp closest to the sewing machine 20, panel 100 tends to be urged in a direction toward edge guide 50 to urge edge 106 into registration with plate 51. This process insures proper registration of edge 106 during the sewing process.
If the panel 100 is properly oriented the process proceeds. If the panel is not properly oriented, controller 90 prompts the operator and the system returns to the load position and the process is repeated. Assuming that the panel is in its proper orientation, edge 106 is manually loaded by the operator into the sewing machine 20 beneath needles 22. The operator then pushes a "start" button on the touch screen or control point. This location is the start point. Thereafter, edge guide 50 is returned by motor 176 toward table 110 to the sew position in which plate 51 is aligned with edge 106. Upper plate 52 is dropped to the fixed position which was previously determined by the controller 90 as discussed aborts. The sewing needles and the feed elements of sewing machine 20 move into position. Sled 40 begins to pull panel 100 through sewing machine 20 to begin the stitching and cutting operation and slip clutch 131 is activated. The sewing head 22 then automatically sews a predetermined distance, such as 6", as measured by shaft encoder 135. The number of stitches is noted by controller 90 which determines the stitch rate for this panel. This stitch rate is required to determine the rate at which the panel should be rotated around each corner to maintain the same number of stitches per inch during rotation. As edge 104 passes sensor 57, the stitching rate is reduced to a slower stitching rate. This distance from sensor 57 to sewing needle 22 is typically about 6". Once edge 104 passes sensor 56, the sewing operation is stopped as shown in FIG. 9. Sensor 56 is spaced from sewing needle 22 a distance approximately equal to the point at which the turning operation should begin, or the tangent point of the radius of the corner which is to be formed between edges 104 and 106. This distance is, for example, about 4 inches from needles 22. Sewing needles 22 then stop. Pivot arm 30 drops, allowing projections 35 to engage the top surface of panel 100. Controller 90 causes pivot arm 30 to drop an amount that causes projections 35 to engage panel 100 without damaging the panel. Since controller 90 knows the thickness of panel 100, it spaces projections 35 from table 120 some pre-programmed amount, such as 50% of the panel thickness. Clamp 43 releases edge 102, and plate 52 rises upwardly. Arm 30 is then rotated by motor 31 through 90 degrees to rotate panel 100 around the corner between edges 104 and 106, as shown in FIG. 10.
The controller 90 knows the desired stitches per inch, and the speed of rotation of panel 100 is calculated to produce the same number of stitches per inch during the rotation. The length of the corner is equal to pi multiplied by the radius of the corner, and thus the distance to be stitched is known. Since the controller 90 knows this distance and knows the desired number of stitches per inch and the speed of the sewing machine, it can compute the rate of rotation required to produce the desired number of stitches per inch. Controller 90 also notes the stop position of sled 40 which provides information to controller 90 about the dimension of panel 100 between edge 104 and edge 102. During the rotation of panel 100, the sewing operation proceeds at a reduced speed, and cutter 25 continues to trim the edge of panel 100 to produce a rounded corner, and edge guide 50 is open to its full height so as not to impede rotation of panel 100. Also, during rotation, the speed of the edge flattener 60 is adjusted by controller 90 to provide the desired edge flattening effect on the corners to prevent wrinkles or radially extending redges. Typically, the speed of flattener 60 is increased over that employed when sewing the straight edges of the fabric panels.
After this process has been completed, the sled returns to its home position in which clamps 43 and 44 are adjacent a new forward edge 102, and edge guide 150 returns to its fixed position for this particular panel as previously discussed, as shown in FIG. 11. At this point, only clamp 43 grasps edge 102. Arm 30 is raised off panel 100. Again, the slip clutch is activated and sewing restarts as sled 40 pulls a new edge 106 of panel 100 through sewing machine 20. The next corner is stitched in the same manner as the first corner, and the process is repeated until the final corner is reached. Since controller 90 knows the length of edges 106 and 107, if it is desired to stitch a label onto one of the edges, controller 90 can be programmed to stop at the middle of that edge to allow insertion of a label to be stitched by machine 20 as the flange material is attached.
As the fourth corner is approached, or the corner just prior to original edge 106, this corner is stitched like the others. Once the original edge 106 is in registration with edge guide 50, wheel 80 is extended by arm 82 and is dropped onto the upper surface of panel 100 by being pivoted about support 84. The wheel drop point is monitored by shaft encoder 135. Sewing machine 20 begins sewing and cutting along original edge 106 approaching the start point. As this step occurs, dolly 120 begins to back sewing machine 20 and flange guidance system 150 away from table 110, as illustrated by FIG. 12, so that by the time the start point is reached, the sewing needle has completely sewn off edge 106 and no longer performs any sewing operation on panel 100. At the same time, cutter 25 also is being withdrawn, so that at the time cutter 25 reaches the start point, no more material is being cut from the edge of panel 100. Thus, there is a smooth transition back to the start point providing a straight edge with the proper dimension. Sewing machine 20 continues to sew on the flange material. Since the dimension of panel 100 is known, when the final edge 104 passes by sewing machine 20, sled 40 is stopped. Cutter 70 is then activated to cut the flange material and the sewing threads along the back edge 104 of panel 100. The panel is then carried by sled 40 to a position at the far end of table 110 as shown by the dotted lines in FIG. 14. At this point, wheels 134 are pivoted into contact with panel 100 and are activated to propel panel 100 in a direction generally transverse to the feed direction 24 off table 110 or to the edge of table 110 remote from sewing machine 20 as shown in FIG. 12. Thereafter, sled 40 returns to the home position and the process is repeated for the next panel.
In view of the above description it is likely that modifications and improvements will occur to those skilled in the art, which should be deemed as being within the scope of this invention. The above description is intended to be exemplary only, the scope of the invention being defined by the following claims and their equivalents.
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A method and apparatus for sewing flange material to a fabric panel, preferably the top or bottom panel of a mattress sack. The apparatus includes a sled which pulls the fabric panel to and through the sewing machine. The apparatus also includes an edge guide that guides one edge of the panel to the sewing machine as well as provides a thickness measurement of the panel and smooths the fabric panel prior to sewing. The apparatus also includes a moveable dolly which carries the sewing machine find the flange material, and a wheel which engages the fabric panel during movement of the sewing machine away from the fabric panel to prevent movement of the fabric panel. The apparatus also includes apparatus for automatically removing the fabric panel from the table after completion of the sewing operation, as well as a cutter for cutting the trailing flange material and the sewing threads. The method of this invention includes the steps of sewing each edge sequentially, rotating the parcel around the corners while cutting and sewing the corners, and measuring the thickness of the panel to space the rotating arm from the table a specified distance less than the thickness of the panel. The method also includes the steps of adjusting the speed of rotation of the edge flattened to produce a flattened corner without wrinkles or ridges.
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This application is a continuation of application Ser. No. 346,142, filed May 4, 1989, now abandoned, which is a continuation in part of Ser. No. 204,431, filed June 9, 1988, now abandoned.
FIELD OF THE INVENTION
The present invention relates to devices for collecting and transporting biological specimens. More particularly, it relates to an improved swab for collecting samples and a simplified transport device incorporating the improved swab.
BACKGROUND OF THE INVENTION
Detecting the presence of pathogenic microbial species requires, as a first step, collection of an appropriate sample. Typically a sterile collection device such as a swab is used. In the past, these swabs have been made of various materials such as cotton, sheep wool, polyester and rayon.
After the sample has been collected on a swab it is transported to a microbiology laboratory where any organisms present are identified. The identification method may be conventional culturing followed by identification or immunometric assay. A persistent problem for samples to be cultured has been maintaining viability of pathogenic organisms. Where the sample is to be processed for an immunoassay, a persistent problem has been recovery of immunologicaly active material. Additionally, the sample needs to be protected from contamination by the environment during transport. Numerous devices have been devised that provide both a means for obtaining the sample and means for protecting the sample during transport. Most often these devices comprise a swabbing element having a shaft typically of wood or plastic and a swabbing tip which has universally been produced from fibrous material such as cotton fibers, wool, polyester fibers or rayon fibers.
Further elements common to most devices are a cap to which the shaft is fixed and which mates with a lower swab cover to protect the swabbing tip both before and after collection of sample and a liquid medium containing reservoir such as a frangible glass ampoule that can be broken to release aqueous medium to keep the swab and sample moist. Representative collection and transport devices are shown in U.S. Pat. Nos. 4,223,093 (to Newman et al.), 4,030,978 (to Abramson), 4,175,008 (to White), 4,311,792 (to Avery), and 4,014,748 (to Spinner et al.).
Media described by Stuart et al. "The Problem of Transport of Specimens for Culture of Gonococci," Can. J. Pub. Health, vol. 45, pp. 73-83 (1954) and a later modification by Amies "A Modified Formula for the Preparation of Stuart's Transport Medium", Can. J. Pub. Health, vol. 58, pp. 296-300 (1967) are examples of growth maintenance media which do not promote growth that are commonly employed. Such media preserve the organisms present in the specimen while retarding or preventing growth during transport.
The medium is often retained inside the specimen collection device and adjacent to the specimen collection swabbing tip by an absorbent fibrous swatch of material. This swatch or pledget, as it is often named, can be a woven or non woven section of fabric or a piece of fibrous material such as cotton or rayon. While serving to restrain the flow of the aqueous media and prevent dehydration of the collected sample, the pledget materials such as cotton, polyester or rayon currently utilized do not enhance and may possibly be detrimental to preserving the viability of the microorganisms collected.
Several studies have attempted to evaluate the toxic nature of various fibrous materials used in the swab and also employed in the pledget. Studies are reported by Ellner et al. "Survival of Bacteria On Swabs", J. Bacteriol., vol. 91, pp. 905-6 (1966); Barry et al. "Efficiency of a Transport Medium for the Recovery of Aerobic and Anaerobic Bacteria from Applicator Swabs," Appl. Micro. Bio., vol. 24, pp. 31-3 (1972); Ross et al. "Swabs and Swab-Transport Media Kits in the Isolation of Upper Respiratory Bacteria," J. Clin. Pathol. vol. 35, pp. 223-7 (1982); Rubbo et al. "Some Observations on Survival of Pathogenic Bacteria on Cotton-Wool Swabs," Brit. Med. J., pp. 983-7 (May 1951), and Anderson "Antibacterial Bacteriological Swabs", Brit. Med. J., pp. 1123-4 (Nov. 1965).
Certain devices have eliminated the need for a liquid retaining pledget by substituting an agar containing medium for the liquid medium. The agar produces a gelled or highly viscous medium into which the specimen swab is placed after collecting the sample. The agar medium provides protection, but leads to agar residue on the swab. This residue can subsequently interfere with analytical procedures such as specimen staining for visual microscopic detection of organisms. Agar has also been found to interfere with certain latex agglutination tests commonly employed. Stuart et al. (cited above) have shown agar to be toxic to certain organisms.
A very recent study, Appelbaum, Peter C. et al., "Survival of Bacteria in Difco CultureSwab and Marion Culturette II Transport Systems," J. Clin. Micro. Biol., vol. 26, pp. 136-8 (1988), typifies the commercial "state of the art" in describing two commonly available commercial systems with fibrous swabs and a media component. This study points out that 90% of the organisms cannot be recovered from either wet system after four hours storage time.
Devices having a liquid transport medium are expensive to make because they have multiple elements which must be formulated or made and then assembled. The devices with agar transport medium are less than acceptable because the agar interferes with subsequent testing. Thus, a substantial need exists for collection and transport devices that will yield viable organisms after four hours storage time.
The prior art clearly discourages the use of dry swabs. Similarly, it universally utilizes fibrous swabs of cotton, wool, rayon, polyester, and calcium alginate. Among the materials not previously used in swabs for collecting and transporting microorganism is polyurethane. At least one study, Bach, John A., et al., "Inhibition of Microbial Growth by Fatty Amine Catalysts from Polyurethane Foam Test Tube Plugs", Appl. Micro. Biol., vol. 29 no. 5, pp. 615-620 (1975), has concluded that the material is not suitable for use when culturing microorganisms because autoclaving the polyurethane releases substances which are toxic to microorganisms.
Another acknowledgment that polyurethane may harm an organism with prolonged contact is found in U.S. Pat. No. 4,401,130 to Halford et al. That patent addresses the problem of joining a polyurethane foam swab to its stick without leaving dust which it characterizes as "possibly dangerous when open wounds are subject to treatment using the swabs." Col. 2, lines 27-8.
Polyurethane has been used in other health care applications. For example, one brand of contraceptive sponge is made from a special grade of polyurethane foam made from a foamable hydrophilic prepolymer resin available from W. R. Grace Co. and sold with the trademark Hypol. These resins are derived from toluene diisocyanate and methylenediphenyl diisocyanate. They have also been used in wound dressings. The polymers made from these resins are said to have no extractable toluene diamine, toluene diisocyanate, or other primary aromatic amines.
Polyurethane is recommended for use in a unitary molded swab described in U.S. Pat. No. 3,871,375. That patent states that the swab may be used for "application of medication, the removal of earwax, and all of the other uses for which swabs are normally employed." Col. 2, lines 16-18. It also states that the swab may be sterilized. It does not suggest use for collecting biological specimens and therefore does not address the known toxicity of polyurethane to microorganisms.
Additionally, polyurethane foam has been reported to be useful as a swab tip for removing foreign materials from a surface and to apply fluids such as paint, cosmetics, and medicines. U.S. Pat. No. 3,724,018 describes a swab made with a reticulated plastic foam material, such as polyurethane foam, wrapped around an end of a stick. The patent does not address sterilizing the swab or the known toxicity of polyurethane to microorganisms.
SUMMARY OF THE INVENTION
Surprisingly, many of the problems associated with existing devices are solved by using as the swabbing material a polyurethane foam which is non-toxic as demonstrated by a lack of a zone of growth inhibition when placed on a semi solid growth medium smeared with a suspension of N. meningitidis (Quality Control Collection, Becton Dickinson Microbioloqy Systems, ATCC 53900), N. gonorrhoeae (ATCC 19424) or N. gonorrhoeae (ATCC 43070) and which has open cells at its exposed surface. The new swab is comprised of a shaft and a sterile swabbing tip secured to one end of the shaft. The swabbing tip is formed with a polyurethane foam which is non-toxic as demonstrated by a lack of a zone of growth inhibition when placed on a semi-solid medium smeared with a suspension of N. meningitidis (Quality Control Collection, Becton Dickinson Microbioloqy Systems, ATCC 53900), N. gonorrhoeae (ATCC 19424) or N. gonorrhoeae (ATCC 43070) and which has open cells at its exposed surface.
This new swab can be used in a collection and transport device that is much simpler than existing devices. The new collection and transport device of the present invention comprises the new swab together with a cap secured to the end of the shaft opposite the swabbing tip and a tubular swab cover which covers the swab and mates with the cap to create a tortuous pathway and thereby to protect the swab from the environment. The collection and transport device may be free of any transport medium.
In a further aspect of the invention a sample inoculator is provided. Preferably the sample inoculator is secured to the exterior of the cap and a inoculator cover is provided to protect the inoculator from contamination prior to use.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows the transport and collection device of the present invention; and
FIG. 2 shows a detail in cross section of the swabbing tip of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As shown in the figures, the swab 9 of the present invention has a shaft 10and a swabbing tip 11. The swab is secured to a cap 12 that mates with a swab cover 13 to form a slidable seal. An optional sample inoculator 15 isattached to cap 12 and protected by inoculator cover 14. While the inoculator is shown in an elliptical shape, those skilled in the art will appreciate that a variety of geometries can be used. For example, the inoculator could be formed as a cube or a tetrahedron.
The transport and collection device of the present invention does not require a liquid or solid transport medium. Elimination of these elements makes manufacture and assembly of the device much easier and therefore less expensive than manufacture and assembly of presently existing devices. The preferred foams used in the present invention can be sterilized with autoclaves opening up the possibility of using this sterilization procedure if appropriate materials are used for the remaining components of the transport device. The addition of sample inoculator 15 and inoculator cover 14 further enhances the usefulness of the device.
A variety of lengths and materials are possible for shaft 10 for example wood, plastic or wire might be utilized. Similarly the cap 12, swab cover 13, and sample inoculator 15 can be made of materials well known to those skilled in the art.
The advance of the present invention is use for the swabbing tip 11 of a sterile polyurethane foam which is non-toxic as demonstrated by a lack of a zone of growth inhibition when placed on a semi-solid growth medium smeared with a suspension of N. meningitidis (Quality Control Collection, Becton Dickinson Microbiology Systems, ATCC 53900), N. gonorrhoeae (ATCC 19424) or N. gonorrhoeae (ATCC 43070) and which has open cells on its exposed surface. Swabs which are found to be non-toxic to these three organisms after incubations on suitable semi solid growth media for twentyfour, twenty four and forty eight hours respectively have been found to be non-toxic to a wide variety of human pathogens that are cultured from specimens collected with swabs and transported to the microbiology laboratory under conditions typically encountered by microbiologists. Theyhave also been found to provide substantial improvement in recovery of materials that will participate in specific binding reactions in immunoassays.
The swabbing tip has open cells at its exposed surface which in use contacts the sampling site to collect the sample. The open cells at the surface may be achieved by using a reticulated foam or by using a non-reticulated foam and shearing the cells at the surface to create open cells. Preferably the foam has 20 to 200 pores per inch (8 to 80 pores percm) at the surface and the cells fall within a size range of 0.0196 mm to 0.196 mm average diameter. Most preferably cells having an average diameter greater than 0.2 mm should be avoided. Shearing of a non-reticulated foam to create open cells at the surface may conveniently occur in a fabrication step whereby large blocks of foam are cut to size for attachment to the shaft. The swabbing tip 11 may have an inner core 16to facilitate attachment and manufacture or may be attached directly to shaft 10.
The foam should be a medical grade foam substantially free of leachable monomers that can be toxic to microorganisms. Particularly preferred are foams sold under trade designations "SCOTFOAM Custom Foam", "SCOTFOAM Custom Foam CL", and "SCOTFOAM Special Pore-Custom Foam" having 60 to 100 pores per inch (24 to 40 pores per cm) in either pigmented or unpigmented form (all from SCOTFOAM Corp., Eddystone, Pa.).
The unexpected and unique ability of the polyurethane foam to maintain viable microorganisms without an aqueous medium and a pledqet is most unexpected. Nothing in the prior art of microbiological swabs or polyurethane foams suggests that the polyurethane foam will provide a device that maintains the viability of microorganisms for periods equal orgreater to the periods for which a medium wetted fiber swab can maintain such organism viability.
The unexpected benefits of the invention and other features of the invention will be appreciated from the following nonlimiting examples. In Examples 1 to 5 microorganisms used were obtained from the sources shown in Table I.
TABLE I______________________________________MICROORGANISM STRAINS UTILIZEDCODE TEST ORGANISM SOURCE.sup.a, b, c______________________________________CAL Candida albicans QCC, BDMSESC Escherichia coli ATCC 25922GCA Neisseria gonorrhoeae ATCC 19424GCB Neisseria gonorrhoeae ATCC 35201GCC Neisseria gonorrhoeae ATCC 43070HIA Haemophilus influenzae ATCC 35056HIB Haemophilus influenzae CI, JHHNMA Neisseria meningitidis ATCC 53900NMB Neisseria meningitidis ATCC 13090PAA Pseudomonas aeruginosa ATCC 27853PRM Proteus mirabilis ATCC 12453SAC Salmonella cholerasuis ATCC 10708SGB Streptococcus Group B ATCC 10586SGD Streptococcus Group D ATCC 10541SHS Shigella sonnei ATCC 9290SPA Streptococcus pyogenes ATCC 10389SPB Streptococcus pyogenes QCC, BCMSSNA Streptococcus pneumoniae ATCC 6305SNB Streptococcus pneumoniae CI, JHHSTA Staphylococcus aureus ATCC 25923VBP Vibrio parahaemolyticus QCC, BDMSYRE Yersinia enterocolitica QCC, BDMS______________________________________ .sup.a) ATCC = American Type Culture Collection .sup.b) QCC, BDMS = Quality Control Collection, Becton Dickinson Microbiology Systems, Cockeysville, MD 21030 .sup.c) CI, JHH = Clinical Isolate, Johns Hopkins Hospital, Baltimore, MD
COMPARATIVE EXAMPLE 1
The sterile swabbing tip made with a non-toxic polyurethane foam having open cells at its exposed surface and the simplified collection and transport device of the present invention were compared to commercially available products. Fastidious organisms used were Haemophilus influenzae,Neisseria meningitidis and Neisseria gonorrhoeae. The non-fastidious organisms Streptococcus pyogenes (Group A Strep) and Streptococcus pneumoniae were also studied. Two different strains of each fastidious andnon-fastidious organisms, A and B, were studied. Table I identifies the actual strains and their sources. These organisms are all common potentialhuman pathogens and are typical of the type of organism which may be sampled from a patient with a swab.
First the bacteria were grown in a broth culture medium. Then a suspension of each organism was diluted and its turbidity was measured in a spectrophotometer. The technique of quantitative plate counts was utilizedto construct a graph relating the measured optical density to the number oforganisms present. Thereafter, the number of organisms in a suspension was estimated by measurement of the optical density of the suspension and reading the concentration from the corresponding graph.
Suspensions were produced that contained approximately 5×10 7 colony forming units (CFU) per milliliter (ml). Each swab tested was inoculated by placing a 0.1 ml aliquot of the standard suspension in a sterile test tube, inserting the swab and allowing the aliquot to absorb into the swabbing tip.
In this experiment, swabs were from commercially available products, a rayon swab provided with the Culturette™ Collection and Transport System (Marion Scientific, Kansas City, Mo.) and a mini-size bonded polyurethane foam tip swab commonly sold for cleaning electronic surfaces (The Texwipe Co., Upper Saddle River, N.J. catalog no. TX710). These polyurethane swabs are made with a non reticulated foam which has open cells at its exposed surface. The rayon swabs were provided sterile. The polyurethane swabs were sterilized by gamma radiation prior to use. The inoculated rayon tipped swabs were returned to the transport tube and activated in accordance with the manufacturer's directions to bring the medium into contact with the pledget and swabbing tip. The inoculated polyurethane foam tipped swabs were placed individually in sterile screw capped plastic tubes. Multiple swabs were inoculated for streaking at the various time intervals.
Replicate samples of each type swab were stored aerobically at ambient temperatures. At timed intervals of 0, 4, 8, 24 or 48 hours, depending on the organism under study, the swab was used to inoculate a petri plate of an appropriate nutritive agar medium. Each inoculated plate was systematically streaked with a bacteriological loop according to the semi-quantitative "four quadrant method" commonly practiced by those skilled in the art of microbiology. Specifically, the plate was inoculatedby:
A. Rolling the swab thoroughly over a first quadrant of the plate.
B. Using a standard bacteriological loop, streak back into quadrant 1 eighttimes.
C. Flame loop and streak back into quadrant 2 four times.
D. Streak back into quadrant 3 twice.
The inoculated plated media were incubated at 37° C. in an atmosphere enriched with 5% carbon dioxide. After twenty four to forty eiqht hours, the plates were observed for growth and graded according to the following scheme:
4=Growth in quadrant 4 (20 to 100 colonies)
3=Growth in quadrant 3 (20 to 100 colonies)
2=Growth in quadrant 2 (20 to 100 colonies)
1=Growth in quadrant 1 (20 to 100 colonies)
+=Heavy growth (greater than 100 colonies)
-=Light growth (less than 20 colonies)
The results of this experiment are summarized in Table II (average score for duplicate runs). For each strain for each organism tested, use of the polyurethane swab demonstrated improved recovery of the organisms over that obtained from the rayon swab. Additionally, for 7 of 10 organisms studied the use of the polyurethane swab allowed recovery at time periods where the rayon swab showed no growth.
TABLE II______________________________________RECOVERY OF ORGANISMS FROM MARIONCULTURETTE COLLECTION AND TRANSPORTDEVICE AND POLYURETHANE FOAM TIP SWABS Recovery at ElapsedOrganism Swab Storage Time (HR)Strain Material 0 4 8 24______________________________________HIA Rayon 3- 1- 0 0 Polyurethane 4- 3- 2 1-HIB Rayon 3 2- 1 0 Polyurethane 4- 3 3- 1+NMA Rayon 2 1- 0 0 Polyurethane 3- 2+ 2- 1+NMB Rayon 4- 1+ 1- 0 Polyurethane 3- 3- 3- 2GCA Rayon 2 0 0 0 Polyurethane 3- 1- 1- 0GCB Rayon 2- 0 0 0 Polyurethane 2- 1 1- 0SPA Rayon 2 1 0 0 Polyurethane 2 2 2 1+SPB Rayon 3- 2+ 1+ 1+ Polyurethane 3- 2+ 3- 2-SNA Rayon 2 2- 1 1+ Polyurethane 3- 3- 3- 3-SNB Rayon 3- 1+ 1- 1- Polyurethane 3- 2+ 2- 1______________________________________
EXAMPLE 2
In this example, the sterile swabbing tip made with a non-toxic polyurethane foam having open cells at its exposed surface and the simplified collection and transport device of the present invention were compared to another commercially available sterile swabbing tip. The BBL Port-A-Cul™ Aerobic Transport Device (Becton Dickinson Microbiology Systems, Cockeysville, Md.), has a rayon tipped swab, a rayon pledget and a medium following the formulation of Amies. The devices are sterilized bygamma radiation. After inoculation of the rayon swabs as in Example 1, the swabs were returned to the Port-A-Cul™device and activated according tothe manufacturer's directions. The polyurethane swabs used and their methodof inoculation and storage were as in Example 1. These tests were conductedwith a similar panel of organisms as was used in Example 1. The results areshown in Table III (average score for duplicate runs). Here again a patternof improved organism recovery through use of the polyurethane swabs over that obtained from the rayon swabs was observed. For some organisms, the use of the polyurethane swabs allowed recovery at time periods where the rayon swabs showed no growth.
TABLE III______________________________________RECOVERY OF ORGANISMS FROM BBL PORT-A-CULAEROBIC TRANSPORT DEVICES ANDPOLYURETHANE FOAM TIP SWABS Recovery at ElapsedOrganism Swab Storage Time (HR)Strain Material 0 4 8 24______________________________________HIA Rayon 3- 1- 1- 0 Polyurethane 3- 3- 2+ 2-HIB Rayon 3 2- 1 0 Polyurethane 3- 3- 3- 2NMA Rayon 3- 1- 0 0 Polyurethane 3- 3- 2+ 2-NMB Rayon 4- 2- 1 0 Polyurethane 4- 4- 3- 2+SPA Rayon 3 2+ 2 2- Polyurethane 3- 2+ 2 2-SPB Rayon 3 3- 2+ 3- Polyurethane 4- 3 2+ 3-SNA Rayon 3- 2+ 2- 1 Polyurethane 3- 3- 2+ 2SNB Rayon 3- 2+ 2- 1 Polyurethane 2 3- 2- 1______________________________________
EXAMPLE 3
The sterile swabbing tip made with a non-toxic polyurethane foam having open cells at its exposed surface and the simplified collection and transport device of the present invention were compared again to a commercially available swabbing tip. The procedure followed and the commercially available rayon tip were identical to those of Example 2. Theorganisms were different. An additional 11 bacterial species and 1 yeast species were tested. The organisms are all potential human pathogens whichcan be collected from a patient using a swab collection and transport device. The results of this experiment are summarized in Table IV (averagescore for duplicate runs). With seven of eleven organisms studied, recoveryfrom the polyurethane swab was equal to or better than that observed with the BBL Device, though recovery of all organisms was observed at 48 hours with both type swab sample devices.
TABLE IV______________________________________RECOVERY OF PATHOGENIC AND OPPORTUNISTICORGANISMS FROM BBL PORT-A-CUL AEROBICTRANSPORT DEVICES AND POLYURETHANEFOAM TIP SWABS Recovery at Elapsed StorageOrganism Swab Time (HR)Strain Material 0 24 48______________________________________PAA Rayon 3- 3 4- Polyurethane 3- 4- 3ESC Rayon 2 2+ 2 Polyurethane 3- 3- 3-SAC Rayon 4- 2 2- Polyurethane 4 3 3+SHS Rayon 3- 2+ 2- Polyurethane 4- 3 2+PRM Rayon 4- 3- 2 Polyurethane 4- 3- 3VBP Rayon 2 2- 1- Polyurethane 2 4- 3-YRE Rayon 2 2- 2+ Polyurethane 2 4- 1+STA Rayon 4- 3- 2+ Polyurethane 4- 3- 3+SGB Rayon 3 2+ 3- Polyurethane 3- 3- 2+SGD Rayon 3 3- 2 Polyurethane 3 3- 2CAL Rayon 3 4- 4- Polyurethane 3 3- 2+______________________________________
EXAMPLE 4
In Examples 1, 2, and 3, the sterile swabbing tips made with a non toxic polyurethane foam having open cells at its exposed surface which were studied received no additional media after inoculation and during storage.In contrast, the rayon tipped swabs were moistened after activation in accordance with the instructions of their respective manufacturers. In this experiment, all of the swabs were stored in dry tubes. The polyurethane swabs were the same as those used in Examples 1, 2, and 3. Rayon tipped swabs were obtained from BBL Port-A-Cul™ devices (Becton Dickinson Microbiology Systems, Cockeysville, Md.) and from Culturette™devices (Marion Scientific, Kansas City, Mo.). After inoculation, all rayonswabs were stored in the storage tube supplied by the manufacturer from which the fluid medium reservoir and pledget material were aseptically removed. Dacron tipped swab devices were obtained commercially from American Scientific Products (McGaw Park, Ill. catalog no. A5005-1). Theseswabs are provided sterile in a paper package.
Inoculation of all swabs in this experiment with Streptococcus pyogenes (Group A Streptococcus, SPA) was as in Example 1. Each inoculated rayon tipped swab was returned to its modified transport tube for storage. The polyurethane and Dacron swabs were placed individually in sterile screw capped tubes for storage. Additionally wet storage experiments were run byinoculating and activating swabs from Marion Culturette™ and BBL Port-A-Cul™ devices as in Examples 1 and 2.
The results of this experiment are summarized in Table V (average scores for duplicate runs). Organism recovery from polyurethane swabs, sterilizedby three different methods, was better than that observed with either rayonor Dacron type swabs stored under similar dry conditions. Thus, enhanced recovery observed with the polyurethane swabs is related to type swab material and not method of storage or sterilization. Also, the use of polyurethane swabs again allowed recovery at time periods where rayon swabs, stored under moist or dry conditions, showed no growth.
TABLE 5______________________________________RECOVERY OF GROUP A STREPTOCOCCI FROMMOISTENED AND NON-MOISTENED SWAB DEVICES Recovery atSwab Swab Storage Elapsed Time (HR)Source Material Condition 0 2 4______________________________________Marion Rayon Moist 3- 2 0BBL Rayon Moist ND.sup.a ND 2+BBL Rayon Dry 3- 0 0Scientific Dacron Dry 3 1- 1-Prods.Texwipe Polyurethane.sup.b Dry 3 3- 2+ Polyurethane.sup.c Dry 3 3- 3+ Polyurethane.sup.d Dry 3- 3- 2-______________________________________ .sup.a ND, not determined .sup.b Sterilized by gamma radiation .sup.c Sterilized by particle beam radiation .sup.d Sterilized by ethylene oxide gas
EXAMPLE 5
This experiment was undertaken to demonstrate the beneficial effect of selecting as the swabbing tip a non-toxic polyurethane foam having open cells at its exposed surface. Several fastidious organisms were chosen to probe for toxic effects of the swabbing material.
Bacteria used in this experiment are as identified in Table I, and media used for growth and toxicity testing are as listed in Table VI. Each strain was grown overnight on the appropriate medium at 37° C. in an atmosphere enriched with 5% carbon dioxide. A suspension of each organism was then prepared in saline that contained approximately 1.5×10 8 cfu/ml. For each strain the surface of the toxicity testing medium indicated in Table 6 was systematically inoculated by a cross-streaked method, commonly practiced by those skilled in the art of microbiology, so as to produce confluent growth over the surface of the medium after incubation at 37° C. in an atmosphere enriched with 5%carbon dioxide. After each plate was so inoculated, swab tip materials wereaseptically placed on the inoculated medium surface and plates were incubated as described above.
After twenty four hours incubation for strains NMA, NMB, and SPA and forty eight hours incubation for strains GCA and GCC, the plates were examined for a zone of growth inhibition about the swabbing tip material. The size of each zone of inhibition was measured and recorded in millimeters.
Rayon tipped swabs were obtained from Culturette™ devices (Marion Scientific, Kansas City, Mo.) and BBL Port-A-Cul™ devices (Becton Dickinson Microbiology Systems, Cockeysville, Md.). Polyurethane tipped swabs were obtained from two sources: The Texwipe Co., Upper Saddle River,N.J. (Catalog No. TX710)Catalog No. TX710) and Wilshire Foam Products, Inc., Carson City, Calif. (Catalog Nos. HT1001 and HT1005). The rayon swabs were provided sterile. The Texwipe and Wilshire HT1001 polyurethane swabs were sterilized with gamma radiation. The Wilshire HT1005 was asceptically used as supplied.
The results of this experiment are summarized in Table VII (average score for duplicate runs). These results serve to differentiate among polyurethane type materials. The preferred type polyurethane swabbing material should not be toxic. The Texwipe and Wilshire (H1001) are shown to be suitable for this purpose. Wilshire (H1005) was shown to be toxic tothree of the five fastidious strains tested. For comparative purposes this experiment also demonstrates that differing sources of rayon swabbing materials may be differentiated relative to inherent toxicity.
TABLE VI______________________________________MEDIA USED FOR GROWTH AND TOXICITY TESTING GROWTH TOXICITY MEDIUM TEST MEDIUM (CATALOGUE (CATALOGUEORGANISM TESTED NO.) NO.)______________________________________NMA CHOC II AGAR MUELLER HIN- (BDMS 21267).sup.a TON II AGAR (BDMS 21800)NMB CHOC II AGAR MUELLER HIN- (BDMS 21267) TON CHOC AGAR (BDMS 21802)GCA CHOC II AGAR MUELLER HIN- (BDMS 21267) TON CHOC AGAR (BDMS 21802)GCC CHOC II AGAR MUELLER HIN- (BDMS 21267) TON CHOC AGAR (BDMS 21802)SPA TSA II AGAR MUELLER HIN- (BDMS 21261) TON II AGAR (BDMS 21800)______________________________________ .sup.a BDMS, Becton Dickinson Microbiology Systems, Cockeysville, MD.
TABLE VII______________________________________DETERMINATION OF TOXIC PROPERTIES OFPOLYURETHANE AND RAYON SWABBING TIPMATERIALSSwab Swab Inhibition Zone Size (MM)Source Material NMA NMB GCA GCC SPA______________________________________TEXWIPE POLYUR- 0 0 0 0 0 ETHANE (#710)WIL- POLYUR- 0 0 0 0 0SHIRE ETHANE (#1001)WIL- POLYUR- 1 0 2 4 0SHIRE ETHANE (#1005)MARION RAYON 6 0 0 1 0BBL RAYON 0 0 0 0 0______________________________________
EXAMPLE 6
In this example, the ability to recover detectable Group A Streptococcal antigen was tested. Group A Streptococcus (Streptococcus pyogenes, ATCC 12385) was grown on blood agar plates for 24 hours at 37° C. A was adjusted with a spectrophotometer to obtain approximately 1×10 9 colony forming units (CFU) per milliliter (ml). Additional dilutions of this stock suspension were prepared in saline so as to contain in 0.050 ml50×10 5 , 12.5×10 5 , 3.0×10 5 , 1.5×10 5 and 0.75×10 5 CFU. A series of swabs were then inoculated by placing a 0.050 ml aliqout of suspension a sterile testtube, inserting the swab and allowing the aliquot to absorb into the swabbing tip. As a control for the assay system, swabs were also placed intubes containing only 0.050 ml of saline before extraction. All swabs were tested in duplicate. Each set of duplicate swabs as well as the control swabs were assayed directly for Group A streptococcal antigen using the Directigen 1-2-3™ Group A liposome immunoassay (Becton Dickinson Microbiology Systems, Cockeysville, Md.; cat. no. 8525-40). In this assay organisms are extracted from the swabs with nitrous acid, neutralized, andthe resultant liquid extract is applied directly to a membrane containing antibody specific for Group A Streptococcus. Any Group A Streptococcus antigen present binds to the antibody. After washing, a suspension of liposomes having antibodies to Group A Streptococcus on their surface was applied to the membrane. The presence of antigen in the extracted materialis detected by visually observing a pink triangle on the membrane surface. Intensely colored triangles were scored "reactive"; faintly colored triangles were scored as "minimally reactive"; and the absence of a visible triangle was scored as "non reactive".
Three of the four swabs tested in this experiment were commercially available products. A dacron Swab supplied with the Directigen 1-2-3™ assay kit, the polyurethane swab available described in Example 1, and thepolyurethane swab described in Example 5 (Wilshire Contamination Control, Carson, Calif.; catalog no. 1001). Also tested was an experimental swab manufactured by Wilshire Contamination Control using ScotFoam Special Pore-Custom Foam™ having 100 pores per inch (40 pores per cm) and whitepigment. Each swab had an over all length of 6.0 in. (15.24 cm) and was comprised of a swabbing tip measuring about 0.625 in (1.59 cm) in length and 0.188 in. (0.48 cm) in diameter secured to a white polystyrene shaft of 0.094 in (0.238 cm) diameter. All polyurethane swabs were sterilized with gamma irradiation prior to use.
The results of this experiment are summarized in Table VIII (average of duplicate runs). In Table VIII "R" means reactive, "RM" means minimally reactive, "N" means non reactive, and "ND" means not determined. Group A streptococcal antigen was recoverable and detectable from foam swabs having one fourth the quantity of organisms of the least concentrated sample from which a detectable antigen could be recovered with the dacron swab. Thus when compared to the dacron swab utilized in the Directigen 1-2-3™ test, the assay sensitivity was improved two to four fold.
TABLE VIII______________________________________RECOVERY OF GROUP A STREPTOCOCCUSANTIGEN FROM DACRON AND POLYURETHANEFOAM TIP SWABS ORGANISM CONCENTRATIONSwab Swab (10.sup.5 CFU)Source Material 50 12.5 3.0 1.5 0.75 0______________________________________Becton Dacron R R N N N NDickinsonTexwipe Polyurethane R R R RM N N (#710)Wilshire Polyurethane R R R RM N N (#1001)Wilshire Polyurethane ND R RM RM RM N (experi- mental)______________________________________
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A microbiological culture collection and transport device maintains viable organisms for periods of time longer than possible with existing sampling devices. It also allows recovery of detectable antigen at levels not achievable with conventional swabs. The new device has a sterile swabbing tip made with a non-toxic polyurethane foam having open cells at its exposed surface. It does not require a transport medium and can be used dry. The device may further include a sample inoculator to distribute organisms collected onto a solid or semi solid medium. Methods for collecting and transporting microbiological specimens and for recovering detectable antigen are also described.
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This application is a division of application Ser. No. 116,030, filed Feb. 17, 1971 now U.S. Pat. No. 3,758,926 which in turn is a continuation-in-part of application Ser. No. 882,391 filed Dec. 1, 1969, now abandoned, which is a division of application Ser. No. 741,492, filed July 1, 1968, now U.S. Pat. No. 3,530,557, dated Sept. 29, 1970.
BACKGROUND OF THE INVENTION
This invention relates to non-woven textiles, and particularly to tubing essentially consisting of helically wound turns of a non-woven fibrous web, to a method of producing such tubing, and to an apparatus for performing the method.
Sleeves of felt and similar non-woven textile material find many applications in industry, such as surface layers on rollers in processing equipment and the like. The range of fibrous materials capable of being converted into felts having the necessary mechanical strength is quite narrow because smooth fibers do not engage each other with sufficient friction to provide a felt made therefrom with adequate cohesive strength. The fibers which are converted to felts by fulling or other conventional methods must contain a sizable percentage of wool for adequate strength of the tubing to be prepared therefrom. Wool, however, is sensitive to acid and particularly to alkali, and quickly deteriorates when used with these and many other chemicals.
An object of the invention is the provision of nonwoven textile tubing whose mechanical strength does not depend on a specific configuration of the fibers employed, and is thus capable of being prepared from synthetic fibers of all types, including monofilaments, and from inorganic fibers which may have completely smooth surfaces.
Concomitant objects of the invention are a method of producing such non-woven tubing, and apparatus for performing the method.
SUMMARY OF THE INVENTION
In one of its aspects, the invention therefore resides mainly in tubing essentially consisting of a plurality of helically wound, coaxial turns of at least one fibrous web of non-woven fabric, each turn overlapping at least one preceding turn and being overlapped by at least one succeeding turn. A plurality of fibers integral with each other extend angularly from that turn through at least one subjacent turn, the turns being fastened to each other by the angularly extending fibers.
In the method of making continuous tubing of the aforedescribed type, at least one non-woven fibrous web is wound in a plurality of coaxial helical turns at such a helix angle that each turn axially overlaps at least one preceding turn and is itself overlapped by at least one succeeding turn. A multiplicity of needles is passed inwardly through the overlapping turns until fibers from an outer turn are drawn inwardly through at least one subjacent turn, whereby the turns are fastened to each other. The needles are then withdrawn from the tubing so formed in an outward direction.
The web may be fed continuously to a drum member in a tangential direction while the drum member rotates about its axis, and the turns so formed are axially drawn from the drum. The turns are fastened to each other by the aforementioned needles while supported on the drum.
More specifically, the apparatus employed may mainly consist of a drum arrangement which tapers in the direction of its axis of rotation (not shown in the drawings), a feeding mechanism for continuously feeding a web of non-woven material to an axial portion of the drum arrangement in a direction substantially tangential relative to the axis of rotation, a needling mechanism for needle stitching consecutive turns of the web wound on the drum arrangement and a take-up mechanism for axially moving the turns on the drum arrangement. By the simultaneous rotation of the drum arrangement and the axial motion imparted by the take-up mechanism, the turns of web material form a helix of partly radially superimposed turns when the velocity of axial movement does not exceed a predetermined velocity. The several turns are thus stitched to each other in the form of continuous tubing, and the tubing is drawn from the drum arrangement by the take-up mechanism.
Other features, additional objects and many of the attendant advantages of this invention will be readly understood by reference to the following detailed description of a preferred embodiment when considered in connection with the attached drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawing:
FIG. 1 shows an apparatus of the invention for the continuous production of non-woven textile tubing in side elevation;
FIG. 2 shows the apparatus of FIG. 1 in front elevation;
FIGS. 3 to 5 show the apparatus of FIG. 1 in sections on the line A--A, B--B and C--C, respectively;
FIG. 6 illustrates a modified apparatus of the invention in side elevation;
FIGS. 7 and 8 show the apparatus of FIG. 6 in sections on the lines E--E and D--D, respectively.
FIG. 9 is a transverse section, similar to FIG. 3, illustrating the use of a set of needles spanning about one-half of the diameter of the mandril.
FIG. 10 is a similar transverse section illustrating the needles applied to a cylindrical product and extending across the entire diameter of the mandril; and
FIG. 11 is a diagrammatic view of a portion of the needled web on a greatly enlarged scale illustrating the various angular paths of the needles through the web.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing in detail, and initially to FIGS. 1 and 2, there is seen a machine frame 1 which supports an elongated drum 2 of circular cross section. The drum 2 tapers slightly from the left toward the right (not shown in the drawings), as viewed in FIG. 1, and has a multiplicity of circumferential grooves. For the sake of convenient pictorial representation, relatively few grooves have been shown in FIG. 1, and their axial width has been exaggerated. The drum 2 is mounted on a shaft which is driven at a constant speed by a non-illustrated electric motor, whenever the machine operates.
A thin cylindrical roller 3 is journaled in a non-illustrated bearing on the frame 1 below the drum 2, and the bearing is adjustable on the frame to vary the axial spacing of the drum 2 and the roller 3, the respective axes being parallel.
A plate 4 carrying a multiplicity of needles is mounted above the drum 2 on a carrier 5. The carrier is vertically slidable on the frame 1 and is reciprocated by the drive motor of the drum 2 so that the needles on the plate 4 are inserted into the grooves of the drum 2 and withdrawn at a speed which can be adjusted by a variable transmission, not shown, which is interposed between the non-illustrated drive motor and the carrier 5.
As is seen in FIG. 3, a narrow fibrous web 6 of non-woven fabric is fed by an endless conveyor to the drum 2 and the roller 3, and is initially wound in a continuous loop over the drum and the roller. The several layers of fibrous material superimposed during the joint rotation of the drum and the roller, the latter being turned by the fibrous material, are continuously interwoven by the reciprocating needles on the board 4 in a manner conventional in the manufacture of non-woven fabrics. When the starting loop reaches the desired thickness, it is pulled manually along the drum 2 from the wide toward the narror axial end at a rate to maintain the desired thickness in the multilayered, helically wound tube 7 of needled non-woven fabric which is thereafter produced. The end of the tube is ultimately drawn from the drum 2 and pulled through an opening 8 in the frame 1 to a take-up mechanism which thereafter collects the tubular material at a rate to provide the desired overlapping of sequential turns of the web 6.
The take-up mechanism is mounted on a carriage 10 which travels on rails 11 on the table 9, a spindle 12 equipped with a handwheel being journaled on the table 9 and engaging a threaded sleeve on the carriage 10 to move the carriage horizontal at right angles to the axis of the drum 2. The table 9 is mounted on legs 13 which are hydraulic cylinders containing pistons attached to the table 9, but not visible in the retracted position shown in the drawing. The take-up mechanism may thus be shifted in two directions to accommodate tubes 7 of different width, as determined by the radial spacing of the drum 2 and roller 3.
Two annular upright plates 14, 15 are mounted on the carrier 10 in such a manner that the axes of their openings coincide and are parallel to the axis of the drum 2. A flat annular pulley 16 is supported between the plates 14, 15 on rollers 17 which engage the outer circumference of the pulley and whose shafts connect the plates 14, 15. A V-belt 18 is trained over the pulley 16 and over the drive pulley of a variable-speed electric motor 19 mounted on the frame 1.
A friction roller 20 engages the inner circumference of the pulley 16, and drives a shaft 21 which passes freely through the central opening in the plate 15. The shaft 21 carries a worm 22 which meshes with a gear 24 on one of two take-up rolls 23 drivingly connected by the gears 24.
During operation of the illustrated apparatus, the tube 7 is flattened and pulled through the opening 8 in the frame 1 by the take-up rolls 23 driven by gear 24. It is stored on a wind-up reel 25 driven by its own non-illustrated electric motor equipped with a slip clutch to maintain the necessary slight tension in the flattened tube.
The tube 7 rotates about its axis as it is discharged from the drum 2 and roller 3, and the entire take-up mechanism turns with it. A spur gear 26 is rotatably mounted on the plate 15 by means of circumferentially distributed stub shafts 27 on the gear 26, which carry V-notched rollers 28. The rollers 28 travel on the rim of the plate 15 around the central opening of the plate so that the gear 26 rotates coaxially with the pulley 16. The gear 26 is driven by a pinion on the output shaft of a variable-speed electric motor 29 at the same surface speed as the drum 2. As is best seen in FIG. 5, the flattened tube 7 passes through a diametrical slot 30 in the gear 26.
The aforementioned shaft 21, which connects the worm 22 to the friction roller 20, is journaled in the gear 26. The take-up rollers 23 driven by gear 24, the wind-up reel 25, and the non-illustrated drive motor of the latter are mounted on a sheet metal bracket fixedly attached to the gear 26 and extending through the central openings in the plates 14, 15.
Typically, the drum 2 and the roller 3 in the apparatus shown in FIGS. 1 to 5 may be set to produce helically wound, needle-stitched, non-woven fabric tubing 4 to 12 cm. in diameter. The needle plate 4 may carry about 1300 needles arranged in 13 rows extending axially of the drum 2, one needle of each row being aligned with a groove in the drum 2 and with one row of needles passing through the center line of the drum in a radial direction while the other rows are spaced from the center line in parallel planes. Depending on the requirements, the needle plate carrier 5 may be reciprocated approximately 100 to 1000 times per minute. The thickness of the tube 7 depends on the characteristics of the web 6 and on the pitch of the helix in which the web is wound over the drum 2 and the roller 3. The helix pitch is determined by the rotary speed of the take-up roll 24 at fixed rotary speed of the drum 2, and thus by the relationship of the speeds of the motors 19 and 29 which can be adjusted in a non-illustrated conventional manner.
The tubing produced on the aforementioned apparatus is being used successfully as a surface cover on cylindrical rollers employed in the paper industry and on tannery equipment. It can also be used as a filter medium on drum filters and, generally, where felt sleeves are presently used.
Conventional felt sleeves are prepared from woven fabrics or by fulling. In order to possess the required mechanical strength, they must contain an adequate amount of wool and have, therefore, limited resistance to acids, and particularly to alkaline liquids. The apparatus described above produces strong tubing from all types of fibers including smooth fibers which cannot be felted by fulling or other conventional methods. I have successfully prepared felt-like tubes from all commonly available synthetic fibers but also from inorganic fibers, such as metal, glass and asbestos fibers, without the admixture of wool. All conventional textile materials, including wool, can of course be converted to tubing on the illustrated apparatus.
When the tubing made according to this invention includes thermoplastic fibers, such as fibers of polyesters, polyamides, polypropylene, or acrylics, they may be subjected to a thermal aftertreatment. Typically, they may be subjected to infrared radiation from the outside or the inside to soften and fuse as much of the fibrous material as is desired. Depending on the readily controlled input of thermal energy, the tubing may be converted to a continuous, homogeneous structure, to an otherwise continuous film tube having pores of controlled size, or to a material of recognizable fiber structure in which the fibers are partly bonded to each other by heat sealing.
Bonding of the fibers to each other with or without thermal sealing may also be achieved by conventional admixtures to the initial web 6, such as elastomers (natural or synthetic rubber), and thermoplastic resins or thermosetting resins in the uncured condition, particularly phenol-formaldehyde and amine-formaldehyde resins, and by subsequently setting the adhesive. Other bonding materials suitable for use in preparing webs i6 include starch, starch ethers or esters, glues and adhesives of animal or plant origin (alginates, caseinates), also cellulose derivatives (cellulose esters, cellulose ethers, viscose) and vinyl alcohol.
Adhesives or bonding agents which have been used with particular success on the illustrated apparatus include a latex of butadiene-styrene elastomer, a latex of butadieneacrylonitrile copolymer, and natural rubber latex. These bonding agents are set by heating the tube until the water is substantially completely evaporated. The configuration of the pores in the non-woven fabric tube so obtained can be controlled precisely and reproducibly by selecting the setting conditions. The bonding agent, while still fluid, tends to migrate toward the source of heat, and the pores thus are smaller on the side of the tubing from which the heat is applied. The performance of filtering media of the invention can be improved by controlling the direction in which the flow section of the medium decreases.
Other bonding agents which have been used successfully in webs 6 fed to the apparatus of FIGS. 1 to 5 are aqueous dispersions of plasticized vinyl ester polymers, such as polymers and copolymers of vinyl acetate and vinyl chloride.
The modified apparatus shown in FIGS. 6 to 8 operates in substantially the same manner as that described hereinabove to produce corresponding products from non-woven webs with or without bonding agents.
Referring initially to FIG. 6, there are seen a frame 1, a drum 2, and a roller 3, identical with the corresponding elements shown in FIG. 1, and two needle-studded plates 4 on respective carriers 5 which move radially toward and away from the drum 2 in opposite directions for needle-stitching a tube 7 formed on the drum in the general manner described above with reference to FIGS. 1 to 5. The modified apparatus is capable of producing tubing 7 of a diameter selected by varying the spacing of the drum 2 and of the roller 3.
The take-up mechanism best seen in FIGS. 6 and 7 is mounted on a support 30' by means of rails 31 elongated axially of the drum 2 and a carrier plate longitudinally guided on the rails 31. The plate 32 is moved by continuous drive chains 33 attached to lateral lugs 34 of the plate. The chains are trained over sprockets of which one is driven by an electric motor 35 equipped with an infinitely adjustable variable-speed transmission 36, and connected to the driven sprocket by an overriding clutch 53, pulleys and a belt 37.
An electric motor 38 is mounted on the plate 32 for turning the hub 39 of a tube gripping mechanism about the axis of the drum 2 through a variable speed transmission which permits the rotary speed of the hub 39 to be adjusted to the rotary speed at which the drum 2 is turned by its non-illustrated drive motor.
Three pairs of guide channels 40 equiangularly radiate from the hub 39. The opposite grooves of each pair hold a pneumatically operated clamping mechanism in a radially adjustable position. Each mechanism consists of a cylinder 42 carrying an anvil 41 in radially inwardly spaced relationship, and a spring-loaded plunger in the cylinder 42 which moves toward and away from the anvil 41 when the cylinder 42 is supplied with operating fluid from compressed air line and vented through a solenoid valve in a conventional manner, not explicitly illustrated in the drawing.
The modified apparatus also is equipped with a cut-off mechanism which has been omitted for the sake of clarity from FIG. 6 where it would be largely obscured by the motor 35 and associated elements of the drive mechanism for the chains 33, but is shown in FIG. 8. The cutting mechanism is mounted on the frame 1 by means of a shaft 43 and a rocker plate 44 movable on the shaft 43. The portion of the rocker plate to the left of the shaft 43, as viewed in FIG. 8, carries an electric motor 45 connected by a belt drive to a circular cutting blade 46 mounted on the rocker plate 44 to the left of the motor. A pneumatically operated cylinder 47 is attached to the frame 1 under the portion of the plate 44 which carries the shaft of the blade 46. Another pneumatically operated cylinder 48 attached to the plate 44 carries a coupling clamp 49 which permits the plate 44 to be coupled to one of the drive chains 33 for axial movement thereby on the shaft 43.
The apparatus shown in FIGS. 6 to 8 automatically produces cut lengths of non-woven fabric tubing in the following manner:
At the start of each operating cycle, the carrier plate 32 is located at the left end of the support 30', as viewed in FIG. 6, and the leading circular edge of the tube 7 is located between the anvils 41 and the retracted plungers of the clamping mechanisms. As the plungers are expelled from the cylinders 42 by compressed air, they clamp the tube 7 to the take-up mechanism while the hub 39 turns in unison with the drum 2 and the roller 3. The carrier plate 32 is moved toward the right by the chains 33 at a rate which determines the helix angle of the web which is being wound on the drum 2 and the cylinder 3 while the several layers of the tube 7 formed thereby are stitched to each other by the needles on the needle plates 4.
The carrier plate 32 is moved toward the right until it abuts against a limit switch 50 which may be shifted on the support 30 according to the length of the tubing pieces which it is desired to produce. The switch 50 controls admission of compressed air to the cylinder 47 through a non-illustrated solenoid valve which also provides air for the coupling cylinder 48. The rocker plate 44 is tilted clockwise, as viewed in FIG. 8, so that the rotating blade 46 cuts the tube 7 while the plate 44 is moved by the chains 33 on the shaft 43 in unison with the take-up mechanism. The front end of the tube 7 is severed from the remainder of the tube after one revolution of the hub 39, and upward pivoting of the plate 44 by cylinder 47 and drops from the machine while the rocker plate 44 hits another limit switch 51 on the frame 1, which shifts the aforementioned non-illustrated solenoid switch to vent the cylinders 47, 48 and energizes another motor 52 connected to sprockets for the chains 33.
A non-illustrated return spring moves the rocker plate 44 on the shaft 43 into its starting position, and the motor 52 shifts the carrier plate toward the left, as viewed in FIG. 6, until the clamping mechanism 41, 42 grasps the freshly cut leading edge of the tube 7, and a new operating cycle is started by abutting engagement of the carrier plate 32 with yet another limit switch 54 on the frame 1. The switch 54 deenergizes the motor 52 and actuates the clamping mechanisms 41, 42. The latter are released by a non-illustrated solenoid valve when the limit switch 50 is operated. The overriding clutch 53 permits the carrier plate 32 to be returned to its starting position by the motor 52 while the motor 35 is energized.
The relays which connect the limit switches 50, 51, 54 with the pneumatic circuit of the machine and with the associated electric motors, and the pneumatic circuit itself have not been shown since they are conventional and obvious to those skilled in the art from the above description of their mode of operation.
The tubing 7 produced on the apparatus shown in FIGS. 6 to 8 is indistinguishable from that made on the apparatus of FIGS. 1 to 5. As released from the illustrated machines, it consists essentially of a helically wound fibrous web, each helical turn axially overlapping at least one axially preceding turn and being itself overlapped by an axially succeeding turn, the several superimposed turns being connected by fibers of an outer web extending partly radially inwardly through the inner layers, as is inherent in the needling operation by which the several layers are firmly anchored to each other.
While it is preferred to equip the apparatus of the invention with an auxiliary roller 3 to permit the diameter of the tubing to be changed as needed, the slightly tapering drum 2 alone is sufficient if long lengths of tubing of uniform diameter are to be made. It will further be appreciated that more than one web 6 may be fed simultaneously to the same drum 3 if so desired.
In the embodiment of FIG. 9, the mandril 2a, web 6a, and corresponding parts are given the same reference numbers as in FIGS. 1 to 8 and are similar to that above described. In this form the needle bar 4a is substantially wider than the needle bar 4 of FIG. 3 and contains nine longitudinal rows of needles 60a.
It will be noted that these rows of needles 60a extend from about the center of the mandril to the periphery thereof and have their points disposed in an arc corresponding to the periphery of the mandril 2a. The needles at the center line of the mandril enter the web 6a radially, that is, they extend through the finished web substantially transversely. The needles in the outer row of the periphery of the mandril extend through the web substantially tangentially, that is, substantially longitudinally of the finished web. The intermediate needles extend through the web on the mandril at various angles from transverse to longitudinal. Hence, the fibers are displaced at random angles across the web.
As the mandril rotates a slight amount between needle strokes, the angles of the needles in the web are varied as the web advances, thus producing a web wherein the displacement of the fibers in each part of the web lie at various random angles.
As further layers of the web are laid on the mandril and the needling continues, additional fibers are displaced in each layer and through adjacent layers to bind the layers together so that the felted web in the final product possesses a substantial amount of tensile strength and can be reduced to a semi-rigid state.
FIG. 10 illustrates a further embodiment which is similar to that above described except that the idler roll 3 is omitted and the web 6b is wound in a cylindrical form on the mandril 2b. In this form the needle bar 4b is of sufficient width to carry sets of needles which extend across substantially the entire diameter of the mandril. In the form shown there are 12 parallel sets of needles 60b, having their points disposed in an arc corresponding to the periphery of the mandril 2b. The central rows of needles extend substantially radially through the web and the outer rows of needles extend substantially tangentially therethrough. The intermediate rows extend at various angles therebetween as in the form of FIG. 9. The product of FIG. 10 differs from that of FIG. 9 in that the angles vary through substantially 180° across the web, whereas in FIG. 9 the variation is approximately 90°. As the mandril 2b rotates a slight amount, such as an amount comparable to the needle spacing between successive needle strokes, the fibers in each area of the web are displaced at various angles within a substantially 180° range.
The product obtained by the needle arrangement of FIG. 10 may be made relatively hard and stiff so that when applied to a roll of a paper making machine it will have a long life.
Since the points of the needles in FIG. 9 and 10 are arranged on an arcuate line conforming generally to the periphery of the mandril, each needle penetrates the entire thickness of the web but does not extend substantially therebeyond. Of course the needles may be disposed to extend only partly through the web, if desired, depending upon the arrangement and upon the needle stroke. It will be noted that the needles displace the fibers between the layers so that the various layers of web are securely bound together by the displaced fibers and in the product the separate layers are substantially indistinguishable.
FIG. 11 illustrates diagrammatically the various angular paths of the needles. In this FIG. the paths of the needles and consequently the displacement of the fibers in one layer of web is indicated by transverse angular lines 61. It will be apparent from this FIG. that the web can be subjected to a large number of needle strokes in any one area and that the random displacement of the fibers extends throughout the various areas of the web and through and between the layers, although only a single layer is shown in FIG. 11 for purposes of clarity.
FIGS. 1 to 8 show the unfelted web as being wound spirally on the mandril 2 to produce a continuous tubular product. It is to be understood that the unfelted web may be made the full axial length of the mandril and may be wrapped successively around the mandril to build up a tubular product of the desired thickness, in which case the axial length of the tubular product will correspond to the width of the unfelted web. Various other arrangements will be apparent to a person skilled in the art.
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A continuous fabric tubing is prepared by helically winding non-woven webs on a rotating drum in partly overlapping relationship, stitching the partly superimposed turns to each other by needling, and axially pulling the tubing so formed from the drum. The take-up mechanism, which pulls the tubing from the drum, rotates with the drum, and an automatic cut-off mechanism may be provided for automatically cutting the continuous tubing to uniform, adjustable lengths. The tubing may consist entirely of monofilaments and other smooth fibers not capable of normal felting.
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BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The present invention relates generally to riding mowers, and in particular, to a hydrostatically controlled rear steer mower with a front steering mechanism.
[0003] (2) Description of the Prior Art
[0004] Lawnmowers are well known in the art and have been used for decades to maintain a lawn's appearance. In the prior art, the lawnmower design has typically been of the form of a riding mower that is propelled by the use of a gasoline or diesel engine. A mowing deck is located beneath the mower, and in some circumstances in front or behind of mower. The mowing deck is usually powered by the same gasoline or diesel mower that propels the vehicle. The mowing deck may contain a series of pulleys connected with mowing blades that operate in a rotational pattern to cut a lawn.
[0005] Many problems have plagued the riding lawnmower. In the past, riding lawnmowers were incapable of cornering in an acceptable turn radius. In order to correct this problem, the prior art implemented a rear steer mowing system, commonly called a zero turn mower. This rear steer mechanism made each rear wheel independently controllable by the operator and turning was facilitated by slowing the inner turn radius wheel while accelerating the outer turn radius wheel. However, these zero turn mowers were deficient in the regards that they were susceptible to loss of tire grip while cornering and on steep terrain. When the rider was operating the vehicle on a steep terrain, the higher elevated tire would lose contact with the terrain surface and thereby cause the mower to sway out of control from the operator. This created a dangerous and inefficient method of mowing.
[0006] Thus, there remains a need for a new and improved hydrostatically controlled rear steer mower that is capable of maintaining tire grip while traversing rough, uneven or highly sloped terrain.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a rear steer mower having a front steering assembly. The front steering assembly includes a steering wheel configured for receiving rotational input from a rider and a steering shaft connected with the steering wheel and configured to receive rotational input from the steering wheel. A steering hub is connected with the steering shaft and configured to receive a pair of linking elements for transferring rotational input. A first spindle hub is located at a first predetermined distance from the steering hub and attached with a first pivotally movable front wheel, wherein the wheel is pivotally movable in a horizontal plane relative to the mower. A second spindle hub is located at a second predetermined distance from the steering hub and attached with a second pivotally movable front wheel, wherein the second pivotally movable wheel is movable in a horizontal plane relative to the mower. A first linking element extends from the first spindle hub to the steering hub, and a second linking element extends from the second spindle hub to the steering hub. Rotation of the steering wheel imparts rotational movement to the steering hub through the steering shaft, and the linking element imparts rotational movement to the first and second spindle hubs, thereby rotating the front tires of the rear steer mower in response to rotational input from the steering wheel.
[0008] In another embodiment, the steering wheel includes a slip joint connection and is selectively engageable.
[0009] In another embodiment, the front tires are negatively castered.
[0010] In another embodiment, the steering hub, first spindle hub, and second spindle hub are geared and the first linking element and the second linking element are chains, and the steering hub, first spindle hub, and second spindle hub are configured to receive the chain of the first linking element and second linking element, thereby forming a chain driven front end assembly.
[0011] In another embodiment, the steering hub, first spindle hub, and second spindle hub are pulleys and the first linking element and the second linking element are belts, and the steering hub, first spindle hub, and second spindle hub are configured to receive the belts of the first linking element and second linking element, thereby forming a belt driven front end assembly.
[0012] In another embodiment, the first front wheel and second front wheel are toed out in a horizontal plane relative to the mower.
[0013] In another embodiment, the steering shaft further includes universal joints.
[0014] In another embodiment, the mower includes a support for maintaining the front steering assembly in an upright position.
[0015] These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a side view of a mower constructed according to the prior art;
[0017] FIG. 2 is a side view of a mower constructed according to the present invention including the negatively castered pair of front wheels;
[0018] FIG. 3 is a perspective view of a mower constructed according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “left,” “right,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms. Referring now to the drawings in general and FIG. 1 in particular, it will be understood that the illustrations are for the purpose of describing an embodiment of the invention and are not intended to limit the invention thereto. As best seen in FIG. 1 , though also seen effectively in FIG. 2 and FIG. 3 , an improved vehicle 10 is shown according to the present invention. The vehicle 10 includes a steering assembly generally designated 12 , which includes a steering shaft 14 , steering support 16 , steering wheel 18 , and steering hub 20 for rotating the steering assembly 10 . The steering shaft 14 is support by the steering support 16 . The steering shaft 14 is also connected with the steering wheel 18 for receiving driver input. The steering shaft 14 may include a series of universal joints 52 for facilitating turning of the steering shaft 14 . The vehicle 10 includes a seat 26 , a mowing deck 24 and a hydrostatically operated rear axle 28 . As shown in FIG. 2 , the vehicle also includes an engine 13 , a chassis 11 and a pair of front wheels 15 . The steering wheel may be selectively engageable by the use of a slip joint, clutch or similar device.
[0020] As best shown in FIG. 2 , the vehicle 10 may contain a castered front end assembly, generally designated 30 .
[0021] As best seen in FIG. 3 , but also seen effectively in FIG. 1 and FIG. 2 , the steering assembly generally designated 12 contains a steering hub 20 . This steering assembly includes a series of gears 22 which are axially aligned with the steering axis of the steering shaft 14 and the pair of front wheels 15 . This steering hub 20 is connected with a chain 23 that is linked within the gears 22 of the steering shaft 14 and the pair of front wheels 15 . A pair of spindle hubs 25 are also provided that are coaxially with the pivotal point of each of the pair of front wheels 15 . The gears may be positioned such that the front tires are toed outward from each other. Alternatively, a series of pulleys and belts may be used in lieu of the gear and chain assembly. The pair of spindle hubs are configured such that the front wheels 15 may be rotated a full 360 degrees of motion.
[0022] In operation, the operator maneuvers the vehicle by engaging the hydrostatically or by other means controlled axle. If the operator desires, they may aid the vehicle in turning by using the selectively engageable steering wheel to rotate the pair of front wheels in the desired location. In the preferred embodiment, the front tires are toed out by the rotational transmission means assembly and are therefore able to corner more effectively. In embodiments with the castered front end assembly 30 , when the operator rotates the wheel assembly, the outer turn radius wheel will move diagonally upwards and the inner turn radius wheel will move diagonally downward. In cases on extreme inclines, this will aid the user in maintaining vehicle balance and stability.
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A rear steer mower having a front steering assembly is provided. The front steering assembly includes a steering wheel, a steering shaft, a pair of toed out negatively castered front wheels and a linking element configured to receive rotational input from the steering wheel to the pair of front wheels.
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BACKGROUND OF INVENTION
[0001] Articles produced from virgin polymers are typically colored for both practical and aesthetic reasons. Articles other than fibers typically have colorants dispersed throughout the article in addition, polyolefin fibers have colorants dispersed throughout the fiber because surface dyeing techniques have proven unsuccessful. Polyester, Nylon 6, and Nylon 6,6 fibers are typically colored by dyeing the surface of the already-formed fibers.
[0002] One significant limitation to the utility of recycled polymer derived from post-consumer fibers is the color difference between virgin polymer and recycled polymer. The dyes on the surface of recycled polymeric fibers may significantly decrease the suitability of the constituent polymer for reuse because color is not necessarily removed during conventional recycling processes.
[0003] A process directed to the removal of surface colorants is applicable only to certain polymeric fibers. However, a substantial quantity of polyamide fiber from post consumer carpet is potentially available for recycle. Approximately 40% of the face fibers in post residential carpet waste in the United States is surface dyed Nylon 6, while another 40% is surface dyed Nylon 6,6.
[0004] Processes for stripping dyes from fabric include U.S. Pat. No. 4,227,881 (Foho) which discloses a process for stripping dyes from textile fabric which involving heating an aqueous solution of an ammonium salt, a sulfite salt and an organic sulfonate, such as sodium hydroxymethane sulfonate, to at least 60 degrees Celsius and adding the dyed fabric to the heated solution while maintaining the temperature of the solution. This process is believed to result in less that satisfactory colorant removal.
[0005] U.S. Pat. No. 4,783,193 (Pensa) teaches a process for stripping color from synthetic polymer products by contacting the colored polymer with a chemical system including unstable dispersions of alkyl halides and aqueous solutions of bleaching/oxidizing agents to which specified quantities of acids and surfactant/wetting agents are added. The use of this chemical system may restrict the recyclability of the decolorized polymeric materials.
[0006] U.S. Pat. No. 5,989,296 (Patton) teaches a process for removing indigo dye from denim scrap by extracting the fabric with an organic solvent such as 1,1,2-trichloroethane in which the indigo dye is soluble at elevated temperatures, the solvent is cooled and extracted with an aqueous phase containing a reducing agent, and the aqueous phase is treated to oxidize and recover the indigo dye. This process is applicable only to indigo dyes.
[0007] U.S. Pat. No. 6,083,283 (Berkstresser, IV) teaches a process for removing color and extracting dyes from polymeric materials by contacting them with a swelling agent under conditions such that the swelling agent interrupts the molecular forces within the polymer matrix and opens the polymer structure sufficiently to remove natural and synthetic pigments dispersed throughout a polymeric article, thus it has wide applicability for colored polymeric articles other than surface dyed fibers. The use of swelling agents which penetrate throughout the polymer matrix to remove surface dyes is potentially undesirable because completely removing them after decolorization of the fiber would be expected to involve extensive washing.
[0008] Thus an unmet need exists for a cost-effective and environmentally friendly process for removing surface colorant from synthetic polymeric fibers without degrading the fiber, or otherwise compromising the polymeric material's suitability for recycling and re-use. This unmet need exists particularly for a process to remove surface colorants from the substantial surface dyed Nylon 6 and Nylon 6,6 fiber component of post-residential waste carpet. A process that can be conducted at atmospheric pressure is most attractive.
SUMMARY OF INVENTION
[0009] The present invention is directed to a method for removing surface dyes and colorants from polymeric materials. More particularly, the present invention is directed to a method for decolorizing Nylon 6, and Nylon 6,6 fibers for the purpose of increasing the suitability of the constituent polymers for subsequent reuse.
[0010] The present invention is directed to a cost-effective and environmentally friendly process for removing surface stains and dye-imparted color from colored polymeric fibers.
[0011] The process and composition of the present invention are particularly useful in the recycling of thermoplastic materials. Materials decolorized by the process of the present invention may be utilized in place of or blended with virgin thermoplastics in any known thermoplastics applications including extruding the melted material to form fiber which may be dyed.
[0012] It was unexpectedly discovered that a dye or other colorant can be substantially removed from the surface of polymeric materials, particularly fibers, by contacting the materials with an organic ester solvent stripping composition containing a cyclic ester, particularly ethylene carbonate, propylene carbonate, or butylene carbonate, at a temperature below the boiling temperature of the ester solvent stripping composition to effect the release of dye or other colorant from the surface of the polymer. Thus the process can be carried out at ambient pressure.
[0013] Copending patent application Ser. No. 10/708,479 (Mauldin) discloses that polyester polymer is decomposed when heated in the presence of a cyclic ester such as propylene carbonate to form an admixture having utility as an industrial solvent. This novel solvent composition has been found to remove colorants from the surface of polyamide polymer fibers. In this embodiment of the invention, the colored polyamide fibers are contacted with the ester solvent stripping composition at a temperature between about 90 degrees Celsius and about 220 degrees Celsius. Optionally, the decolored polymeric material can be subsequently washed with a polar cyclic ester such as ethylene carbonate, propylene carbonate, butylene carbonate, and mixtures thereof, containing no dissolved colorant.
[0014] The process of the present invention includes contacting colored polyamide fibers with at least one ester solvent stripping composition under conditions sufficient to effect release of the colorant from the surface of the fibers. The process is especially useful for quickly and thoroughly removing colorants from surface dyed polyamide fibers as part of a recycling process for such fibers. Colorants are considered to be any dye, pigment or colored composition or combinations thereof that may intentionally or accidentally color or stain polymeric materials, while dyes are considered to be organic materials which impart color to a polymer and which chemically bond to the polymer surface primarily by ionic mechanisms. The process of the present invention removes colorants from the surface of polyamide fibers without substantially degrading Nylon 6 or Nylon 6,6 polyamide polymers, thus allowing for their recovery and reuse.
[0015] In one embodiment of the present invention, a process for recycling colored polyamide fibers comprises the steps of shearing or cutting Nylon 6 or Nylon 6,6 face fibers from post consumer carpet waste, then contacting the colored polyamide fibers with an ester stripping solvent solution at a temperature effective to remove colorant from the surface of the polymeric material. In another embodiment, a process for recycling colored polyamide fibers comprises the steps of shredding the entire carpet and grinding the face fibers and backing components to yield individual fibers commingled with discrete particles of backing materials, then separating the fibers from the non-fibrous components before contacting the colored polyamide fibers with an ester stripping solvent solution at a temperature effective to remove colorant from the surface of the polymeric material. These two embodiments are especially useful in recycling the surface dyed polyamide face fiber component of post-consumer carpet.
[0016] Another embodiment of the process of the present invention which can allow recycling of the ester solvent stripping composition used to decolorize colored polyamide material comprising: (a) removal of colorant from colored polyamide fibers utilizing an ester solvent stripping composition further containing an alcohol that separates as an immiscible liquid phase as the ester solvent stripping composition is cooled to ambient temperature; (b) cooling the ester solvent stripping composition to a temperature between about 20 degrees and about 90 degrees Celsius, whereby the solution separates into an ester phase and an alcohol phase containing colorant; and (c) removing colorant from the alcohol phase through further separate processing while the ester phase is immediately available for reuse as a component of the ester solvent stripping composition.
[0017] In practicing the present invention to decolorize the colored polymeric face fiber component of post consumer carpet waste, the process of decolorization should preferably be preceded by one or more of the preliminary steps of (a) physically segregating carpet pieces having Nylon 6, or Nylon 6,6 face fibers; (b) cleaning the group of carpet pieces containing only one of Nylon 6 or Nylon 6,6 face fibers from step (a) by mechanically separating dirt and other loosely-attached foreign materials; (c) separating the Nylon 6 or Nylon 6,6 face fibers from the backing of the carpet by a method selected from the group consisting of mechanical shearing, melt-cutting with a hot wire, melt-cutting with a laser, shredding followed by grinding and air elutriation, and combinations thereof; and (d) cutting, shearing, or grinding the colored fibers into fibrous particles having reduced size.
[0018] The present invention has a number of advantages over prior art decolorization methods.
[0019] The present invention does not substantially degrade the polymer and therefore recovered polymer can be used in new polymeric materials or articles in place of virgin polymer. The stripping solvents of the present invention laden with colorants can be thoroughly removed from the surface of the fibers with relative ease because the stripping agent does not penetrate into the fibers and disrupt the molecular forces within the polymer matrix sufficiently to result in an opening of the polymer structure.
DETAILED DESCRIPTION
[0020] The process of the present invention includes contacting colored polymeric fibers with at least one ester solvent stripping composition under conditions so as to effect the release of a dye or other colorant from the surface of the polymeric material. The amount of the ester solvent stripping composition and the conditions under which the contacting takes place are selected so that the polymeric material does not undergo substantial destruction or degradation. The contacting step is most preferably performed at ambient pressure.
[0021] As will be apparent to one skilled in the art, the combined effect of temperature and the formulation of a suitable contacting composition can be used to control the processes of the present invention. Thus variation and optimization of the contacting composition, and the temperature, time, and repetition conditions of the contacting process in order to maximize the decolorizing effect of the contacting composition are considered to be within the scope of the present invention. It should be noted that since the process is conducted at ambient pressure, only ester solvent stripping compositions containing esters and alcohols that boil at relatively high temperatures can be used.
[0022] A preferred practice of this invention utilizes the temperature dependence of the solubility of dyes in the ester solvent stripping compositions to effect separation of dyes from the ester solvent stripping compositions. The dyes are removed as particulate precipitates, thus allowing recycling of the ester solvent stripping compositions.
[0023] Alternatively, the dissolved dyes can be removed from the ester solvent stripping compositions by prior art techniques such as adsorption onto activated carbon or some other solid surface, chemical destruction, or electrolytic coagulation. The residence time for contacting the colored polymeric material with the contacting composition during the contacting step may be controlled to ensure the desired degree of color removal. Suitable residence times for the contacting step will depend upon the conditions of the contacting step. The preferred residence time is at least about ½ minute and no greater than about 20 minutes, more preferably about 3 to 10 minutes. The contacting step in these embodiments may include a plurality of contacting stages wherein the colored polymeric material is contacted with an ester solvent stripping composition at each stage. One skilled in the art would appreciate that the residence time varies depending on the temperature and other conditions in order to achieve the results of the present invention. The process of the present invention may further include a washing step, wherein any residual dye, colorant, or ester solvent stripping composition is removed. Suitable washing agents should at least partially solubilize residual dye, colorant or ester solvent stripping composition without harming the decolorized polymeric material. Washing agents should be polar liquids and preferably are selected from the group including ethylene carbonate and propylene carbonate. Water, C.sub.1 to C.sub.4 aliphatic alcohols, and mixtures thereof may also be used. An after treatment wash with an aqueous 0.1% to 0.3% sodium hydrosulfite solution may also be employed to enhance final polymer color. The contacting step may be performed using a variety of techniques that will be apparent to one of ordinary skill in the art. Such techniques include immersing the colored polymeric material in the ester solvent stripping composition, spraying an effective amount of ester solvent stripping composition onto the polymeric material, and other similar such techniques. Further the contacting step may be carried out in lots in a batch-wise manner or it may be carried out in a continuous manner. In an especially preferred embodiment, dyed nylon fiber is contacted with the solvent composition disclosed in copending patent application Ser. No. 10/708,479 (Mauldin) at a temperature of at least about 130 degrees Celsius for a period of about 0.5 to 5 minutes. A series of two or three sequential treatments can be employed to improve the final polymer product color.
[0024] The following examples are included to demonstrate preferred embodiments of the invention. Those skilled in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the spirit and scope of the invention.
EXAMPLE 1
[0025] A deep red surface-dyed Nylon 6 yarn was cut into about 1 inch lengths and 10 grams of the yarn was placed into an Erlenmeyer flask with 100 grams of solvent prepared by admixing 100 grams of Propylene Carbonate with 20 grams of Poly(ethylene terephthalate) yarn and heating the admixture to 230 degrees Celsius for 15 minutes. The Nylon 6 yarn pieces were immersed in the ester solvent composition, heated to a temperature of 160 degrees Celsius, whereupon the solvent was separated from the Nylon 6 fibers by filtration. The Nylon 6 yarn pieces were visably lighter in color and the ester solvent composition was observed have a strong red color.
EXAMPLE 2
[0026] Colored Nylon 6,6 carpet fibers recovered from post-residential carpet waste were obtained from a commercial broker of recycled thermoplastic materials. Ten grams of these fibers were selected to obtain fibers of at least four distinct colors including red, blue, beige, and brown; the fibers were placed into an Erlenmeyer flask with 100 grams of solvent composed of 70 grams of Propylene Carbonate and 30 grams of “Soygold 1000” methyl ester of soybean oil. The fibers were immersed in the ester solvent and heated to a temperature of 200 degrees Celsius, whereupon the solvent was separated from the Nylon 6,6 fibers by filtration. The fibers had assumed a uniform light grey appearance while the ester solvent composition was observed to have a brown coloration.
EXAMPLE 3
[0027] Surface-dyed Nylon 6 carpet fibers recovered from industrial commercial carpet waste were obtained from a commercial carpet manufacturer. The fibers were deep blue in color. Ten grams of these fibers were placed into an Erlenmeyer flask with 100 grams of solvent composed of 80 grams of Propylene Carbonate and 20 grams of 2-Octanol. The fibers were immersed in the solvent and heated to a temperature of 130 degrees Celsius, whereupon the solvent was separated from the Nylon 6 fibers by filtration. The fibers had assumed an off-white color. The solvent was observed to have a blue color. Upon cooling below 55 degrees Celsius, the solvent separated into 2 liquid phases with the greatest volume represented by the lower phase. The 2-Octanol phase was substantially darker blue in color than the Propylene Carbonate phase. While the compositions and methods of this invention have been described in terms of preferred embodiments, the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.
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Novel organic compositions for removing dyes from the surface of polymeric fibers are disclosed. The method for dye removal from the surface of fibers includes contacting the fibers with a non-aqueous ester stripping composition preferably containing at least one cyclic ester and optionally containing a surfactant, an alcohol, or both. The process of the present invention is especially useful for removing color from dyed polyamide fibers as part of a recycling process for such materials.
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FIELD OF THE INVENTION
[0001] The present invention relates to fabric treatment compositions comprising an aminosilioxane polymer nanoemulsion and methods of making said nanoemulsions and fabric treatment compositions. More specifically, the present invention relates to a process for making aminosiloxane polymer nanoemulsions that may be used to protect surfaces from being soiled or wetted.
BACKGROUND OF THE INVENTION
[0002] Numerous attempts have been made to develop a treatment composition that provides protection of surfaces by repelling water and oil based soils from the surface. Fluoropolymers, such as those used in Scotchguard® from 3M, have become well established as soil-repellant molecules. However, fluoropolymers are not preferred due to environmental, health and safety concerns, such as the potential and possibility of persistent bioaccumulation and toxicity.
[0003] Amino-modified silicone microemulsions that contain an amino-modified silicone and a high concentration of both ethylene glycol monoalkyl ether and nonionic surfactant, e.g., polyoxyalkylene branched decyl ether, are known and generally described as transparent in appearance and having a small particle diameter. However, these compositions have the challenge of delivering maximum hydrophobicity to a surface since they incorporate significant amounts of nonionic surfactant to obtain desired stability and particle sizes.
[0004] Unfortunately, to date, the attempts at non-fluorpolymer protection of surfaces continue to demonstrate disadvantages, including low efficiency, difficulty in achieving the desired benefits at affordable cost and in a preferred format, processing and formulation challenges, and product instability. A continued need exists for a non-fluoropolymer technology that delivers depositable benefits to surfaces, such as water and oily soil repellency, in a convenient and stable form and at a high efficiency.
[0005] Even attempts at using non-fluoropolymer technologies have been less than successful due to a general failure to recognize the importance of the order of addition of materials during the making process as well as the processing conditions themselves, in addition to optimization of the solvent system, addition of adjunct ingredients that can enhance performance, and equally the removal of adjuncts that can hinder performance. Applicants have found that by optimizing the order of addition of the raw materials during emulsion making and finished product formulation using said emulsion, the overall stability of the emulsion and finished product can be greatly enhanced. Furthermore, the deposition efficiency and overall soil repellency benefit can be maximized, whilst minimizing the potential for negative results often seen with silicone-containing compositions, such as staining or spotting of fabrics, laundry machine residues, and product discoloration.
SUMMARY OF THE INVENTION
[0006] The present invention provides a fabric treatment composition comprising a nanoemulsion made by a process comprising the steps of:
a) solubilizing a silicone resin in an organic solvent system to yield a silicone resin solution concentration of about 80% or less, wherein the organic solvent system comprises diethyleneglycol monobutyl ether and at least one additional solvent selected from the list consisting of monoalcohols, polyalcohols, ethers of monoalcohols, ethers of polyalcohols, fatty esters, Guerbet alcohols, isoparaffins, naphthols, glycol ethers or mixtures thereof, provided that if the additional solvent is a glycol ether it is not diethyleneglycol monobutyl ether; b) mixing the silicone resin solution from a) with an aminosiloxane polymer to obtain an aminosiloxane polymer:silicone resin mixture having ratio of about 20:1; c) allowing the aminosiloxane polymer:silicone resin mixture to age for at least about 6 hours at ambient temperature; d) adding the aminosiloxane polymer:silicone resin mixture to a vessel; e) optionally adding with agitation an additional organic solvent to the aminosiloxane polymer:silicone resin mixture; f) mixing until homogenous; g) adding a protonating agent; h) additionally adding an aqueous carrier in an amount to produce the desired concentration of emulsion.
[0015] The present invention attempts to solve one more of the needs by providing, in one aspect of the invention, a method of making an aminosiloxane polymer nanoemulsion which can be incorporated into a surface treatment composition, comprising the nanoemulsion. Said nanoemulsion comprising a silicone resin, an aminosiloxane polymer having an amine equivalent of less than about 0.6 meq/g, wherein said polymer has greater than about 5% but less than about 25% of terminal groups comprising hydroxyl functionality; at least one an organic solvent selected from the group consisting of linear alcohols, branched alcohols, Guerbet alcohols, fatty esters, glycol ethers, isoparaffins, naphthols, and mixtures thereof; optionally a second organic solvent; an aqueous carrier; a protonating agent; optionally, a deposition aid polymer selected from cationic and amphoteric polymers, and adjunct ingredients; wherein said nanoemulsion is substantially free of surfactant.
[0016] Another aspect of the invention includes treatment compositions comprising the amino silicone nanoemulsions as described herein. Other aspects of the invention include methods of making treatment compositions comprising the amino silicone nanoemulsions and methods of treating surfaces with treatment compositions comprising the amino silicone nanoemulsions.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Features and benefits of the various embodiments of the present invention will become apparent from the following description, which includes examples of specific embodiments intended to give a broad representation of the invention. Various modifications will be apparent to those skilled in the art from this description and from practice of the invention. The scope is not intended to be limited to the particular forms disclosed and the invention covers all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the claims.
[0018] As used herein, the articles including “the,” “a” and “an” when used in a claim or in the specification, are understood to mean one or more of what is claimed or described.
[0019] As used herein, the terms “include,” “includes” and “including” are meant to be non-limiting.
[0020] As used herein, the terms “substantially free of” or “substantially free from” means that the indicated material is at the very minimum not deliberately added to the composition to form part of it, or, preferably, is not present at analytically detectable levels. It is meant to include compositions whereby the indicated material is present only as an impurity in one of the other materials deliberately included.
[0021] Preferably, substantially free from surfactant means that the emulsion comprises at most 1 percent by weight of surfactant, more preferably at most 0.1 percent by weight of surfactant.
[0022] As used herein, the term nanoemulsion refers to thermodynamically stable oil in water emulsions that have extremely small droplet sizes (below 750 nm, or typically below 250 nm). These materials have special properties, including optical translucency, very large dispersed phase surface-to-volume ratios and long term kinetic stability. Due to similarity in appearance, translucent nanoemulsions are sometimes confused with microemulsions, which belong to another class of stable (thermodynamically) and optically clear colloidal systems. Microemulsions are spontaneously formed by “solubilizing” oil molecules with a mixture of surfactants, co-surfactants and co-solvents. The required surfactant concentration in a microemulsion is typically several times higher than that in a nanoemulsion and significantly exceeds the concentration of the dispersed phase (generally, oil). Because of many undesirable side-effects caused by surfactants, this is disadvantageous or prohibitive for many applications. In addition, the stability of microemulsions is easily compromised by dilution, heating, or changing pH levels. By contrast nanoemulsions in accordance with the present invention are formed by judiciously selecting solvent systems that provide adequate dissolution of the siloxanes and also exhibit some level of miscibility with water, thus a stable aqueous emulsion can be achieved without the use of surfactants. Without wishing to be bound by theory, applicants believe that choosing a solvent or solvent system whereby the solvents exhibit dual polarity, these solvents of choice can behave similarly to surfactants in solution without introducing the wetting effect that surfactants typically bring. Thus, it is possible to deliver an oil-in-water emulsion, without having surfactant present, that is capable of providing maximum hydrophobicity to a target surface.
[0023] All cited patents and other documents are, in relevant part, incorporated by reference as if fully restated herein. The citation of any patent or other document is not an admission that the cited patent or other document is prior art with respect to the present invention.
[0024] In this description, all concentrations and ratios are on a weight basis of the total nanoemulsion composition, all pressures are equal to 0.10 MPa (absolute) and all temperatures are equal to 20° C. unless otherwise specified.
[0025] Known amino silicone microemulsions and methods for preparing amino silicone microemulsions employ high levels of solvent and nonionic surfactant (e.g., 12% ethylene glycol monohexyl ether per 100% of amino silicone and 40% polyoxyalkylene branched decyl ether per 100% of amino silicone), and/or require high energy in the form of heat or high shearing forces in order to obtain the desired nanoparticle size. Without being bound by theory, it is believed that the presence of high levels of solvent and surfactant in the emulsion hinders the deposition of the amino silicone on the surface that is to be treated; amino silicone droplets in high-solvent and high-surfactant emulsions tend to stay in the emulsion, rather than deposit on the surface. This results in a poor delivery of any benefit, such as increased water repellency or oil repellency, to the surface. Such benefits may be measured as an increased time to wick on treated fabrics, a reduced dry-time for treated fabrics and/or an increased contact angle on a hard surface.
[0026] In contrast to conventional amino silicone microemulsions, the amino silicone nanoemulsions of the present invention comprise reduced levels of solvent and no intentionally added surfactant and may be obtained without the input of high energy to process the emulsion. Yet, the amino silicone nanoemulsions disclosed herein provide highly efficient deposition on a target surface. Benefits derived from this deposition may generally apply in the area of repellency of water and/or water-based compositions and/or oil and/or oil-based compositions, such as water-based stains and oily soils. Without being bound by theory, it is believed that the amino silicone nanoemulsions disclosed herein comprise self-assembled, spherical, positively charged amino silicone nano-particles (which contain reduced levels of solvent and surfactant). These self-assembled, spherical, positively charged nano-particles exhibit efficient deposition and controlled spreading, that is believed to form a structured film on a surface that provides the repellency benefit as determined by the below specified time to wick method.
[0027] The average particle sizes of the disclosed nanoemulsions range from about 20 nm to about 750 nm, or about 20 nm to about 500 nm, or about 50 nm to about 350 nm, or about 80 nm to about 200 nm, or about 90 nm to about 150 nm. (as measured by Malvern Zetasizer Nano Series instrument). The disclosed nanoemulsions are generally transparent or slightly milky in appearance.
Silicone Resin
[0028] Typically, the amino silicone nanoemulsion of the present invention comprises a silicone resin.
[0029] An example of a silicone resin is a mixture of polyorganosiloxane-silicone resins, where each of the one or more silicone resins of the polyorganosiloxane-silicone resin mixture contains at least about 80 mol % of units selected from the group consisting of units of the general formulas 3, 4, 5, 6:
[0000] R 3 SiO 1/2 (3),
[0000] R 2 SiO 2/2 (4),
[0000] RSiO 3/2 (5),
[0000] in which R is selected from H, —OR 10 , or —OH residues or monovalent hydrocarbon residues with 1 to 40 carbon atoms, optionally substituted with halogens, where at least 20 mol % of the units are selected from the group consisting of units of the general formulas (5) and (6), and a maximum of 10 wt % of the R residues are —OR 10 and —OH residues.
[0030] The silicone resins may preferably be MQ silicon resins (MQ) comprising at least 80 mol % of units, preferably at least 95 mol % and particularly at least 97 mol % of units of the general formula (3) and (6). The average ratio of units of the general formula (3) to (6) is preferably at least 0.25, particularly at least 0.5, preferably at most 4, and more preferably at most 1.5.
[0031] The silicon resins may also preferably be DT silicone resins (DT) comprising at least 80 mol % of units, preferably at least 95 mol % and particularly at least 97 mol % of units of the general formula (4) and (5). The average ratio of units of the general formula (4) to (5) is preferably at least 0.01, particularly at least 0.2, preferably at most 3.5, and more preferably at most 0.5.
[0032] Preferred halogen substituents of the hydrocarbon residues R are fluorine and chlorine. Preferred monovalent hydrocarbyl radicals R are methyl, ethyl, phenyl.
[0033] Preferred monovalent hydrocarbyl radicals R 10 are methyl, ethyl, propyl and butyl.
Aminosiloxane Polymer
[0034] Suitable aminosiloxane polymers are represented by of one or more liquid aminoalkyl-containing polyorganosiloxanes (P) comprising at least 80 mol % of units selected from units of the general formulas (7), (8), (9) and (10):
[0000] R 1 2 SiO 2/2 (7),
[0000] R 1 a R 2 b SiO (4-a-b)/2 (8),
[0000] R 3 3 SiO (1/2) (9),
[0000] R 3 2 R 4 SiO (10),
where a has the value 0 or 1, b has the value 1 or 2, a+b has a value of 2, R 1 represents monovalent hydrocarbyl radicals having 1-40 carbon atoms and optionally substituted with halogens, R 2 represents either a) aminoalkyl radicals of the general formula (11)
[0000] —R 5 —NR 6 R 7 (11)
where R 5 represents divalent hydrocarbyl radicals having 1-40 carbon atoms, R 6 represents monovalent hydrocarbyl radicals having 1-40 carbon atoms, H, hydroxymethyl or alkanoyl radicals, and R 7 represents a radical of the general formula (12)
[0000] —(R 8 —NR 6 ) x R 6 (12)
where x has the value 0 or an integer value from 1 to 40, and R 8 represents a divalent radical of the general formula (13)
[0000] —(CR 9 2 − ) y (13)
[0000] where y has an integer value from 1 to 6, and
R 9 represents H or hydrocarbyl radicals having 1-40 carbon atoms, or b) in the general formula (11) R 6 and R 7 combine with the nitrogen atom to form a cyclic organic radical having 3 to 8 —CH 2 — units, although nonadjacent —CH 2 — units may be replaced by units selected from —C(═O)—, —NH—, —O— and —S—, R 3 represents hydrocarbyl radicals having 1-40 carbon atoms and optionally substituted with halogens, R 4 represents —OR or —OH radicals, and
wherein, in the polyorganosiloxanes (P), the average ratio of the sum of units of the general formula (7) and (8) to the sum of units of the general formula (9) and (10) is in the range from 0.5 to 500, the average ratio of units (9) to (10) being in the range from 1.86 to 100, and the polyorganosiloxanes (P) have an average amine number of at least 0.01 mequiv/g.
[0055] The monohydric hydrocarbyl radicals R, R 1 , R 3 , R 6 , R 9 and R 10 may be halogen substituted, linear, cyclic, branched, aromatic, saturated or unsaturated. Preferably, the monovalent hydrocarbyl radicals R, R 1 , R 3 , R 6 , R 9 and R 10 each have 1 to 6 carbon atoms, and particular preference is given to alkyl radicals and phenyl radicals. Preferred halogen substituents are fluorine and chlorine. Particularly preferred monovalent hydrocarbyl radicals R, R 1 , R 3 , R 6 , R 9 and R 10 are methyl, ethyl, phenyl.
[0056] The divalent hydrocarbyl radicals R 5 may be halogen substituted, linear, cyclic, branched, aromatic, saturated or unsaturated. Preferably, the R 5 radicals have 1 to 10 carbon atoms, and particular preference is given to alkylene radicals having 1 to 6 carbon atoms, in particular propylene. Preferred halogen substituents are fluorine and chlorine.
[0057] Preferred R 6 radicals are alkyl and alkanoyl radicals. Preferred halogen substituents are fluorine and chlorine. Preferred alkanoyl radicals are —C(═O)R 11 , where R 11 has the meanings and preferred meanings of R 1 . Particularly preferred substituents R 6 are methyl, ethyl, cyclohexyl, acetyl and H. It is particularly preferable for the R 6 and R 7 radicals to have the meaning H.
[0058] Preferred cyclic organic radicals formed from R 6 and R 7 in the general formula (11) together with the attached nitrogen atom are the five and six rings, in particular the residues of pyrrolidine, pyrrolidin-2-one, pyrrolidine-2,4-dione, pyrrolidin-3-one, pyrazol-3-one, oxazolidine, oxazolidin-2-one, thiazolidine, thiazolidin-2-one, piperidine, piperazine, piperazine-2,5-dione and morpholine.
[0059] Particularly preferred R 2 radicals are —CH 2 NR 6 R 7 , —(CH 2 ) 3 NR 6 R 7 and —(CH 2 ) 3 N(R 6 )(CH 2 ) 2 N(R 6 ) 2 . Examples of particularly preferred R 2 radicals are aminoethylamino-propyl and cyclohexylaminopropyl.
[0060] Preference is also given to mixtures (M) wherein at least 1 mol %, more preferably at least 5 mol %, particularly at least 20 mol % and at most 90 mol %, more preferably at most 70 mol % and particularly at most 60 mol % of the R 6 and R 7 radicals are acetyl radicals and the remaining R 6 and R 7 radicals have the meaning H.
[0061] Preferably, b is 1. Preferably, a+b has an average value from 1.9 to 2.2.
[0062] Preferably, x has the value 0 or a value from 1 to 18, more preferably 1 to 6.
[0063] Preferably, y has the values of 1, 2 or 3.
[0064] Preferably, the polydiorganosiloxanes (P) comprise at least 3 and particularly at least 10 units of the general formula (7) and (8).
[0065] Preferably, the liquid aminoalkyl-containing polyorganosiloxanes (P) comprise at least 95 mol %, more preferably at least 98 mol % and particularly at least 99.5 mol % of units selected from units of the general formula (7), (8), (9) and (10).
[0066] Further units of the polyorganosiloxanes (P) can be selected for example from units selected from units of the general formulae (3), (4,) (5) and (6).
[0067] The ratio of a to b is chosen such that the polyorganosiloxanes (P) preferably have an amine number of at least 0.1, in particular at least 0.3 mequiv/g of polyorganosiloxane (P). The amine number of the polyorganosiloxanes (P) is preferably at most 7, more preferably at most 4.0 and particularly at most 3.0 mequiv/g of polyorganosiloxane (P).
[0068] The amine number designates the number of ml of 1N HCl which are required for neutralizing 1 g of polyorganosiloxane (P).
[0069] The viscosity of the polyorganosiloxanes (P) is preferably at least 1 and particularly at least 10 mPa·s and preferably at most 100,000 and particularly at most 10,000 mPa·s at 25° C.
[0070] The ratio of the units of the general formula (7) and (8) to the sum total of (9) and (10) is preferably at least 10, particularly at least 50 and preferably at most 250, particularly at most 150.
[0071] The ratio of units (9) to (10) is preferably at least 1.9 and particularly at least 2.0 and preferably at most 70 and particularly at most 50.
[0072] The polyorganosiloxanes (P) are obtainable via known chemical processes such as, for example, hydrolysis or equilibration.
Organic Solvent System
[0073] The amino silicone nanoemulsion of the present invention comprises from about 0.1% to about 50% of one or more solvents, by weight of the amino silicone. In certain aspects, the amino silicone nanoemulsion comprises from about 5% to about 30% of one or more solvents, by weight of the amino silicone. In some aspects, the amino silicone nanoemulsion comprises from about 10% to about 25% of one or more solvents, by weight of the amino silicone. In other aspects, the amino silicone nanoemulsion comprises from about 15% to about 23% or from about 18% to about 21% of one or more solvents, by weight of the amino silicone.
[0074] In one aspect of the invention the solvent system contains at least two solvents wherein one is diethyleneglycol monobutyl ether, such as that sold under the trade name Butyl Carbitol™ from Dow Chemical (Midland, Mich.), and additional solvent(s) are selected from monoalcohols, polyalcohols, ethers of monoalcohols, ethers of polyalcohols, fatty esters, Guerbet alcohols, isoparaffins, naphthols, glycol ethers or mixtures thereof, provided that if the additional solvent is a glycol ether it is not diethyleneglycol monobutyl ether.
[0075] In some aspects, the solvent is selected from a mono-, di-, or tri-ethylene glycol monoalkyl ether that comprises an alkyl group having 1-12 carbon atoms, or a mixture thereof. Suitable alkyl groups include methyl, ethyl, propyl, butyl groups, hexyl groups, heptyl groups, octyl groups, nonyl groups, decyl groups, undecyl groups, phenyl, and dodecyl groups, as well as acetate groups of each.
[0076] Suitable examples of monoethylene glycol monoalkyl ethers, include ethyleneglycol methyl ether, ethyleneglycol ethyl ether, ethyleneglycol propyl ether, ethyleneglycol butyl ether, ethyleneglycol butyl ether acetate, ethyleneglycol phenyl ether, ethyleneglycol hexyl ether, and combinations thereof. Suitable examples of diethylene glycol monoalkyl ethers, include diethyleneglycol methyl ether, diethyleneglycol ethyl ether, diethyleneglycol propyl ether, diethyleneglycol butyl ether, diethyleneglycol phenyl ether, diethyleneglycol hexyl ether, and combinations thereof.
[0077] In some aspects, the solvent is selected from a mono-, di-, or tri-propylene glycol monoalkyl ether that comprises an alkyl group having 1-12 carbon atoms, or a mixture thereof. Suitable alkyl groups include methyl, ethyl, propyl, butyl groups, hexyl groups, heptyl groups, octyl groups, nonyl groups, decyl groups, undecyl groups, phenyl, and dodecyl groups, as well as acetate groups of each.
[0078] Suitable examples of monopropylene glycol monoalkyl ethers, include propyleneglycol methyl ether, propyleneglycol methyl ether acetate, propyleneglycol methyl ether diacetate, propyleneglycol propyl ether, propyleneglycol butyl ether, propyleneglycol phenyl ether, and combinations thereof. Suitable examples of dipropylene glycol monoalkyl ethers, include dipropyleneglycol methyl ether, dipropyleneglycol methyl ether acetate, dipropyleneglycol propyl ether, dipropyleneglycol butyl ether, and combinations thereof. Suitable examples of tripropylene glycol monoalkyl ethers, include tripropyleneglycol methyl ether, tripropyleneglycol propyl ether, tripropyleneglycol butyl ether, and combinations thereof.
[0079] In some aspects the solvent is selected from fatty esters such as isopropyl esters of long chain fatty acids having 8 to 21 carbon atoms. Suitable examples of fatty esters include isopropyl laurate, isopropyl myristate, isopropyl palmitate, isopropyl stearate, isopropyl oleate, isopropyl linoleate, and combinations thereof.
[0080] In some aspects, the solvent comprises a linear or branched mono- or polyhydric alcohol, or a Guerbet alcohol, such as 2-ethylhexanol, 2-butyloctanol, or 2-hexyldecanol, or mixtures thereof.
[0081] In some aspects the solvent comprises a naphthol or isoparaffin having from about 8 to about 16 carbon atoms, such as isoparaffins sold under the trade name Isopar E™, Isopar L™ Isopar G™, or Isopar M™ (available from ExxonMobile Chemicals, Houston, Tex.).
[0082] Protonating Agent
[0083] The protonating agent is generally a monoprotic or multiprotic, water-soluble or water-insoluble, organic or inorganic acid. Suitable protonating agents include, for example, formic acid, acetic acid, propionic acid, malonic acid, citric acid, hydrochloric acid, sulfuric acid, phosphoric acid, nitric acid, or mixtures thereof. In some aspects, the protonating agent is selected from formic acid, acetic acid, or a mixture thereof. In some aspects, the protonating agent is acetic acid. Generally, the acid is added in the form of an acidic aqueous solution. The protonating agent is added in an amount necessary to achieve a nanoemulsion pH of from about 3.5 to about 7.0. In certain aspects, the aminosiloxane polymer nanoemulsions comprise the protonating agent in an amount necessary to achieve a pH of from about 3.5 to about 6.5 or about 4.0 to about 6.0. In other aspects, the aminosiloxane polymer nanoemulsions comprise the protonating agent in an amount necessary to achieve a pH of most preferably from about 3.5 to about 5.0.
Water
[0084] The aminosilicone nanoemulsions of the present invention can be diluted to produce any desired concentration of nanoemulsion by the addition of water.
Optional Adjunct Ingredients
[0085] The amino silicone nanoemulsions may additionally include further substances, such as preservatives, scents, corrosion inhibitors, UV absorbers, structurants, opacifiers, optical brighteners, and dyes. Examples of preservatives are alcohols, formaldehyde, parabens, benzyl alcohol, propionic acid and salts thereof and also isothiazolinones. The nanoemulsions may further include yet other additives, such as non-silicon-containing oils and waxes. Examples thereof are rapeseed oil, olive oil, mineral oil, paraffin oil or non-silicon-containing waxes, for example carnauba wax and candelilla wax incipiently oxidized synthetic paraffins, polyethylene waxes, polyvinyl ether waxes and metal-soap-containing waxes. In some aspects, the amino silicone nanoemulsions further comprise carnauba wax, paraffin wax, polyethylene wax, or a mixture thereof. The nanoemulsions may comprise up to about 5% by weight of the nanoemulsion or from about 0.05% to about 2.5% by weight of the nanoemulsion of such further substances.
Method of Making
[0086] The method for preparing the amino silicone nanoemulsions of the present invention includes the steps of: solubilizing the silicone resin in an organic solvent or mixture of organic solvents to yield a resin solution concentration of about 80% or less, preferably of about 70% or less, more preferably of about 60% or less, or most preferably of about 55% or less, followed by mixing the resin solution with an amino siloxane polymer to obtain an amino siloxane polymer:resin ratio of about 20:1, preferably about 10:1, more preferably about 7:1, most preferably about 5.8:1, and allowing the mixture to age for at least about 6 hours at room temperature; the emulsion is then prepared by adding the amino siloxane polymer:resin mixture to a vessel containing a small amount of water with agitation, optionally followed by addition of a second organic solvent to aid in the dispersion of the amino siloxane polymer:resin mixture in aqueous carrier; once the solvent, silicone and carrier mixture has become homogenous, then the protonating agent is added, followed by additional amounts of carrier to produce a nanoemulsion at the desired concentration. Optional adjunct materials are then added to the mixture and agitated until thoroughly mixed.
Treatment Composition
[0087] The amino silicone nanoemulsions of the present invention may be incorporated into treatment compositions or cleaning compositions, such as, but not limited to, a fabric care composition, a hard surface care composition, or a home care composition. In some aspects, the treatment composition comprises from about 0.001% to about 99% by weight of the composition, of the amino silicone nanoemulsion. In certain aspects, the treatment composition comprises from about 0.001% to about 40%, or from about 0.1% to about 35%, or from about 1% to about 30%, or from about 5% to about 25%, or from about 9% to about 22% or from about 13% to about 18% of the amino silicone nanoemulsion, by weight of the composition.
[0088] In one aspect, the fabric treatment composition comprising a nanoemulsion of the present invention may be made according to a process comprising the steps of:
a) solubilizing a silicone resin in an organic solvent system to yield a silicone resin solution concentration of about 80% or less, wherein the organic solvent system comprises a single solvent selected from the group consisting of monoalcohols, polyalcohols, ethers of monoalcohols, ethers of polyalcohols, fatty esters, Guerbet alcohols, isoparaffins, naphthols, glycol ethers, provided that if the solvent is a glycol ether it is not diethyleneglycol monobutyl ether; b) mixing the silicone resin solution from a) with an aminosiloxane polymer to obtain an aminosiloxane polymer:silicone resin mixture having ratio of about 20:1; c) allowing the aminosiloxane polymer:silicone resin mixture to age for at least about 6 hours at ambient temperature; d) adding the aminosiloxane polymer:silicone resin mixture to a vessel; e) optionally adding with agitation an additional organic solvent to the aminosiloxane polymer:silicone resin mixture; f) mixing until homogenous; g) adding a protonating agent; h) additionally adding an aqueous carrier in an amount to produce the desired concentration of nanoemulsion i) adding the nanoemulsion to a vessel; j) optionally, adding to the vessel containing the aforementioned nanoemulsion a perfume oil; k) adding an organic solvent; l) optionally, adding a deposition aid polymer; m) adding additional water to achieve the desired finished product concentration; n) optionally, adding a preservative; o) optionally, adding a dispersant; p) adding a protonating agent; and q) optionally, adding a dye.
[0106] Examples of treatment compositions include, but are not limited to, laundry spray treatment products, laundry pre-treatment products, fabric enhancer products, hard surface treatment compositions (hard surfaces include exterior surfaces, such as vinyl siding, windows, and decks), carpet treatment compositions, and household treatment compositions. Examples of fabric care compositions suitable for the present disclosure include, but are not limited to, laundry spray treatment products, laundry pre-treatment products, laundry soak products, and rinse additives. Examples of suitable home care compositions include, but are not limited to, rug or carpet treatment compositions, hard surface treatment compositions, floor treatment compositions, and window treatment compositions.
[0107] In some aspects, the treatment composition may be provided in combination with a nonwoven substrate, as a treatment implement.
[0108] In certain aspects, the compositions provide water and/or oil repellency to the treated surfaces, thereby reducing the propensity of the treated surface to become stained by deposited water- or oil-based soils.
[0109] By “surfaces” it is meant any surface. These surfaces may include porous or non-porous, absorptive or non-absorptive substrates. Surfaces may include, but are not limited to, celluloses, paper, natural and/or synthetic textiles fibers and fabrics, imitation leather and leather. Selected aspects of the present invention are applied to natural and/or synthetic textile fibers and fabrics.
[0110] By “treating a surface” it is meant the application of the composition onto the surface. The application may be performed directly, such as spraying or wiping the composition onto a hard surface. The composition may or may not be rinsed off, depending on the desired benefit.
[0111] The present invention also encompasses the treatment of a fabric as the surface. This can be done either in a “pretreatment mode”, where the composition is applied neat onto the fabric before the fabrics are washed or rinsed, or a “post-treatment mode”, where the composition is applied neat onto the fabric after the fabric is washed or rinsed. The treatment may be performed in a “soaking mode”, where the fabric is immersed and soaked in a bath of neat or diluted composition. The treatment may also be performed in a “through the wash” or “through the rinse” mode where the treatment composition, as defined herein, is added to the wash cycle or the rinse cycle of a typical laundry wash machine cycle. When used in the wash or rinse cycle, the compositions are typically used in a diluted form. By “diluted form” it is meant that the compositions may be diluted in the use, preferably with water at a ratio of water to composition up to 2000:1, or from 1:1 to about 1000:1, or from 3:1 to about 500:1, or from 5:1 to 200:1, or from 10:1 to 80:1.
[0112] Such treatment compositions may comprise carriers, which may be any known material that is useful in delivering the treatment compositions to the surface to be treated. The carrier may be as simple as a single component delivery vehicle, such as water or alcohol, which would allow the nanoemulsion to be sprayed onto a surface. Alternatively, the carrier may be complex, such as a cleaning composition, e.g., a laundry detergent where the nanoemulsion would be applied in conjunction with the other beneficial uses of the complex carrier.
[0113] Such treatment compositions may comprise various other materials, including bleaching agents, bleach activators, builders, chelating agents, smectite clays, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic metal complexes, polymeric dispersing agents, clay and soil removal/anti-redeposition agents, brighteners, suds suppressors, suds boosters, dyes, additional perfumes and perfume delivery systems, structure elasticizing agents, fabric softeners, carriers, hydrotropes, processing aids and/or pigments.
[0114] Deposition Assisting Polymer or Deposition Polymer—The compositions of the present invention contain non-polysaccharide based cationic copolymers comprising the polymerized monomer unit residues of one or more ethylenically unsaturated cationic or amine monomers and one or more ethylenically unsaturated nonionic monomer and optionally one or more ethylenically unsaturated anionic monomers. When anionic monomeric units are present in the polymer, it is understood that the polymer is net cationic i.e., the number of cationic monomeric units are more than the number of anionic monomeric units in the polymer chain. Specifically, the cationic polymers are compatible with detersive enzymes in the detergent composition and are capable of assisting and/or enhancing the deposition of benefit agents onto fabrics during laundering.
[0115] Exemplary cationic or amine monomers useful in this invention are N,N-dialkylaminoalkyl methacrylate, N,N-dialkylaminoalkyl acrylate, N,N-dialkylaminoalkyl acrylamide, N,N-dialkylaminoalkylmethacrylamide, methacylamidoalkyl trialkylammonium chloride, acrylamidoalkylltrialkylamminium chloride, vinylamine, vinyl imidazole, quaternized vinyl imidazole and diallyl dialkyl ammonium chloride. Preferred cationic and amine monomers are N,N-dimethyl aminoethyl acrylate, N,N-dimethyl aminoethyl methacrylate (DMAM), [2-(methacryloylamino)ethyl]tri-methylammonium chloride (QDMAM), N,N-dimethylaminopropyl acrylamide (DMAPA), N,N-dimethylaminopropyl methacrylamide (DMAPMA), acrylamidopropyl trimethyl ammonium chloride, methacrylamidopropyl trimethylammonium chloride (MAPTAC), quaternized vinyl imidazole and diallyldimethylammonium chloride.
[0116] Exemplary nonionic monomers suitable for use in this invention are acrylamide (AM), N,N-dialkyl acrylamide, methacrylamide, N,N-dialkylmethacrylamide, C1-C12 alkyl acrylate, C1-C12 hydroxyalkyl acrylate, C1-C12 hydroxyetheralkyl acrylate, C1-C12 alkyl methacrylate, C1-C12 hydroxyalkyl methacrylate, vinyl acetate, vinyl alcohol, vinyl formamide. Preferred nonionic monomers are acrylamide, N,N-dimethyl acrylamide, C1-C4 alkyl acrylate, C1-C4 hydroxyalkylacrylate, vinyl formamide, vinyl acetate, and vinyl alcohol. Most preferred nonionic monomers are acrylamide, hydroxyethyl acrylate (HEA), hydroxypropyl acrylate (HPA), vinyl formamide, vinyl acetate, and vinyl alcohol.
[0000]
[0117] The polymer may optionally comprises anionic monomers, such as acrylic acid, methacrylic acid, maleic acid, vinyl sulfonic acid, styrene sulfonic acid, acrylamidopropylmethane sulfonic acid (AMPS) and their salts.
[0118] The polymer may optionally be cross-linked. Crosslinking monomers include, but are not limited to, ethylene glycoldiacrylatate, divinylbenzene, butadiene.
[0119] The most preferred polymers are poly(acrylamide-co-diallyldimethylammonium chloride), poly(acrylamide-methacrylamidopropyltrimethyl ammonium chloride), poly(acrylamide-co-N,N-dimethyl aminoethyl methacrylate), poly(acrylamide-co-N,N-dimethyl aminoethyl methacrylate), poly(hydroxyethylacrylate-co-dimethyl aminoethyl methacrylate), poly(hydroxpropylacrylate-co-dimethyl aminoethyl methacrylate), poly(hydroxpropylacrylate-co-methacrylamidopropyltrimethylammonium chloride).
[0120] In order for the deposition polymers to be formulable and stable in the composition, it is important that the monomers are incorporated in the polymer to form a copolymer, especially true when monomers have widely different reactivity ratios are used. In contrast to the commercial copolymers, the deposition polymers herein have a free monomer content less than 10%, preferably less than 5%, by weight of the monomers. Preferred synthesis conditions to produce reaction products containing the deposition polymers and low free monomer content are described below.
[0121] The deposition assisting polymers can be random, block or grafted. They can be linear or branched. The deposition assisting polymers comprises from about 1 to about 60 mol percent, preferably from about 1 to about 40 mol percent, of the cationic monomer repeat units and from about 98 to about 40 mol percent, from about 60 to about 95 mol percent, of the nonionic (i.e., “neutral”) monomer repeat units.
[0122] The deposition assisting polymer has a charge density of about 0.1 to about 5.0 milliequivalents/g (meq/g) of dry polymer, preferably about 0.2 to about 3 meq/g. This refers to the charge density of the polymer itself and is often different from the monomer feedstock. For example, for the copolymer of acrylamide and diallyldimethylammonium chloride with a monomer feed ratio of 70:30, the charge density of the feed monomers is about 3.05 meq/g. However, if only 50% of diallyldimethylammonium is polymerized, the polymer charge density is only about 1.6 meq/g. The polymer charge density is measured by dialyzing the polymer with a dialysisis membrane or by NMR. For polymers with amine monomers, the charge density depends on the pH of the carrier. For these polymers, charge density is measured at a pH of 7. The weight-average molecular weight of the polymer will generally be between 10,000 and 5,000,000, preferably from 100,000 to 2,00,000 and even more preferably from 200,000 and 1,500,000, as determined by size exclusion chromatography relative to polyethyleneoxide standards with RI detection. The mobile phase used is a solution of 20% methanol in 0.4M MEA, 0.1 M NaNO 3 , 3% acetic acid on a Waters Linear Ultrandyrogel column, 2 in series. Columns and detectors are kept at 40° C. Flow is set to 0.5 mL/min.
Perfume—The treatment composition of the present disclosure may optionally comprise a perfume component selected from the group consisting of: (1) a perfume microcapsule, or a moisture-activated perfume microcapsule, comprising a perfume carrier and an encapsulated perfume composition, wherein said perfume carrier may be selected from the group consisting of cyclodextrins, starch microcapsules, porous carrier microcapsules, and mixtures thereof; and wherein said encapsulated perfume composition may comprise low volatile perfume ingredients, high volatile perfume ingredients, and mixtures thereof; (2) a pro-perfume; (3) a low odor detection threshold perfume ingredients, wherein said low odor detection threshold perfume ingredients may comprise less than about 25%, by weight of the total neat perfume composition; and (4) mixtures thereof. Microcapsule—The treatment composition of the present disclosure may comprise from about 0.05% to about 5%; or from about 0.1% to about 1% of a microcapsule. In one aspect, the microcapsule may comprise a shell comprising a polymer crosslinked with an aldehyde. In one aspect, the microcapsule may comprise a shell comprising a polymer selected from the group consisting of polyurea, polyurethane, polyamine, urea crosslinked with an aldehyde or melamine crosslinked with an aldehyde. Examples of materials suitable for making the shell of the microcapsule include melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde, or other condensation polymers with formaldehyde.
[0129] In one aspect, the microcapsules may vary in size (i.e., the maximum diameter is from about 1 to about 75 microns, or from about 5 to about 30 microns). The capsules may have an average shell thickness ranging from about 0.05 to about 10 microns, alternatively from about 0.05 to about 1 micron.
[0130] In one aspect, the microcapsule may comprise a perfume microcapsule. In turn, the perfume core may comprise a perfume and optionally a diluent. Suitable perfume microcapsules may include those described in the following references: published USPA Nos 2003-215417 A1; 2003-216488 A1; 2003-158344 A1; 2003-165692 A1; 2004-071742 A1; 2004-071746 A1; 2004-072719 A1; 2004-072720 A1; 2003-203829 A1; 2003-195133 A1; 2004-087477 A1; 2004-0106536 A1; U.S. Pat. Nos. 6,645,479; 6,200,949; 4,882,220; 4,917,920; 4,514,461; RE32,713; 4,234,627; EP 1393706 A1. Capsules having a perfume loading of from about 50% to about 95% by weight of the capsule may be employed.
Pro-perfume—The perfume component of the treatment composition of the present disclosure may additionally include a pro-perfume. Pro-perfumes may comprise nonvolatile materials that release or convert to a perfume material as a result of, e.g., simple hydrolysis, or may be pH-change-triggered pro-perfumes (e.g. triggered by a pH drop) or may be enzymatically releasable pro-perfumes, or light-triggered pro-perfumes. The pro-perfumes may exhibit varying release rates depending upon the pro-perfume chosen. Pro-perfumes suitable for use in the disclosed compositions are described in the following: U.S. Pat. Nos. 5,378,468; 5,626,852; 5,710,122; 5,716,918; 5,721,202; 5,744,435; 5,756,827; 5,830,835; and 5,919,752. Builders—The treatment compositions of the present disclosure may comprise one or more detergent builders or builder systems. When present, the compositions will typically comprise at least about 1% builder, or from about 5% or 10% to about 80%, 50%, or even 30% by weight, of said builder. Builders include, but are not limited to, the alkali metal, ammonium and alkanolammonium salts of polyphosphates, alkali metal silicates, alkaline earth and alkali metal carbonates, aluminosilicate builders polycarboxylate compounds, ether hydroxypolycarboxylates, copolymers of maleic anhydride with ethylene or vinyl methyl ether, 1,3,5-trihydroxybenzene-2,4,6-trisulphonic acid, and carboxymethyl-oxysuccinic acid, the various alkali metal, ammonium and substituted ammonium salts of polyacetic acids such as ethylenediamine tetraacetic acid and nitrilotriacetic acid, as well as polycarboxylates such as mellitic acid, succinic acid, oxydisuccinic acid, polymaleic acid, benzene 1,3,5-tricarboxylic acid, carboxymethyloxysuccinic acid, and soluble salts thereof. Chelating Agents—The treatment compositions may also optionally contain one or more copper, iron and/or manganese chelating agents. If utilized, chelating agents will generally comprise from about 0.1% by weight of the compositions herein to about 15%, or even from about 3.0% to about 15% by weight of the compositions herein. Dye Transfer Inhibiting Agents—The treatment compositions of the present disclosure may also include one or more dye transfer inhibiting agents. Suitable polymeric dye transfer inhibiting agents include, but are not limited to, polyvinylpyrrolidone polymers, polyamine N-oxide polymers, copolymers of N-vinylpyrrolidone and N-vinylimidazole (PVPVI), polyvinyloxazolidones and polyvinylimidazoles or mixtures thereof. When present in the compositions herein, the dye transfer inhibiting agents are present at levels from about 0.0001%, from about 0.01%, from about 0.05% by weight of the cleaning compositions to about 10%, about 2%, or even about 1% by weight of the cleaning compositions.
[0135] Dispersants—The treatment compositions of the present disclosure may also contain dispersants. Suitable water-soluble organic materials are the homo- or co-polymeric acids or their salts, in which the polycarboxylic acid may comprise at least two carboxyl radicals separated from each other by not more than two carbon atoms, ethoxylated tallow amines, linear or branched fatty alcohol alkoxylates, and mixtures thereof.
Enzymes—The treatment compositions may comprise one or more detergent enzymes, which provide cleaning performance and/or fabric care benefits. Examples of suitable enzymes include, but are not limited to, hemicellulases, peroxidases, proteases, cellulases, xylanases, lipases, phospholipases, esterases, cutinases, pectinases, keratanases, reductases, oxidases, phenoloxidases, lipoxygenases, ligninases, pullulanases, tannases, pentosanases, malanases, β-glucanases, arabinosidases, hyaluronidase, chondroitinase, laccase, and amylases, or mixtures thereof. A typical combination is a cocktail of conventional applicable enzymes like protease, lipase, cutinase and/or cellulase in conjunction with amylase. Enzyme Stabilizers—Enzymes for use in the treatment compositions, e.g., detergents, may be stabilized by various techniques. The enzymes employed herein can be stabilized by the presence of water-soluble sources of calcium and/or magnesium ions in the finished compositions that provide such ions to the enzymes. Hueing Dyes—The composition may comprise a fabric hueing agent (sometimes referred to as shading, bluing or whitening agents). Typically the hueing agent provides a blue or violet shade to fabric. Hueing agents can be used either alone or in combination to create a specific shade of hueing and/or to shade different fabric types. This may be provided for example by mixing a red and green-blue dye to yield a blue or violet shade. Hueing agents may be selected from any known chemical class of dye, including but not limited to acridine, anthraquinone (including polycyclic quinones), azine, azo (e.g., monoazo, disazo, trisazo, tetrakisazo, polyazo), including premetallized azo, benzodifurane and benzodifuranone, carotenoid, coumarin, cyanine, diazahemicyanine, diphenylmethane, formazan, hemicyanine, indigoids, methane, naphthalimides, naphthoquinone, nitro and nitroso, oxazine, phthalocyanine, pyrazoles, stilbene, styryl, triarylmethane, triphenylmethane, xanthenes and mixtures thereof.
[0139] In some aspects, the treatment composition comprises an amino silicone nanoemulsion and a carrier. In some aspects, the treatment composition comprises an amino silicone nanoemulsion, a carrier, and a perfume.
[0140] In certain aspects of the present disclosure, the treatment composition is a fabric care composition. Such a fabric care composition may take the form of a rinse added fabric conditioning compositions. Such compositions may comprise a fabric softening active and a dispersant polymer, to provide a stain repellency benefit to fabrics treated by the composition, typically from about 0.00001 wt. % (0.1 ppm) to about 1 wt. % (10,000 ppm), or even from about 0.0003 wt. % (3 ppm) to about 0.03 wt. % (300 ppm) based on total rinse added fabric conditioning composition weight. In another specific aspect, the compositions are rinse added fabric conditioning compositions. Examples of typical rinse added conditioning composition can be found in U.S. Provisional Patent Application Ser. No. 60/687,582 filed on Oct. 8, 2004.
Methods of Using Treatment Compositions
[0141] The treatment compositions of the present disclosure may be used in a method of treating a surface. The method of treating a surface comprises the step of applying the amino silicone nanoemulsion treatment composition of the present disclosure to a surface, where the surface is selected from fabric or a hard surface.
Fabric Treatment
[0142] The treatment compositions disclosed in the present specification may be used to treat a fabric, such as those described herein. Typically at least a portion of the fabric is contacted with an embodiment of the aforementioned fabric care compositions, in neat form or diluted in a liquor, for example, a wash liquor and then the fabric may be optionally washed and/or rinsed and/or dried without further treatment. In one aspect, a fabric is optionally washed and/or rinsed, contacted with an embodiment of the aforementioned fabric care compositions and then optionally washed and/or rinsed. For purposes of the present disclosure, washing includes but is not limited to, scrubbing, and mechanical agitation. The fabric may comprise most any fabric capable of being laundered or treated.
[0143] The fabric care compositions disclosed in the present specification can be used to form aqueous washing or treatment solutions for use in the laundering and/or treatment of fabrics. Generally, an effective amount of such compositions is added to water, preferably in a conventional fabric laundering automatic washing machine, to form such aqueous laundering solutions. The aqueous washing solution so formed is then contacted, preferably under agitation, with the fabrics to be laundered therewith. An effective amount of the fabric care composition, such as the liquid detergent compositions disclosed in the present specification, may be added to water to form aqueous laundering solutions that may comprise from about 500 to about 7,000 ppm or even from about 1,000 to about 3,000 ppm of fabric care composition.
[0144] In one aspect, the fabric care compositions may be employed as a laundry additive, a pre-treatment composition and/or a post-treatment composition.
[0145] Without being bound by theory it is believed the treatment of a fabric with compositions disclosed in the present specification may increase the time-to-wick of the fabric. Table VII shows an increase in the time-to-wick of cotton fabric as a result of treatment with examples of compositions disclosed in the present specification.
[0146] In some aspects, there is provided a method of treating a surface comprising the step of applying the amino silicone nanoemulsion treatment composition of the present disclosure to a surface, where the surface is a fabric and where the water repellency relative to the untreated fabric is increased, as measured by an increase in Time to Wick. In certain aspects, the increase in Time to Wick is greater than about 100 seconds, or greater than about 500 seconds, or greater than about 1200 seconds. In some aspects, the oil repellency relative to the untreated fabric is increased, as measured by an increase in Time to Wick. In some aspects, the oil repellency relative to the untreated fabric is increased, as measured by an increase in Time to Wick greater than about 10 seconds.
Hard Surfaces
[0147] The treatment compositions disclosed in the present specification may be used to clean or treat hard surfaces, such as those described herein. Typically at least a portion of the hard surface is contacted with an embodiment of the aforementioned hard surface care compositions, in neat form or diluted in a liquor, for example, a wash liquor and then the hard surface may be optionally washed and/or rinsed and/or dried without further treatment. In one aspect, a hard surface is optionally washed and/or rinsed, contacted with an embodiment of the aforementioned hard surface care compositions and then optionally washed and/or rinsed and/or dried without further treatment. For purposes of the present disclosure, washing includes but is not limited to, scrubbing, and mechanical agitation.
[0148] The hard surface care compositions disclosed in the present specification can be used to form aqueous washing or treatment solutions for use in the washing and/or treatment of hard surfaces. Generally, an effective amount of such compositions is added to water to form such aqueous washing and/or treatment solutions. The aqueous washing and/or treatment solution so formed is then contacted with the hard surface to be washed or treated therewith.
[0149] Without being bound by theory, it is believed the treatment of the hard surface with compositions disclosed in the present specification may increase the contact angle of water or water-based composition and/or oily substances on the hard surface. Without being bound by theory it is believed that increasing the contact angle of substances on a hard surface increases the ease of removing said substances from the surface
[0150] In some aspects, there is provided a method of treating a surface comprising the step of applying the amino silicone nanoemulsion treatment composition of the present disclosure to a surface, where the surface is a hard surface and where the contact angle relative to the untreated hard surface is increased.
[0151] While various specific embodiments have been described in detail herein, the present disclosure is intended to cover various different combinations of the disclosed embodiments and is not limited to those specific embodiments described herein. The various embodiments of the present disclosure may be better understood, when read in conjunction with the following representative examples. The following representative examples are included for purposes of illustration and not limitation.
Test Methods
[0152] Time to Wick (T2W) Measurement Method
[0153] The fabric Time to Wick property is a measure of the water repellency of a fabric, where longer times indicate greater repellency. Water repellency is measured when a drop of water is applied to the fabric, such as white 6.1 oz (165-200 gsm) Gildan Ultra 100% Cotton t-shirts (size large, item number 2000, Gildan USA, Charleston, S.C.). The Gildan t-shirts are prepared by de-sizing for 2 cycles of laundering with clean rinses using the AATCC 2003 standard reference liquid detergent without optical brighteners (AATCC—American Association of Textile Chemists and Colorists, Research Triangle Park, N.C., USA) in a standard top-loader, North American style washing machine, such as a Kenmore 600 Model 110.28622701. For treatment, 12 t-shirts are added to the drum of a standard washing machine, set on Heavy Duty wash cycle, water level equal to 17 gallons (Super load size), warm water, selected with single rinse option. Water is regulated to standardize the wash temperature to 90° F., Rinse to 60° F., and water hardness to 6 grain per gallon. Detergent is added to the wash water, such as Tide liquid Detergent (50.0 g dose), Clean Breeze scent. With the fabrics in the washer, the rinse water is allowed to fill the tub. Prior to agitation, the fabric treatment composition of the present invention (40 grams) is equally dispersed and added to the rinse water, followed by completion of the rinse cycle. The garments are then placed in a standard dryer, such as a Kenmore standard 80 series, cotton cycle (high heat), for 30 minutes or until dry. The fabrics are then removed from the dryer and placed in a cool, well ventilated room with controlled humidity set at 50% RH, and temperature regulated to 70° F., for a period of 24-48 hours. The section of the fabric that will be measured for Time to Wick is subjected to UV light, such as standard overhead lab lighting, for 24-48 hours prior to measurement. Treated test fabric is compared for Time to Wick value versus an untreated control fabric that has been prepared in a similar manner as the test fabric without the addition of the fabric treatment composition.
[0154] The Time to Wick value is measured as follows: On a flat, level hard surface (e.g. benchtop) a fresh square of a paper towel at least 10 cm×10 cm in size, is placed inside the prepared t-shirt so that 1 layer of fabric is being measured. A 300 μL drop of DI water is then dispensed onto the fabric surface from a calibrated pipette. The process of absorption of the liquid drop is visually monitored and recorded counting the time elapsed in seconds. Eight drops are administered per t-shirt, with each drop placed at a different location separate from all adjacent drops.
[0155] For each drop, the time differential between when the drop is applied and when absorbed is calculated and recorded in seconds. The time at drop absorption is defined as being the earliest time point at which no portion of the drop is observed remaining above the surface of the fabric. If the drop remains after 10 minutes, observation is discontinued. Such drops are recorded as having a time differential of 600 seconds. The Time to Wick value for a given liquid on fabric is the average of the time differentials recorded for 8 drops of that liquid. In order to determine the effect of a treatment, comparisons are made between the average Time to Wick value obtained from the treated fabric, versus the average obtained from its untreated control fabric using the same liquid, where longer times indicate greater repellency.
Particle Size Measurement Test Method by Using Malvern Zetasizer Nano ZS
[0156] The organosilicone nanoemulsions finished product containing the nanoemulsions are measured either neat or diluted with DI water to a specific concentration (1:10, 1:500 or 1:1000) with filtered DI water (using Gelman acrodisc LC PVDF 0.45 μm) prior to making particle size measurements. The particle size measurement is performed immediately after the sample completely disperses in water. The data is reported as the average of 3 readings.
Sample Preparation:
[0157] The dilution used will be dependent upon the type of sample: silicone emulsions are diluted at a concentration of 1:500 and 1:1000 and finish products are measured as neat and diluted to a concentration of 1:10 in DI water.
Before diluting the sample, gently invert it several times to mix it well. Rinse the 10 ml vial with filtered DI water to remove any dust then pipette a specific amount of filtered DI water and sample to the vial to make up the correct concentration (1:10, 1:500 or 1:1000). Invert the vial several times to make sure the sample completely disperses in water. Add 1 ml of diluted sample or neat sample to a clean cuvette ensuring that there are no air bubbles present in the sample.
Instrument Set up Conditions:
[0161] The particle size measurements are made via Malvern Zetasizer Nano Series ZS, with model #ZEN3600 with the fixed parameter settings for both Silicone emulsion and finish product:
[0000]
Material:
Silicone
Refractive
1.400
Index (RI)
Absorption
0.001
Dispersion:
Water
Temp.
25° C.
Viscosity
0.8872 cP
RI
1.33
General Option:
Using dispersant viscosity as sample viscosity
Temperature:
25° C.
Aging time:
0 second
Cell Type:
DTS0012- Disposable sizing cuvette
Measurement:
Meas. Angle
173° Backscatter
(NIBS default)
Meas. Duration
Manual
Number of runs
3
Run duration
60 s
Number of Meas.
3
Delay between meas.
0 s
Positioning method
Seek for optimum position
Automatic
Yes
attenuation selection
Data
Analysis model
General purpose
Processing:
(normal resolution)
Test Method for Determining the Range of Nanoparticle Typical Diameters and the Presence/Absence of Nanoparticle Aggregates, Using a Cryo-Transmission Electron Microscope (Cryo-TEM).
[0162] Samples of the liquid composition to be tested are prepared for microscopic analysis in order to observe nanoparticles that may be suspended in the composition. Sample preparation involves pipetting approximately 5 μl of the liquid composition onto a holey carbon grid (such as Lacey Formvar Carbon on 300 mesh copper grid, P/N 01883-F, available from Ted Pella Inc., Redding, Calif., U.S.A., or similar). The excess liquid is blotted away from the edge of the grid with a filter paper (such as Whatman brand #4, 70 mm diameter, manufactured by GE Healthcare/General Electric Company, Fairfield, Conn., U.S.A., or similar). The grid-mounted sample is plunged rapidly into liquid ethane using a freezing apparatus capable of producing a flash-frozen vitreous thin film of sample lacking crystalline ice (such as a Controlled Environment Vitrification System (CEVS device), or similar apparatus). The apparatus configuration and use of a CEVS device is described in the Journal of Electron Microscopy Technique volume 10 (1988) pages 87-111. Liquid ethane may be prepared by filling an insulated container with liquid nitrogen and placing a second smaller vessel into the liquid nitrogen. Gaseous ethane blown through a syringe needle into the second vessel will condense into liquid ethane. Tweezers pre-cooled in liquid nitrogen are used to rapidly handle the frozen grids while taking great care to maintain the vitreous non-crystalline state of the sample and minimize the formation of frost on the sample. After being flash frozen the grid-mounted samples are stored under liquid nitrogen until being loaded into the cryo-TEM via a cryo transfer holder (such as Gatan model 626 Cryo-Holder available from Gatan Inc., Warrendale, Pa., U.S.A., attached to a TEM instrument such as the model Tecnai G 2 20 available from FEI Company, Hillsboro, Oreg., U.S.A., or similar). The cryo-TEM is equipped with a camera such as the Gatan Model 994 UltraScan 1000XP (available from Gatan Inc., Warrendale, Pa., U.S.A.). The grid-mounted frozen samples are imaged in the cryo-TEM using low beam dosages (such as 200 KV in Low Dose Mode) in order to minimize sample damage. Suitable magnifications are selected in order to observe the size of nanoparticles which may be present. This may include magnifications in the range of 5,000x-25,000x. During imaging the sample is kept as cold as possible, typically at or near the temperature of liquid nitrogen (approximately minus 175° C.). Images of the samples are carefully examined to detect the presence of artifacts. A grid-mounted sample is discarded if any crystalline ice. Images are inspected for beam damage artifacts and are rejected if damage is observed. For each grid-mounted sample, representative images are captured of approximately 40 fields of view which are representative of the sample. These images are used to determine the range of nanoparticle typical diameters, and to determine the presence or absence of nanoparticle aggregates. In each image, the diameters are measured from nanoparticles which are typical of that image. The range of typical diameter values reported for the composition is the range of the diameters measured across all images captured from that composition. In each image, the spacing between nanoparticles is observed. A nanoparticle aggregate is defined as a cluster which contains at least 10 nanoparticles clumped together, rather than being individually dispersed. Nanoparticle aggregates are reported as present if at least one nanoparticle aggregate is observed in at least one image captured from that composition.
EXAMPLES
1. Solvent Examples
[0163] The following list of solvent options is for illustrative purposes of making the silicone resin solution of example prep 2 below and is considered to be non-limiting:
[0000]
TABLE I
Example Solvents
A
B
C
Guerbet
2-Ethylhexanol 1
2-Butyloctanol 2
2-Hexyldecanol 3
Alcohols
D
E
F
Glycol
Propyleneglycol
Dipropyleneglycol
Tripropyleneglycol
Ethers
n-Butyl ether 4
n-Butyl ether 5
n-Butyl ether 6
G
H
I
Fatty
Isopropyl
Isopropyl
Isopropyl
Esters
Laurate 7
Myristate 8
Palmitate 9
2. Preparation of Resin Solution
[0164] In a 400 mL beaker add specified amount of MQ resin powder ({[Me 3 SiO 1/2 ] 0.373 [SiO 2 ] 0.627 } 40 , Mn=2700 g/mol, resin contains 0.2% OH and 3.1% OEt [corresponds to OR 10 ]) according to Table II below; slowly add solvent(s) and begin mixing using an &a RWA-20 mixer with a 4-blade agitator (2 inch diameter tip-to-tip)_having 45° pitch on each blade using appropriate level of agitation. Continue with gentle mixing until all resin powder is completely dissolved; allow solution to settle at least 24 hours to allow for complete de-aeration.
[0000]
TABLE II
Example Resin solution compositions
Resin Solution Examples
Component
J
K
L
M
N
O
P
Q
R
S
T
Resin Powder 10
55.7
55.7
55.7
55.7
55.7
55.7
55.7
55.7
55.7
55.7
55.7
Total Solvent
44.3
44.3
44.3
44.3
44.3
44.3
44.3
44.3
44.3
44.3
44.3
wt. (g)
Butyl Carbitol 11
0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
18.0
19.0
Solvent A-I
44.3
42.3
40.3
38.3
36.3
34.3
32.3
30.3
28.3
26.3
25.3
3. Preparation of Resin-Aminosilicone Oil Mixture
[0165] To a 6 oz. glass container add 76.3 g of aminosilicone fluid and 23.7 g of resin solution according to Table III below.
The amine oil U has a viscosity about 1000 mm 2 /s at 25° C. [corresponds to units of formulas 7+8+9+10=230], functional radicals —(CH 2 ) 3 NH(CH 2 )NH 2 [corresponds to R 2 ], amine number of 0.5 mmol/g, 92% SiMe 3 end groups, and 8% SiMe 2 OH end groups [corresponds to units of formulas 9/10=11.5]. The amine oil V has a viscosity about 1000 mm 2 /s at 25° C. [corresponds to units of formulas 7+8+9+10=230], functional radicals —(CH 2 ) 3 NH(CH 2 )NH 2 [corresponds to R 2 ], amine number of 0.5 mmol/g, 85% SiMe 3 end groups, and 15% SiMe 2 OH end groups [corresponds to units of formulas 9/10=5.7]. The amine oil W has a viscosity about 1000 mm 2 /s at 25° C. [corresponds to units of formulas 7+8+9+10=230], functional radicals —(CH 2 ) 3 NH(CH 2 )NH 2 [corresponds to R 2 ], amine number of 0.5 mmol/g, 80% SiMe 3 end groups, and 20% SiMe 2 OH end groups [corresponds to units of formulas 9/10=4.0]. Mix fluids until completely homogenous using an Ika® RWA-20 mixer with a 4-blade agitator having 45° pitch on each blade using appropriate level of agitation. Place lid on container and allow oil mixture to age at room temperature for at least 72 hours.
[0000]
TABLE III
Example Resin-Aminosilicone Oil mixture solutions
Resin-AminoSilicone Oil Mixture Examples
Example
U
V
W
Aminosilicone
8% —OH
15% —OH
20% —OH
Terminal group
termination
termination
termination
Aminosilicone
76.3
76.3
76.3
amt. (g)
Resin solution,
23.7
23.7
23.7
Ex. J-T (g)
4. Preparation of Aminosilicone-Resin Emulsion
[0170] In a 250 mL beaker add 78.0 g of oil mixture from examples U-W above, followed by additional solvent according to Table IV below. Begin mixing solution using an Ika® RWA-20 mixer with a 4-blade agitator having 45° pitch on each blade using appropriate level of agitation. Continue mixing; once solvent has completely incorporated, add specified protonation agent to the mixture; add remaining water slowly and in 3 separate but equal increments, allowing each addition to fully incorporate prior to adding the next. Continue agitation to ensure the mixture is completely emulsified.
[0000]
TABLE IV
Example Aminosilicone-Resin Emulsions
Silicone-Resin Emulsion Examples
Component (g)
AA
BB
CC
DD
EE
FF
Oil Mix. Example U-W
39.0
39.0
39.0
39.0
39.0
39.0
Solvent from examples A-I 1-9
—
1.5
1.2
0.8
9.75
19.5
Butyl Carbitol 11
19.5
18.0
18.3
18.7
9.75
0.0
Resin Composition from
T
J, T
T
T
T
J-T
Table II
Protonating Agent 12
0.9
0.9
0.9
0.9
0.9
0.9
Water (13.5 g × 3)
40.6
40.6
40.6
40.6
40.6
40.6
Total Amount (g)
100.0
100.0
100.0
100.0
100.0
100.0
5. Finished Product Formulation Examples
[0171] In a 400 mL beaker, add specified amount of emulsion from examples AA-FF, followed by perfume; begin mixing solution using an Ika® RWA-20 mixer with a 4-blade agitator having 45° pitch on each blade using appropriate level of agitation. Add solvent to the mixture with continued agitation, allowing solvent to fully incorporate. Add deposition aid polymer followed by water; continue to mix until fully incorporated. Add preservative, followed by surfactant, then add the protonating agent and allow the mixture to fully incorporate. Finish product with continued agitation by adding the dye following the specified order of addition in Table V below:
[0000]
TABLE V
Example Finished Product Formulations
Finished Product Example Formulations
Comparative
Component
Example
Order of
Order of
Comparative
Order of
Comparative
Order of
(g)
GG
Addition
HH
Addition
Example II
Addition
Example JJ
Addition
Emulsion
25.8
1
25.8
1
25.8
1
25.8
2
from ex.
AA-FF
Perfume
0.8
2
0.8
2
0.8
2
0.8
3
Butyl
4.0
3
4.0
3
—
—
4.0
4
Carbitol
Solvent ex.
—
—
—
4.0
3
—
—
A-I
Surfactant 12
0.1
4
0.1
7
0.1
7
0.1
5
Protonating
0.25
5
0.25
8
0.25
8
0.25
6
Agent 13
Water
62.65
6
62.65
5
62.65
5
62.65
1
Deposition
6.35
7
6.35
4
6.35
4
6.35
7
Aid
Polymer 14
Preservative 15
0.1
8
0.1
6
0.1
6
0.1
8
Dye 16
0.004
9
0.004
9
0.004
9
0.004
9
1 2-Ethyhexanol: Available from Sigma-Aldrich, St.Louis, MO
2 2-Butyloctanol: Available from Sasol Chemical, Johannesburg, South Africa
3 2-Hexyldecanol: Available from Sigma-Aldrich, St.Louis, MO
4 Propyleneglycol n-butyl ether: Available from Dow Chemical, Midland MI
5 Dipropyleneglycol n-butyl ether: Available from Dow Chemical, Midland MI
6 Tripropyleneglycol n-butyl ether: Available from Dow Chemical, Midland MI
7 Isopropyl Laurate: Available from Sigma-Aldrich, St.Louis, MO
8 Isopropyl Myristate: Available from Evonik Corporation, Hopewell, VA.
9 Isopropyl Palmitate: Available from Evonik Corporation, Hopewell, VA.
10 Silicone MQ Resin: Wacker MQ 803TF, available from Wacker Chemie, AG; Burghausen, Germany
11 Butyl Carbitol: available from Dow Chemical, Midland MI
12 Surfactant: TAE-80, Tallow Alkyl ethoxylate, available from Akzo-Nobel
13 Protonating Agent: Glacial Acetic Acid, 97%, available from Sigma-Aldrich, St.Louis, MO
14 Deposition Aid Polymer: Terpolymer of acrylamide, acrylic acid and methacrylamidopropyl trimethylammonium chloride; Available from Nalco Chemicals, Naperville, IL
15 Preservative: Proxel GXL, available from Lonza Group, Basel, Switzerland
16 Dye: Liquitint Blue AH; available from Milliken, Spartanburg, SC
Data:
[0172]
[0000]
TABLE VI
Characterization of Finished product for Appearance and Particle size
Finished Product (FP) Formulation Example
GG
HH
II
JJ
Cryo-TEM
Product
Uniform
Product
Distribution of
visual
Phase
particles,
Phase
particle sizes,
appearance
split
no void
split
apparent void
volumes
volumes
Avg. Particle
Not
373
Not
497
Size (nm.); FP
Tested
Tested
[0000]
TABLE VII
Stability of Finished Products and Performance
Finished Product (FP) Formulation Example
GG
HH
II
JJ
Initial Product
Fail
Pass
Fail
Pass
Stability
Initial TTW
Not
100% Pass, avg.
Not
92% Pass, avg.
Performance*
Tested
TTW = 328 sec.
Tested
TTW = 162 sec.
8 Week
Not
Pass
Not
Fail
Stability
Tested
tested
8 Week TTW
Not
100% Pass, avg.
Not
Not Tested
Performance
Tested
TTW = 295 sec.
Tested
*TTW = Time to Wick; % Pass is determined by the number of treated garments that exhibit an average Time to Wick of >30 seconds
[0173] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”
[0174] Every document cited herein, including any crossreferenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
[0175] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
|
The present invention relates to amino silicone nanoemulsions. More specifically, the present invention relates to amino silicone nanoemulsions that may be used to protect surfaces from being soiled or wetted.
| 2
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This application is a Continuation of application Ser. No. 07/831,362, filed on Feb. 5, 1992, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to solid-state imaging devices, and more particularly to a semiconductor image sensor employing a charge transfer device such as a charge coupled device.
2. Description of the Related Art
Recently, as charge coupled devices (CCDs) have been much improved in the integration density of photosensitive cells, their applicability has been expanded. In particular, highly integrated CCD image sensors are increasingly used as the image sensing units for small-sized electronic home-use video cameras. Typically, the CCD device includes a planar matrix configuration of picture elements arranged on the substrate. The cell matrix essentially consists of an array of rows and columns of picture elements (referred to as "pixels" among those skilled in the art). Each pixel has a photodiode acting as a photosensing section for producing electrical charge carriers (generally called the "signal carriers") in response to an incident light and temporarily storing the carriers therein. The signal carriers read out from each column of pixels are then transferred to an output section of the CCD device through a corresponding vertical transfer CCD section associated therewith and a horizontal transfer CCD section coupled thereto.
According to expanding demands for further improvement in the integration density, when the allocated area for each pixel on the substrate surface decreases, it becomes more difficult to maintain good quality of images sensed by a presently available CCD image sensing device. The major reason for this is as follows. The CCD image sensor basically employs a PN-junction semiconductor photodiode as its photosensitive cell element. The photodiode is formed in a selected pixel area on the top surface of a silicon substrate. The substrate surface is covered by a transparent dielectric layer such as a silicon oxide film. A multi-stage transfer electrode, which defines a vertical charge-transfer section associated with a corresponding column of pixels, is buried in the dielectric layer. The dielectric layer is of uniform thickness on the substrate. A shielding electrode is disposed on the dielectric layer and has an opening that is formed therein to define a light-reception area of one pixel.
The pixel opening of the shielding electrode is arranged to partly overlap the PN-junction section of photodiode. In other words, the shielding electrode overlies the vertical transfer section, and its side end portion for defining the opening edge overlaps the peripheral area of the PN-junction photodiode section to provide an "overhung" portion. This overhung portion may function to cut off a leak component of incident light, which tends to straggle or "migrate" into the vertical charge-transfer section. This may be similar in function to eaves of an ordinary house. It will possibly happen for the incident light to be partially "straggled" to enter the vertical transfer section, rather than into the aimed PN-junction photodiode, due to what is called the "multi-reflection" in the transparent dielectric layer between the substrate surface and the shielding electrode. Such a light leakage to the vertical transfer section behaves badly to reduce the effective (net) amount of signal carriers, which leads to undesirable generation of a false image, such as "smear," on a sensed image. The aforementioned overhung portion of the shielding electrode must be required to eliminate such image-quality degradation.
The overhung arrangement, however, suffers from very serious conflicting problems as will be described below. As the integration density of CCD image sensors is being further improved, the occupation area of each pixel on the substrate will decrease. This will cause the overhung (or "eaves") portion of the shielding electrode to be narrower. This should be required because, if the overhung portion is simply kept constant while the cell size is decreased, the effective photosensing area of cell opening will obviously become smaller. The reduction of effective cell area will limit the amount of sensible light that is permitted to enter the photodiode. The resultant amount of signal carriers to be photoelectrically produced therein will also be reduced accordingly. This brings another problem: reduction of the signal-to-noise ratio of the image sensor. In view of the above, the elimination of leak light component and the accomplishment of higher integration density are technically in conflict with each other. Solving these conflicting problems has been long desired by the semiconductor manufacturers.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a new and improved solid-state imaging device that is highly integrated on a substrate and yet can perform image sensing operations with higher quality.
In accordance with the above object, the present invention is drawn to a specific imaging device that includes an array of photosensitive cells, each of which includes a photoelectric conversion section arranged in the surface of a substrate, for having a light-incident opening, and for generating electrical charge carriers in accordance with a light incident thereinto through the opening. A charge-transfer section is arranged adjacent to the photoelectric conversion section in the substrate surface, for defining thereunder a transfer channel region extending in a predetermined direction in the substrate, and for causing charge carriers to move through the channel region. A light-shield section is arranged to cover the photoelectric conversion section except the opening, for preventing an incident light through the opening from being introduced into the transfer channel region as a leak component, by cutting off an internal reflection path of the leak component thereto.
The foregoing and other objects, features, and advantages of the invention will become apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing schematically the overall arrangement of a CCD image sensor in accordance with one preferred embodiment of the present invention.
FIG. 2 is a partly enlarged plan view of the CCD image sensor of FIG. 1.
FIG. 3 is a diagram showing the cross-sectional view of the embodiment shown in FIG. 2 along line III--III.
FIG. 4 reveals the detailed layout of the underlying layers of the embodiment shown in FIG. 2 by removing the uppermost shielding electrode thereof.
FIGS. 5A and 5B illustrate cross-sectional CCD structures according to the prior art.
FIG. 5C shows the cross-sectional CCD structure of an embodiment of the invention corresponding to FIGS. 1 through 4 for purposes of comparison with the conventional structures of FIGS. 5A and 5B;
FIG. 6A-6H illustrate, in schematic cross-section, some of the major steps in the process of the CCD image sensor shown in FIGS. 1 to 4.
FIG. 7 is a cross-sectional view of one modification of the CCD image sensor shown in FIG. 3.
FIGS. 8A-8C illustrate, in schematic cross-section, some of the major steps in the process of the CCD image sensor shown in FIG. 7.
FIG. 9 is a diagram showing schematically the plan view of a CCD image sensor in accordance with another embodiment of the present invention.
FIG. 10 is a diagram showing the cross-sectional view of the embodiment shown in FIG. 9 along line X--X.
FIGS. 11 to 13 are diagrams showing the cross-sectional structures of some possible modification of the embodiment shown in FIG. 10.
FIG. 14 is a diagram schematically the fragmentary plan view of a CCD image sensor in accordance with a still another embodiment of the present invention.
FIG. 15 is a diagram showing the cross-sectional view of the embodiment shown in FIG. 9 along line XV--XV.
FIGS. 16A-16F illustrate, in schematic cross-section, some of the major steps in the process of the CCD image sensor shown in FIGS. 14 and 15.
FIG. 17 is a diagram schematically the fragmentary plan view of a CCD image sensor in accordance with a further embodiment of the present invention.
FIG. 18 is a diagram showing the cross-sectional view of the embodiment of FIG. 17 along line XVIII--XVIII;
FIG. 19 is a diagram showing the cross-sectional view of the embodiment of FIG. 17 along line XIX--XIX.
FIG. 20 is a diagram showing the cross-sectional view of the peripheral section of the sensor shown in FIG. 17, including a signal carrier-adder section and a horizontal charge transfer section.
FIG. 21 is a diagram schematically the fragmentary plan view of a CCD image sensor in accordance with a still further embodiment of the present invention.
FIG. 22 is a diagram showing the cross-sectional view of the embodiment of FIG. 21 along line XXII--XXII.
FIGS. 23A-23E illustrate, in schematic longitudinal cross-section, some of the major steps in the process of the CCD image sensor shown in FIGS. 21 and 22.
FIGS. 24A-24E illustrate, in schematic transverse cross-section, some of the major steps in the process of the CCD image sensor shown in FIGS. 21 and 22.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a CCD image sensor in accordance with one preferred embodiment of the present invention is generally designated by numeral "10." CCD image sensor 10 has a semiconductive substrate 12. This substrate may be made from silicon of N type conductivity. An array of rows and columns of picture elements 14 are arranged on the substrate 12 as shown in FIG. 1. These picture elements 14 will be called the "pixels," or more simply "cells." Cells 14 have a matrix configuration on the substrate surface. Each of these pixels 14 includes a PN-junction photodiode element, the detailed internal structure of which will be explained later in this description.
Each column of photodiode cells is associated with a corresponding one of vertical charge-transfer sections 16. A signal carrier readout section 18 is arranged between each cell column and a corresponding vertical transfer section 16 associated therewith. Vertical transfer sections 16 may also be referred to as "vertical CCD channels" in some situations.
As shown in FIG. 1, the vertical transfer sections 16 have signal-carrier outputs, at which these sections are coupled to a horizontal charge-transfer section 20. Horizontal transfer section 20 may also be called the "horizontal CCD channel." Horizontal transfer section 20 receives signal carriers that are transferred from vertical transfer sections 16, and cause them to move sequentially toward the output thereof. A known amplifier circuit 22 is connected to the output of horizontal transfer section 20. This amplifier amplifies the signal carriers; the amplified carriers appear at an output terminal 24 of the CCD image sensor 10.
A certain vertical transfer section 16 and two cells 14a and 14b that are positioned on the opposite sides of section 16 are illustrated in detail in FIG. 2. The cross-sectional view of the structure along line III--III is shown in FIG. 3 (not drawn to scale). For reference convenience, the internal multi-layered structure is presented in FIG. 4, by removing the illustration of the uppermost layer (a shielding layer) to reveal a detailed patterning layout of the underlying layers. Intermediate dielectric layers are omitted from FIGS. 2 and 4 for illustration purposes only.
As is apparent from FIG. 3, the N type silicon substrate 12 has a P type well region 30 in its top surface section. N type diffusion layers 32, 34 are arranged at selected positions corresponding to cells 14a, 14b in well region 30. These layers 32, 34 are in contact with well region 30 while they are spaced apart from each other. The PN junction between layer 32 and well 30 constitutes a photodiode element for cell 14a; the PN-junction between layer 34 and well 30 constitutes a photodiode for cell 14b. These photodiodes serve as photosensitive cell sections. P type layers 36, 38 are formed at the substrate surface section in well 30 so that the layers 36, 38 are in contact with the top portions of N type layers 32, 34, respectively. P type layers 36, 38 are added to suppress or eliminate the generation of dark current.
As shown in FIG. 3, an N type charge-transfer channel layer is formed between spaced-apart layers 32, 34 in well region 30, to act as the vertical transfer section 16 of FIG. 1. An elongate conductive layer 40 is insulatively disposed above channel layer 16. Layer 40 is electrically insulated by a gate insulation film 42 from the substrate 12. Layer 40 is a part of the multi-stage vertical transfer electrode structure aligned along the extending direction of N type channel layer 16. As is apparent from FIG. 4, this multi-stage electrode structure includes two types of layers 40, 42 that partly overlap with each other in the vertical transfer direction of the image sensor 10. Each of layers 40, 42 is a conductive layer which extends in a specific direction transverse to the row direction--i.e., the longitudinal direction of the vertical transfer sections 16--and which has a rectangular cut-off portion 41 (or 43) in the cell area. A dielectric layer 44 overlies vertical transfer electrode 40. A metallic layer 46 overlies dielectric layer 44, and serves as the previously described shielding electrode, which "intercepts" incident light.
As shown in FIG. 2, the shielding electrode 46 has openings (windows) 48a, 48b, which are located in the specific surface areas corresponding to photodiode cells 14a, 14b, respectively, and which permit incident light to enter the photodiodes through openings 48a, 48b. These openings are shown by a dash-and-dot line (imaginary line) in FIG. 4, wherein the illustration of shielding electrode 46 is omitted. The multi-layered structure including shield electrode 46 on substrate 12 is entirely covered by a dielectric layer 50, which is made from silicon oxide material and serves as a protection layer.
very importantly, the shielding electrode 46 has an edge 46a, which defines the size of the cell opening 48a and which is in directly contact with the top surface of substrate 12 in the photodiode formation area of cell 14a, as clearly shown in FIG. 3. The electrode edge 46a is physically "junctioned" with P type layer 36. Similarly, the opposite edge 46b of shielding electrode 46, which defines cell opening 48b, is in directly contact with the substrate surface in the formation area of cell 14b. Electrode edge 46b is physically junctioned with P type layer 38. The direct junction of shielding electrode 46 with P type layers 36, 38 causes electrode 46 to be electrically separated from N type layers 32, 34 of cell photodiodes 14a, 14b. To enhance this electric separation, shielding electrode 46 is applied with a specific voltage potential that is potentially equal to or greater than the voltage on P type layers 36, 38; normally, it is a reference voltage.
With such an arrangement, since both sides of the vertical transfer electrode 40 can be covered almost perfectly by the overlying shielding electrode 46, it becomes possible to suppress or eliminate any multi-reflection of an incident image light being presently introduced through the windows of cells 14a, 14b, which reflection tends to be generated within the transparent dielectric layer sandwiched between the substrate surface and shielding electrode 46. This enables cutting off almost perfectly any leak components of incident light, which tends to "migrate" into the vertical transfer channel region 16. As a result, it is possible to minimize the generation of leak carriers within the vertical transfer section, thereby to effectively suppress smear phenomenon in the CCD image sensor 10. The image quality can thus be much improved.
Furthermore, carrier injection from the shielding electrode 46 into the individual cell photodiode section can be prevented by causing the voltage to be given to the shielding electrode 46 at a selected potential that is equal to or higher than those at the P type layers 36, 38. This can be lead to successful suppression of pixel defects during image-sense operation, such as what is called the "white scratching" phenomenon. The image quality of sensor 10 can thus be further improved.
In addition, according to the embodiment, the above "shielding-electrode/substrate-surface direct contact" feature can provide a surprising effect: this feature can also contribute to improvement in the integration density of the CCD image sensor 10. The reason for this is as follows. Principally, employing the "direct contact" feature can increase the ratio of opening 48 with respect to the cell occupation area on substrate 12, i.e., the cell aperture ratio. This results in that the effective (net) occupation area of each cell can be decreased while having the cell aperture ratio kept unchanged. The reductionability of the net occupation area for each cell can increase the number of cells allowed to be arranged on the substrate of image sensor 10; obviously, the resultant packing density of photosensing cells can be improved.
The above cell-integration improvement effect will now be demonstrated with reference to the experimental data shown in FIG. 5. First, let's refer to FIG. 5A, which illustrates the cross-sectional structure of one photosensitive cell section that has been conventionally employed in CCD image sensors. To increase efficiency of explanation, similar reference numerals are used to designate similar components to those of the previously described first embodiment.
With the conventional structure of FIG. 5A, unlike the FIG. 3 embodiment of the invention, a dielectric layer 60 overlying the transfer electrodes 40 simply covers the substrate top surface uniformly. Shielding electrode 46 has a cell opening 62. A "migration" leak light component caused due to the multireflection is represented by a "triangular-folded" or zigzag arrow 64. To suppress such leak component 64, shielding electrode 46 is arranged to have an "eaves" portion 66. The amount of leak component into the vertical CCD transfer section can be decreased by increasing the horizontal extending length of portion 66, i.e., by extending the overlap between shielding electrode 46 and photodiode layer 32. Such increase in length of portion 66, however, may reduce the effective (net) area of photosensitive cell, causing the integration density of the CCD image sensor to decrease. This example assumes that one cell is 7 micrometers in size. To eliminate leak component 64, the horizontal length of portion 66 should be required to measure as much as 1.2 micrometers when the opening width of the photodiode section is 1.5 micrometers. The resultant amount of smear in this case is -80 dB.
A cell structure of FIG. 5B is another example that may be conventionally available. Note that, however, one cell is miniaturized to measure 5 micrometers in size in order to attain high integration density of the CCD image sensor. Even with this example, it is still required that the length of eaves portion 66 of the shielding electrode 46 remains unchanged for better elimination of leak component interference. This results in that the net area of cell opening is reduced to 0.6 micrometers. In such a case, better image-sensitivity can no longer be expected. To balance the above conflicting requirements, technical challenge to attain further integration density will soon reach the limit of development.
A cell structure of FIG. 5C, which may correspond to that shown in FIG. 3, employs the previously explained "shielding-electrode/substrate-surface direct contact" feature. Assuming that the structure of FIG. 5C is the same in size as the FIG. 5B structure, the effective photosensible cell area can be approximately doubled 0.6 micrometers up to 1.2 micrometers, by removing the eaves portion 66 of the shielding electrode of FIG. 5B. The cell sensitivity can thus be enhanced. Moreover, it becomes possible, by forcing the edges of shielding layer 46 to be in direct contact with the substrate surface, to prevent almost perfectly any leak component from entering the charge-transfer section. Our experiment tells us that, with the FIG. 5C structure, the measured smear was suppressed down to -100 dB or less. As a consequence, the CCD image sensor in accordance with the present invention can break through the limit and achieve higher integration, without damaging the image sensing performance of the image sensor.
The process of fabricating the image sensor 10 may be effectively performed with presently available manufacturing techniques. The manufacture of it is as follows. Firstly, as shown in FIG. 6A, P type impurity such as boron (B) is doped by known ion implantation into the top surface of N type silicon substrate 12. P type well region 30 is then formed in substrate 12. Subsequently, as shown in FIG. 6B, thermal oxidization process is performed to form a silicon-oxide thin film 42 on the substrate surface. This thin film is the gate insulation film 42 of FIG. 3. Then, N type impurity is selectively doped in well region 30 with a patterned resist layer (now shown) being as a mask therefor, thereby to define N type buried channel region 16. This region may serve as the vertical charge-transfer section of the CCD image sensor 10.
Subsequently, as shown in FIG. 6C, a polycrystalline silicon layer 40 is deposited on the gate insulation layer 42 such that it overlies the vertical transfer channel region 16. Layer 40 is then subjected to a patterning process to become the vertical transfer electrode 40 shown in FIG. 3. Thereafter, as shown in FIG. 6D, the resultant structure is subjected to the second thermal oxidization process, so that an oxide layer 44 is formed overlying the vertical transfer electrode 40. PN-junction photodiodes are then formed in well region 30, with making use of a resist mask (now shown). These photodiodes serve as the photosensitive cell sections. Note that only two photodiodes are visible in FIG. 6D, i.e., a photodiodes having N type layer 32 and P type layer 36 and another one having N type layer 34 and P type layer 38. During this process, the formation of the previously described cell matrix configuration is completed.
A resist layer (not shown) is deposited on the resultant structure of FIG. 6D, and is patterned to form a patterned resist layer 70 shown in FIG. 6E. By using resist layer 70 as a mask, the structure of FIG. 6D is then subjected to an etching process. The gate insulation film 42 is selectively removed at the cell areas, so that the substrate surface is partly exposed. The resist mask 70 is removed.
Subsequently, as shown in FIG. 6F, the resulting structure is entirely covered by a metallic thin-film 46 deposited thereon. Film 46 may be made from metal such as aluminum, high-melting-point metal such as tungsten, or silicide thereof. A resist layer is deposited on film 46, and then subjected to a patterning process, thereby to obtain a patterned resist layer 72 as shown in FIG. 6G. By making use of this resist layer 72 as a mask, the structure of FIG. 6F is etched selectively. With the selective etching process, film 46 is configured to have the cell openings 48a, 48b that are typically shown in FIG. 2. After resist mask 72 is removed, shielding electrode 46 is formed. Finally, dielectric protection film 50 is deposited entirely on the resultant structure. The CCD image sensor 10 is now completed.
A CCD image sensor structure 80 of FIG. 7 is similar to that shown in FIG. 3 with concave or recessed portions (grooves) 82, 84 being additionally formed in the dark-current restriction layer 36. The edges 46a, 46b of shielding electrode 46 terminate on the bottom surfaces of grooves 82, 84. Edges 46a, 46b are in contact with P type layers 36, 38 physically and electrically in the grooves. With such an arrangement, the coverage of shielding electrode 46 over the vertical transfer channel region 16 is strengthened to enhance the smear-eliminating performance.
The process of forming the shielding electrode-contact grooves 82, 84 is as follows. A cross-section shown in FIG. 8A roughly corresponds to that of FIG. 6E. The difference of the structures of FIG. 8A from that of FIG. 6E is that, during the selective etching process using the patterned resist mask 70, its etching condition is so modified as to cause P type layers 36, 38 to be etched at least partially. As a result, while dielectric layer 44 is being etched, concave portions 36, 38 are formed in layers 36, 38. Subsequently, as shown in FIG. 8B, high-melting-point metallic film 46 is formed on the resultant structure. Film 46 is configured by a patterning process, which is similar to the process shown in FIG. 6G, to obtain vertical charge-transfer electrode 46. Then, as shown in FIG. 8C, dielectric protection layer 50 is deposited on the entire surface of the resultant structure to provide the CCD image sensor 80 of FIG. 7.
Turning now to FIG. 9, a CCD image sensor in accordance with the second embodiment of the present invention is generally designated by "90." The cross-sectional view of the image sensor of FIG. 9 along line X--X is shown in FIG. 10. CCD image sensor 90 has a P type silicon substrate 92. As shown in FIG. 10, the top surface of substrate 92 is provided with a lightly-doped N (N-) type layer 94, which defines a vertical transfer channel region therein. A heavily-doped N (N+) type layer 96 is formed in the cell area of substrate 92 to constitute a PN-junction photodiode. A lightly-doped P (P-) type layer 98 is formed at one end portion of N+ type layer 96. The P- type layer 98 defines an element-separation area in the substrate surface.
As shown in FIG. 10, a gate insulation film 100 is arranged on the substrate 92. A multi-layered type transfer electrode structure is arranged on this gate insulation film 100 to extend in the vertical carrier transfer direction of CCD image sensor 90. The electrode structure consists of first vertical carrier transfer electrode layers 102 and second vertical carrier transfer electrode layers 104 that partly overlap the first layers at their edge portions. As shown in FIG. 9, layers 104 have openings 106, which planarly exclude cell openings 108a, 108b, 108c at the mutual overlap edge portions of layers 102, 104. Layers 102, 104 may be polycrystalline silicon layers.
As shown in FIG. 10, the first and second vertical transfer electrodes 102, 104 are covered by a thick dielectric layer 110. Typically, the thickness of dielectric layer 110 ranges from 0.3 to 0.6 micrometers. Dielectric layer 110 has an opening 112 that is substantially self-aligned with the N+ type layer 96 of the cell section. The top surface of thick dielectric layer 110 is covered by a thin dielectric layer 114. Typically, the thickness of dielectric layer 114 ranges from 0.05 to 0.3 micrometers. A lower shielding electrode 116 is arranged on thin dielectric layer 114. This shielding electrode 116 is made from molybdenum-silicide material. Electrode 116 is "adhered" to the side wall of opening 112, which is covered by thin dielectric layer 114. Another thick dielectric layer 118 is deposited on the entire top surface of shielding electrode 116. Dielectric layer 118 has a flat top surface. A metal layer 120, such as aluminum, is arranged on dielectric layer 118 to have the aforementioned openings 108, only one (108b) of which is visible in FIG. 10. Metal layer 120 serves as a second shielding electrode.
With the image sensor 90 shown in FIGS. 9 and 10, after the thick dielectric layer 110 was formed on the second vertical transfer electrodes 104 that may also act as a signal-carrier readout gate, N+ type layer 96 constituting a cell-photodiode is formed using a known ion-implantation technique in the cell area of substrate 92. This may prevent implanted ions from penetrating transfer electrode 104 to be doped into the underlying substrate 92 therethrough, thus eliminating undesirable formation of a "potential pocket" beneath the readout gate in substrate 92. It is therefore possible to prevent a read voltage from being potentially varied during the image sense operations of CCD image sensor 90, and at the same time to suppress the generation of an "after-image" in a sensed image.
Moreover, the thin dielectric layer 114 is adhered to the side wall of the opening 112 of thick dielectric layer 110, and the first shielding electrode 116 is uniformly formed thereon to a decreased thickness. The vertical side wall portion of shielding electrode 116 is allowed to position immediately adjacent to the top surface of substrate 92 in which N+ type layer 96 is arranged, thereby minimizing the possibility of generation of optical leakage therebetween. Therefore, the vertical layer portion of shielding electrode can suppress or prevent any leak component of incident light from being introduced into the vertical transfer section. This may contribute to reduction of smear. At the same time, employing the thin dielectric film 114 on the side wall of cell opening can maximize the cell aperture ratio at each photodiode. Therefore, the image sensing performance can be improved while maintaining high integration density for CCD image sensor 90.
Some modifications to the embodiment 90 are described as follows. The cross-sectional structure of a CCD image sensor 130 of FIG. 11 is similar to that of FIG. 10 with the thin dielectric layer 114 of FIG. 10 being replaced with a vertical layer 132 that is selectively arranged on the internal side wall of the cell opening 112 only. Formation of this layer may be performed by making use of a presently available self-aligned technique employing the reactive ion etching (RIE) method.
The cross-sectional structure of a CCD image sensor 140 of FIG. 12 is similar to that shown in FIG. 10 except that a thick dielectric layer 110a is selectively formed only on the second transfer electrodes 104 with gaps 142 between adjacent ones thereof. Thin dielectric layer 114 is also arranged on the internal side wall of gaps 142. With such an arrangement, it is possible to simplify and speed up the manufacturing process by allowing the etching for two polycrystalline layers on the polycrystalline layer and that for the cell openings to be performed simultaneously.
The cross-sectional structure of a CCD image sensor 150 of FIG. 13 is similar to that shown in FIG. 12 except that the first and second vertical transfer electrodes 102, 104 are alternately positioned in the same level over the substrate surface without having any overlap edge portions therebetween. A thick dielectric layer 110b is deposited on these layers 102, 104.
Turning to FIG. 14, a CCD image sensor in accordance with a third embodiment of the invention is generally designated by numeral "160." The cross-sectional view of one cell structure of FIG. 15 along line XV--XV is illustrated in FIG. 15. The main characteristic feature of this embodiment is that a silicon nitride layer is additionally arranged between transfer electrodes and the overlying shielding electrode as will be described below.
As is apparent from FIG. 15, CCD image sensor 160 has an N type silicon substrate 162. A P type well region 164 is on the top surface of substrate 162. Formation of well region 164 may be made by employing the existing ion-implantation or impurity-diffusion technique. A plurality of N type layers 166 (only one of these layers is visible in FIG. 15) are formed in cell areas of substrate 162; these layers constitute PN-junction photodiodes. A P type layer 167 is in contact with N type layer 166 in well region 164. An N type layer 168 is arranged near N type layer 166 within well region 164, defining a vertical charge-transfer channel region.
Three stacked dielectric layers 170, 172, 174 are formed on the top surface of substrate 162. Layer 170 is a silicon oxide film. Layer 172 is a silicon nitride film. Layer 174 is a silicon oxide film. Layers 172, 174 have an opening 176 that is substantially self-aligned with the underlying N type photodiode layer 166. Conductive layers 178,180 are insulatively laminated on layer 174. Layer 178 has an opening 177 contiguous from opening 176. These layers act as the vertical transfer electrodes. Transfer electrode layers 178, 180 are buried by a silicon oxide layer 182. A silicon nitride layer 184 is insulatively disposed above the underlying electrode layer 182. Silicon nitride layer 184 is covered by a silicon oxide layer 186. In other words, a lamination structure of three dielectric layers 182, 184, 186 is deposited on the upper electrode layer 180. Dielectric layers 182, 184, 186 have a cell opening 187. A shielding electrode 188 is formed on dielectric layer 186; it has a side-wall layer portion 188a, which is adhered to the vertical side wall of cell opening 188 as shown in FIG. 15. Note that the illustration of shielding electrode 188 is omitted from the plan view of FIG. 14 only for illustration purposes to reveal the patterning layout of the underlying layers.
The manufacturing process of the image sensor 160 will be described with reference to FIG. 16 as follows. Note that the structures shown therein are those obtained along line XVI--XVI of FIG. 14. As shown in FIG. 16A, the following layers are sequentially formed on an N type substrate 162 with a P type well region 164: three-laminated insulative layers 170, 172, 174, vertical transfer electrodes 178, 180, a silicon oxide layer 182, and a silicon nitride layer 184. Transfer electrodes 178, 180 are polycrystalline silicon layers that have been formed by a well-known gas-phase crystal-growth method to a predetermined thickness of 200 to 600 nanometers (nm), for example. Silicon nitride layer 184 is deposited by the gas-phase crystal-growth method to a predetermined thickness such as 50 to 300 nm.
Subsequently, as shown in FIG. 16B, a resist layer 190 is formed on the silicon nitride layer 184 in a designated patterning shape. By using resist layer 190 as a mask, a RIE process is performed so that the underlying layers 182, 184 are etched selectively. The resultant patterned layers 182a, 184a exhibit their plan view that is substantially same as that of resist layer 190.
After the resist layer 190 was removed, as shown in FIG. 16C, a RIE process is performed with a silicon nitride layer 184a being as a mask. The selection ratio of polycrystalline silicon and silicon nitride is set in a range from 15 to 20. Polycrystalline silicon transfer electrodes 178, 180 are then subjected to a selective etching process so that only layer portions 178a, 180a remain as shown in FIG. 16C.
Subsequently, as shown in FIG. 16D, the dielectric layer 182a between the resultant transfer electrodes 178a, 180a is removed using ammonium fluoride (NH 4 F). Then, as shown in FIG. 16E, the remainders of polycrystalline silicon layer, which are shown in the center of FIG. 16D, on silicon nitride film 172 are then removed, together with the silicon oxide layer portions being positioned thereunder. The selection ratio of polycrystalline silicon and silicon nitride in this case is similar to that in the previous process. With this process, it is possible to determine the size of light receiving opening 177 at high accuracy, without etching silicon oxide layer 172.
Subsequently, as shown in FIG. 16F, the exposed electrode layers 178a, 180a are subjected to a surface oxidation, thus forming an oxide thin film 192. Thereafter, ion implantation of N type impurity is performed to form N type layer 166 that is substantially self-aligned with cell opening 177 in the cell area of substrate 162. Ion implantation of P type impurity is then performed to form P type layer 167. A PN-junction photodiode is thus obtained. An aluminum thin film is formed as the shielding electrode 188 of FIG. 15, and then subjected to a patterning process, thus completing the image sensor shown in FIGS. 14 and 15.
With the image sensor 160, the total thickness of the dielectric layer between the transfer electrodes 178, 180 and shielding electrode 188 can be minimized, by adding the silicon nitride layer 184 therebetween, without raising any dielectric breakdown. In addition, the distance between the top surface of substrate 162 and the overlying shielding electrode 188 can be decreased, causing a light transmission path therebetween to be narrower. This may lead to reduction of smear due to generation of leak light component. The opening formation for the photosensitive cells can be carried out at high accuracy with a single etching process using the silicon nitride layer 184 as a mask; this is very advantageous in improving the manufacturing efficiency and the manufacturing yield of image sensors of this type, as well as the photosensitibity thereof. The improvement in photosensitibity is effected due to the fact that the alignment margin between layers 177 and 180 can be reduced down to substantially zero, thereby increasing the cell aperture ratio accordingly.
Turning to FIG. 17, a CCD image sensor in accordance with a fourth embodiment of the invention is generally designated by numeral "200." The cross-sectional structure along line XVIII--XVIII is illustrated in FIG. 18; that along line XIV≦XIV is illustrated in FIG. 19. A substrate 202 is made of N type silicon material. A P type well region 204 is formed in the top surface section of substrate 202. PN-junction photosensing cells are arranged in well region 204 in a matrix fashion that is similar to that of the cells 14 shown in FIG. 1.
As shown in FIG. 18, N type layers 206 constituting PN-junction photodiodes are matrix-arranged in the well region 204. A P type layer 208 is formed in the upper section of each N type layer 206. Layer 208 serves to suppress or eliminate dark-current that tends to generate at the photodiode surface region. A lightly-doped N (N-) type diffusion layer 210 is positioned near P type photodiode layer 206. Layer 210 defines a buried vertical transfer channel region of image sensor 200. A P type layer 212 is formed in well region 204 to planarly surround P type photodiode layers 206. Its plan patterning shape is apparent from viewing FIG. 17. In FIG. 17, for illustration purposes only, hatching effect is added to a layer 212, which functions as an element-separator between adjacent ones of the photosensing cells. The top substrate surface where layers 204, 206, 208, 210 are formed is covered by a gate insulation film 214. Formed on this gate insulation film is an elongate conductive layers 216 that act as a vertical transfer electrode of image sensor 200. Layers 216 may be made from specific material that is low in light-transmissivity, such as metal or metal-silicide. In FIG. 17 all but one layer 216 are omitted for illustration purpose to reveal the layout of the underlying element-separation layer 212 more descriptively.
The cross-sectional view of the buried vertical transfer channel layer 210 along the vertical carrier-transfer direction is shown in FIG. 19. Additional layers 218, 220, which are same in conductivity type as each other and different in impurity density from each other, are arranged at a certain interval between adjacent ones thereof in a predetermined order along the longitudinal direction of channel layer 210. Heavily-doped N (N+) type layers 218a, 218b, 218c are formed in N- type channel layer 210 at first intervals; N type layers 220a, 220b are alternately positioned such that each is adjacent to an alternate one of N+ type layers 218. Such an arrangement facilitates that the potential differences (various depths of potential well) are regularly generated in a specific order along the carrier-transfer direction when the same voltage is applied to the layers.
With the image sensor 200, the transfer electrode 216 is formed of a single layer made from a selected conductive material of low-transmissivity. This can decrease the amount of undesirable leak light component to the vertical transfer section. The smear can thus be reduced. Furthermore, the above-mentioned functionality of transfer electrode 216 can eliminate the necessity of adding another light-shielding layer thereon, causing image sensor 200 to be simplified in structure.
The second feature of the image sensor 200 is that, since the transfer electrode 216 is formed on the gate insulation film 214, it is no longer required to provide any additional layer between the shielding layer and the transfer electrode for electrically separating them, unlike the prior art. It thus becomes possible to make image sensor 200 thinner. This feature can eliminate the necessity of forming the "eaves" portion of the transfer electrode at the cell section, which has been employed conventionally. The cell aperture ratio can be improved accordingly. This may enhance the accuracy in the micro-fabrication of cell sections, causing image sensor 200 to exhibit higher sensitivity with maintaining higher integration density.
An exemplary cross-section of the signal-carrier adder section 222 of the image sensor 200 is given in FIG. 20. This adder section is adapted to be arranged on the substrate 202 such that adder 222 has an insulated electrode 224, which is positioned between the end portions of vertical transfer electrodes 216 and the insulated electrode 226 of horizontal transfer section 228. Electrode layers 216, 224, 226 are positioned in the same level over substrate 202.
As shown in FIG. 20, the signal-carrier adder section 222 has an N type diffusion layer 230. Layer 230 is formed in well region 204. An electrode 224 covers layer 230 insulatively. Layer 230 temporarily stores therein packets of signal carriers that are sequentially transferred thereto from the vertical transfer section in response to a pulse signal being externally applied to electrode 224. The pulse signal is a clock pulse signal Φa that controls the signal-carrier adding operation. The carrier transfer and carrier addition operations for an interline image-sensing of sensor 200 may be accomplished by employing one of presently available techniques. For example, to enable of a successful transmission of signal carriers with the single-electrode configuration, it is recommendable to employ a technique known as the "VIRTUAL PHASE CCD TECHNOLOGY," by J. Hynecek, disclosed in IEDM Tech., Digest 1979 at pp. 611-614, or its slightly modified method.
Turning to FIG. 21, a CCD image sensor in accordance with a fifth embodiment of this invention is generally designated by numeral "250." Its cross-sectional structure along line XXII--XXII is shown in FIG. 22. A substrate 252 is made from N type silicon material. A P type well region 254 is arranged in the top surface of substrate 252. Well region 254 is provided with N type diffusion layers 256, which are formed at the positions of photosensitive cells to constitute PN-junction photodiodes. A P type dark-current eliminator layer 258 is in contact with the upper portions of these layers 256. Arranged between layers 256 are elongate N type layers 260 that define a vertical transfer channel region. The arrangement of photodiodes and vertical transfer channel layers is essentially same as those of the previously described embodiments.
As shown in FIG. 21, insulated transfer electrodes 262, 264 are alternately arranged over the buried transfer channel layers 260. These electrodes 262, 264 extend transverse to channel layers 260. Adjacent ones of electrodes 262, 264 partly overlap with each other at their edge portions. Electrodes 262, 264 are provided with openings 266 in the photosensitive cell areas, and electrically separated from each other by a dielectric layer 268, which covers them. As shown in FIG. 22, a first light-shielding film 270 is insulatively disposed above electrode 264. A second light-shielding film 272 is formed on film 272. Second shielding film 272 is specifically arranged so that it is adhered to the internal wall of opening 266 and that an end portion 274 thereof is in direct contact with the substrate surface. A transparent dielectric protection layer 276 overlies second film 272. Note in FIG. 21 that the illustration of first film 270 and protection layer 276 is omitted for simplification purposes only. With such an arrangement also, smear can be reduced successfully while maintaining the integration density higher due to the same principle as previously described.
The manufacture of the image sensor 250 is as follows. FIG. 23A through 23E illustrate the major cross-sectional structures cut along the vertical charge-transfer direction, which may be obtained during the manufacturing process, whereas FIG. 24A through 24E show some cross-sectional structures transverse to the vertical charge-transfer direction. First, as shown in FIG. 23A, P type well region 254 and N type diffusion layer 260 are sequentially formed in the surface section of P type substrate 252. Substrate 252 is subjected to a chemical surface treatment, whereby a gate insulation film 280 is formed on substrate 252. A polycrystalline silicon layer 262 is then deposited on gate insulation film 280 as the first transfer electrode.
Subsequently, as shown in FIG. 23B, the polycrystalline silicon layer 262 is selectively etched with a patterned resist layer (not shown) formed on layer 262 being as a mask therefor. A plurality of openings 266 are thus defined in layer 262. Then, as shown in FIG. 23C, the patterning-processed polycrystalline silicon layer 262 is subjected to a surface treatment, obtaining a dielectric layer 282 thereon. Another polycrystalline silicon layer 264 is formed on layer 282 as the second transfer electrode.
Subsequently, as shown in FIG. 23D, a similar selective-etching process to that of FIG. 23B is carried out to obtain the double-layered structure of the first and second transfer electrodes, the layout of which is shown in FIG. 21. Dielectric protection layer 276 is then deposited on the entire surface of the resultant structure.
The manufacture continues as follows. Subsequently, as shown in FIG. 24A, high-melting-point metallic layer 270 (such as molybdenum, tungsten, or silicide material of either one) is formed to cover the structure of FIG. 23E. Layer 270 may also be made from aluminum. Note that the cross-sectional view of FIG. 24A and the following ones shown in FIGS. 24B to 24E are along a different cut-out plane (a direction transverse to the elongate carrier-transfer channel region) in the same device.
Subsequently, a resist layer 284 is deposited on the layer 270, and is then patterned. By using this resist layer as a mask, a selective etching process is performed to obtain a multi-layered structure shown in FIG. 24B, wherein the underlying layers 280, 262, 282, 264, 276, 270 were etched selectively. An N type impurity is then doped into well region 254 at cell areas thereof, thereby forming photodiode layers 256 therein. Then, a P type impurity is doped into the cell areas of well region 254, forming dark-current eliminator layer 258. Layer 258 is substantially self-aligned with the patterned layers 280, 262, 282, 264, 276,270, as shown in FIG. 24B.
After the resist layer 284 is removed, a silicon oxide film 286 is deposited to cover the resultant structure. An isotropic etching such as RIE is then performed, causing most layer portions to be removed away, except for specific portions 286a that remain contact only with the vertical side wall of a resulting multi-layered structure 288 as shown in FIG. 24D. These layer portions 286a correspond to layers 268 in FIG. 22. This means that side-wall dielectric layers 286a can be easily formed in a self-aligned manner.
Then, an aluminum thin film is deposited on the entire surface of the resulting structure, and subjected to a patterning process, thus forming the second shielding film 272 that covers the multi-layered structure 288 with side-wall layers 286a as shown in FIG. 24E. Subsequently, dielectric protection layer 276 is deposited to entirely cover the resultant structure on substrate 252. The image sensor 250 of FIGS. 21 and 22 is now completed. With the above manufacturing method, it is possible to form side-wall dielectric layers 286a ("268" in FIG. 22) in accurate self-align manner at each cell opening. This can allow the light-shielding section to have the double-layered structure consisting of the thick film 270 and the thin film 272; therefore, any unwanted introduction of leak light component into the vertical channel region can be eliminated more successfully, causing smear to reduce toward zero. The image sense performance can thus be enhanced while maintaining the cell integration density improved.
The present invention is not limited to the above-described specific embodiments and may be practiced or embodied in still other ways without departing from the spirit or essential character thereof.
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A solid-state imaging device includes an array of photosensitive cells, each of which includes a photoelectric conversion section, which is arranged on the surface of a substrate and has a light-receiving opening. The photoelectric conversion section generates a packet of electrical carriers in response to the amount of incident light thereinto through the opening. A charge transfer section is arranged adjacent to the photoelectric conversion section on the substrate surface. This transfer section defines thereunder a transfer channel region that extends linearly in a predetermined direction in the substrate surface, and causes the carriers thus obtained to move sequentially. A light-shield section is arranged to cover the photoelectric conversion section except the opening, for preventing an incident light coming through the opening from being introduced into the transfer channel region as a leak component, by cutting off an internal reflection path of the leak component thereto.
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to peep sights for archery bows, and more particularly to a peep sight assembly having interchangeable inserts with different aperture sizes for accommodating different users and shooting conditions.
[0002] In the field of archery, it is well-known to provide a peep sight on the string above the nocking point of an archery bow. The peep sight must be properly located so that a user may accurately sight in the bow sight with respect to a distant target while in a shooting stance. The particular peep sight position is largely dependent on the archer's anchor point when the bow is fully drawn in relation to his or her aiming eye, which may be different for each archer. Since the bow is custom fit to each archer, there are many variables which affect the sight picture, such as the draw length, the size and location of a front sight aperture with respect to the archer's eye, the shape of the archer's face including the location of the eye with respect to other prominent facial features, as well as an archer's eyesight condition.
[0003] Traditional peep sights are usually designed to be as small and light as possible, so when the peep sight is changed for another size, the length of the bow string is also changed because the outside diameter of the peep sight has changed. The larger the peep sight, the shorter the string becomes because the string halves are being pulled further apart. Consequently, the cam timing must be retuned and the nock height must be readjusted for the bow. Such adjustments are very detail oriented and time consuming, requiring skill and special tools that many archers do not have.
[0004] In addition, when a peep sight is changed for another peep sight, an inexperienced archer may have difficulty in tying the new peep sight to the bow string since the knot tying process may take time and/or the knots may be improperly formed, which may lead to inadvertent movement of the peep sight, or injury if one or more of the knots were to fail, especially when the bow string is released during shooting.
[0005] Accordingly, it would be desirable to provide a peep sight assembly that overcomes at least some of the disadvantages of the prior art.
BRIEF SUMMARY OF THE INVENTION
[0006] According to one aspect of the invention, a peep sight assembly for an archery bow includes a peep sight housing adapted for connection to a bow string of the archery bow and a peep sight insert for changing the size of the sight aperture. The peep sight housing has front and rear surfaces with a first inner surface located therebetween to define a sight aperture with a first dimension. The peep sight insert has a rear flange adapted to abut the rear surface, a front flange adapted to abut the front surface, and a continuous side wall extending between the front and rear flanges to define a sight aperture with a second dimension that is smaller than the first dimension.
[0007] According to a further aspect of the invention, a peep sight insert for installation into an aperture of a peep sight for reducing an aperture size of the peep sight includes a rear flange, a front flange, and a continuous side wall extending between the rear and front flanges to define a sight aperture. The continuous side wall includes a first outer sloped surface extending inwardly and forwardly from the rear flange; and a second outer sloped surface extending inwardly and rearwardly from the front flange.
[0008] According to yet another aspect of the invention, a peep sight kit includes a peep sight housing adapted for connection to a bow string of an archery bow and a plurality of interchangeable peep sight inserts for installation in the peep sight housing. The peep sight housing has rear and front surfaces and a sight aperture located therebetween. A first inner sloped surface extends inwardly and rearwardly from the front surface, and a second inner sloped surface extends inwardly and forwardly from the rear surface. Each peep sight insert has a sight aperture that is different in size than the other sight apertures of the peep sight kit. Each peep sight insert includes a rear flange, a front flange, and a continuous side wall extending between the rear and front flanges to define the sight aperture. The continuous side wall has a first outer sloped surface that extends inwardly and forwardly from the rear flange and is adapted to abut the first inner sloped surface, and a second outer sloped surface that extends inwardly and rearwardly from the front flange and is adapted to abut the second inner sloped surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The foregoing summary as well as the following detailed description of the preferred embodiments of the present invention will be best understood when considered in conjunction with the accompanying drawings, wherein like designations denote like elements throughout the drawings, and wherein:
[0010] FIG. 1 is an isometric view of a peep sight assembly in accordance with the present invention connected to a bow string;
[0011] FIG. 2 is an enlarged isometric view of the peep sight assembly;
[0012] FIG. 3 is an exploded isometric view thereof;
[0013] FIG. 4 is a rear elevational view thereof;
[0014] FIG. 5 is a side elevational view thereof;
[0015] FIG. 6 is a front elevational view of the peep sight assembly with a small aperture insert;
[0016] FIG. 7 is a sectional view taken along line 7 - 7 of FIG. 6 ;
[0017] FIG. 8 is a front elevational view of the peep sight assembly with a medium aperture insert;
[0018] FIG. 9 is a sectional view taken along line 9 - 9 of FIG. 8 ;
[0019] FIG. 10 is a front elevational view of the peep sight assembly with a large aperture insert;
[0020] FIG. 11 is a sectional view taken along line 11 - 11 of FIG. 10 ;
[0021] FIG. 12 is an isometric view of a peep sight insert having a particular aperture size in accordance with a further embodiment of the invention;
[0022] FIG. 13 is a top plan view thereof;
[0023] FIG. 14 is a side elevational view thereof;
[0024] FIG. 15 is a sectional view of the peep sight insert taken along line 15 - 15 of FIG. 13 ;
[0025] FIG. 16 is an isometric view of a peep sight insert having a different aperture size in accordance with the invention;
[0026] FIG. 17 is a sectional view of the insert of FIG. 16 ;
[0027] FIG. 18 is an isometric view of a peep sight kit having a peep sight and a number of differently configured peep sight inserts;
[0028] FIGS. 19-21 show the steps, in a side elevational view, for installing a peep sight insert into a peep sight housing mounted on a bow string; and
[0029] FIGS. 22-24 show the steps, in a side elevational view, for removing a peep sight insert from a peep sight housing mounted on a bow string.
[0030] It is noted that the drawings are intended to depict only typical embodiments of the invention and therefore should not be considered as limiting the scope thereof. It is further noted that the drawings are not necessarily to scale. The invention will now be described in greater detail with reference to the accompanying drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Referring now to the drawings, and to FIG. 1 in particular, a peep sight assembly 10 in accordance with the present invention is shown connected to a bow string 12 of an archery bow (not shown). The peep sight assembly 10 can be adapted for use with any type of bow including, but not limited to, recurve bows, reflex bows, longbows, compound bows, and so on. The bow string 12 is of conventional construction and typically includes multiple elongate strands 14 of any suitable material used to make bowstrings. A peep sight assembly 10 in accordance with the present invention is shown positioned between the strands 14 in FIG. 1 . The strands are sufficiently flexible, at least when the bow string is relaxed or non-stressed, to permit the creation of an opening 16 for receiving the peep sight assembly 10 . Sight holders 18 preferably encircle the strands 14 to secure the peep sight to the string 12 in a conventional manner. As shown, the sight holders are in the form of elongate cords that are tied as nail knots around the strands 14 of the string 12 . It will be understood that the nail knots may be replaced with individual clamps, slidable crimping members or the like.
[0032] With additional reference to FIGS. 2-5 , the peep sight assembly 10 preferably includes a peep sight housing 20 with a sight aperture 22 and at least one peep sight insert 24 that is removably positioned within the sight aperture. The peep sight housing 20 is preferably constructed of a rigid material, such as aluminum or other metal, plastic and/or ceramic materials, and preferably includes an annular body 26 with a rear face 28 , a front face 30 , and a continuous side surface 32 extending between the rear and front faces. A groove 34 is formed in the side surface 32 . Preferably, the groove 34 extends continuously around the periphery of the annular body 26 . Slots 36 , 38 are preferably located on opposite sides of the annular body 26 . Each slot preferably intersects the circular groove 34 and extends downwardly from the front surface 30 to the rear surface 28 of the annular body 26 , as best shown in FIG. 5 . Each slot 36 , 38 is adapted for receiving the strands 14 of the bow string 12 when the peep sight housing 20 is mounted on the bow string. A cord or band 39 ( FIG. 1 ) can be located in the groove 34 and wraps around the strands 14 in the slots 36 , 38 to further secure the peep sight housing 20 to the bow string 12 .
[0033] The sight aperture 22 of the peep sight housing 20 is preferably coaxial with a central axis 40 ( FIG. 3 ) of the annular body 26 and preferably includes a first inner surface 42 , a second inner surface 44 that slopes inwardly from the rear face 28 toward the first inner surface 42 , and a third inner surface 46 that slopes inwardly from the front face 30 to the first inner surface 42 . The first inner surface 42 preferably extends coaxially with the central axis 40 with the second and third inner surfaces sloping away from the first inner surface. The first inner surface 42 forms a sight opening with a predetermined aperture size or diameter D 1 ( FIG. 7 ). Preferably, the peep sight housing 20 can be used without the peep sight insert 24 during aiming. Accordingly, the size of the sight aperture 22 is selected to coincide with a largest aperture size that may be needed for most archers and/or archery bow configurations. It will be understood that the first inner surface 46 can be of any width, including zero width which may be in the form of a peak or circular line resulting from the intersection of the second and third inner surfaces.
[0034] With additional reference to FIGS. 6 and 7 , the peep sight insert 24 preferably includes an annular body 50 with a rear flange 52 , a front flange 54 , and a continuous side wall 56 extending between the rear and front flanges to form a sight aperture 58 that is smaller than the sight aperture 22 previously described. When installed in the peep sight housing 20 , the sight aperture 58 is preferably coaxial with the central axis 40 ( FIG. 3 ) of the annular body 26 . In this manner, the installation and removal of the peep sight insert does not affect the rear aim point of the bow. The continuous side wall 56 preferably includes a first inner surface 60 ( FIG. 7 ), a second inner surface 62 that slopes inwardly from the rear flange 52 toward the first inner surface 60 , and a third inner surface 64 that slopes inwardly from the front flange 54 and the first inner surface 60 . The first inner surface 60 preferably extends coaxially with the central axis 40 with the second and third inner surfaces 62 , 64 sloping away from the first inner surface. The first inner surface 60 forms a sight opening with a predetermined aperture size or diameter D 2 that is smaller than the diameter D 1 of the sight aperture 22 . It will be understood that the first inner surface 60 can be of any width, including zero width which may be in the form of a peak or circular line resulting from the intersection of the second and third inner surfaces 62 , 64 .
[0035] As best shown in FIGS. 3 and 7 , the continuous side wall 56 also preferably includes a first outer surface 66 , a second outer surface 68 that slopes inwardly from the rear flange 52 toward the first outer surface 66 , and a third outer surface 70 that slopes inwardly from the front flange 54 and the first outer surface 66 . Depending on the size of the sight aperture 22 and the thickness of the continuous side wall 56 , the slope of the second and third outer surfaces may be different from the slope of the second and third inner surfaces of the peep sight insert 24 . The slope of the second and third outer surfaces preferably corresponds to the slope of the second and third inner surfaces of the peep sight housing.
[0036] When the peep sight insert 24 is installed in the peep sight housing 20 , the first, second and third outer surfaces of the peep sight insert 24 respectively engage the first, second and third inner surfaces of the peep sight housing 20 , with the rear flange 52 and front flange 54 of the peep sight insert 24 respectively abutting the rear surface 26 and front surface 30 of the peep sight housing 20 . Preferably, the peep sight insert 24 is constructed as a unitary member during the forming process, and is formed of a resilient material, such as rubber, so that the insert 24 can be easily installed and removed by an archer or other person while in the field or other location without tools. Preferably, the material has a Shore A hardness in the range of about 40 to 100 durometer, and more preferably about 70 durometer. However, it will be understood that other rubber compounds or other types of elastomeric material can be used. In addition, the sloped outer surfaces 68 and 70 increase the surface area over a cylindrical or straight outer surface, providing more gripping area between the sloped surfaces of the peep sight housing 20 and the sloped surfaces of the peep sight insert 24 to thereby more securely anchor the insert to the peep sight housing without the need of tools, clamps, adhesives or other secondary securing means. In addition, the outer sloped surfaces 68 , 70 of the peep sight insert 24 are preferably of a uniform matte finish to increase the friction fit between the insert and peep sight housing. Thus, the front and rear flanges together with the sloped surfaces and the surface finish on the outer sloped surfaces 68 , 70 of the peep sight insert 24 contribute to firmly anchoring the peep sight insert within the peep sight housing.
[0037] In addition, the outer surfaces 66 , 68 and 70 are preferably slightly larger than the corresponding inner surfaces 42 , 44 and 46 to create an interference fit when the peep sight insert 24 is installed in the peep sight housing 20 . In this manner, the increased frictional force due to the increased pressure between the outer sloped surfaces of the peep sight insert and the inner sloped surfaces of the peep sight housing together with the material hardness, inner and outer flanges and material finish contribute to firmly anchoring the insert within the peep sight housing even while subjected to high forces exerted on the peep sight assembly 10 when the bow string is released during shooting, in both dry and wet conditions. In accordance with a preferred embodiment of the invention, the interference fit is in the range of about 0.001 to about 0.020 inch overlap, and more preferably about 0.010 inch. It will be understood that the peep sight insert 24 can greatly vary in sloped surface angle, material type, surface finish, material hardness, and dimensions of the various parts without departing from the spirit and scope of the invention.
[0038] Referring now to FIGS. 8 and 9 , a further peep sight insert 72 in accordance with another aspect of the invention is illustrated. The peep sight insert 72 is similar to the peep sight insert 24 previously described, and fits into the peep sight housing 20 substantially in the same way as the peep sight insert 24 , but differs in that the second inner surface 76 and third inner surface 78 slope toward the first inner surface 74 at a different angle than the second and third inner surfaces of the insert 24 to thereby create a sight opening 80 with an aperture size or diameter D 3 that is larger than the diameter D 2 of the peep sight insert 24 .
[0039] Referring now to FIGS. 10 and 11 , a further peep sight insert 82 in accordance with the invention is illustrated. The peep sight insert 82 is similar to the peep sight inserts 24 and 72 previously described, and fits into the peep sight housing 20 substantially in the same way as the peep sight insert 24 and 72 , but differs in that the second inner surface 86 and third inner surface 88 slope toward the first inner surface 84 at a different angle than the second and third inner surfaces of the inserts 24 and 72 to thereby create a sight opening 90 with an aperture size or diameter D 4 that is larger than the diameter D 3 of the insert 24 but smaller than the diameter D 1 of the peep sight housing 20 .
[0040] The provision of a peep sight assembly having interchangeable inserts with different aperture sizes in accordance with the invention accommodates different physical attributes of many users as well as different bow types, shooting styles and conditions without the need to retune the cam timing and nock height of the bow, as well as other adjustments that require skill, attention to detail, and special tools that may not be available or convenient to carry for many archers.
[0041] Furthermore, the provision of a peep sight assembly having interchangeable inserts with different aperture sizes allows the user to easily match the peep diameter (which functions as a rear sight) with the archery sight diameter (which functions as a front sight) more closely for a particular setup. The better the rear peep sight co-witnesses with the front archery sight, the tighter the arrow groupings will be. Since the bow is custom fit to each archer, there are many variables which affect the sight picture, such as draw length, the size and location of front sight aperture relative to the archer's eye, the shape of the archer's face including eye location with respect to other prominent facial features, and the archer's eyesight condition. Having an easily removable peep sight insert is ideal because the user can try all the combinations with his or her own eyes without the use of a bow press or professional archery shop. This is especially handy for users with aging eyes, or for archers using a front lens on their sight. By reducing the peep size, the sight picture through the peep sight is greatly clarified.
[0042] In addition to providing a different aperture size for each peep sight insert 24 , 72 and 82 , the inserts may be formed in different colors to indicate size and/or to accommodate the eyesight of different users as well as shooting conditions. By way of example, certain colors for some archers are more noticeable than the same colors for other archers. For example, the color red may be more prevalent, and thus more preferred, for one archer while the color blue may be more prevalent and more preferred for another archer. To that end, the provision of several visually distinct peep sight inserts facilitates the user's ability to readily locate the peep sight, especially when time is of the essence, such as during aiming at a momentary target. Furthermore, providing different inserts with colors or other visual effects for enhancing the peep sight during different ambient light conditions, such as full sun and low light conditions, is also contemplated.
[0043] Referring now to FIGS. 12-15 , a peep sight insert 92 in accordance with a further embodiment of the invention is illustrated. This peep sight insert 92 is similar to the peep sight inserts 24 , 72 and 82 previously described, and fits into the peep sight housing 20 substantially in the same way as the peep sight insert 24 and 72 , but differs in that one or more labels 94 representing an aperture size or diameter of the insert 92 is formed on the continuous side wall 96 between the front flange 98 and the rear flange 100 . As shown in FIG. 14 , the label 94 is preferably integrally formed on diametrically opposite sides of the third outer surface 102 . However, it will be understood that the label 94 can be formed on the second outer surface 106 or at other locations on the peep sight insert 92 . As shown, the labels 94 extend radially outwardly from the third outer surface 102 to form raised indicia indicating the size of the aperture. By way of example, for an aperture 108 having a 5/32 inch opening, the raised indicia “ 5/32” is formed on diametrically opposite sides of the surface 102 to thereby efficiently inform a user of the aperture size. It will be understood that the fractional indicia can be replaced with and/or supplemented by a decimal equivalent, letter code or other symbols, characters and/or numerals representing the aperture size.
[0044] The label 94 in the form of raised indicia also serves to hold the peep sight insert 92 in place within the peep sight housing 20 in a frictional interference fit since the label 94 will become somewhat compressed when the peep sight insert 92 is installed in the peep sight housing 20 . It will be further understood that the label 94 can be imprinted into the insert 92 to form sunken indicia rather than the raised indicia without departing from the spirit and scope of the invention.
[0045] Referring now to FIGS. 16 and 17 , a peep sight insert 110 in accordance with a further embodiment of the invention is illustrated. The peep sight insert 110 is similar to the peep sight insert 92 previously described, but differs in that the sight aperture 112 is of a different size than the sight aperture 108 . Accordingly, one or more labels 114 representing the aperture size or diameter of the insert 110 is formed on the continuous side wall 96 as in the previous embodiment. For an aperture 112 having a ⅛ inch opening for example, the raised indicia “⅛” is formed on diametrically opposite sides of the surface 102 to thereby efficiently inform a user of the aperture size.
[0046] Referring now to FIG. 18 , the peep sight assembly can be provided in the form of a kit 120 with a peep sight housing 20 having a first aperture size 22 and a plurality of peep sight inserts 92 , 110 and 118 , for example, with different aperture sizes. By way of example, the aperture size of the peep sight housing 20 is ¼ inch, while the aperture sizes of the peep sight inserts 110 , 92 and 118 are respectively ⅛ inch, 5/32 inch and 3/16 inch. When a particular aperture size is desired, the peep sight housing 20 may be used alone or with any of the inserts. In this manner, the aperture size can be quickly and conveniently changed without the need of removing the peep sight from the bowstring and the necessary procedures to install another peep sight as previously described. It will be understood that the particular aperture sizes as shown and described are by way of example only and can greatly vary without departing from the spirit and scope of the invention.
[0047] The peep sight kit 120 of the present invention allows the user to custom select a color and/or aperture size for the rear sight of an archery bow configuration. Since the peep insert is easily changed, the user can try different colors to best suit his or her eyesight condition, since lighter colors tend to pass more light than darker colors. In addition, the archer can simply color coordinate the peep insert with other bow accessories.
[0048] Another advantage of this invention is to allow the user the option to quickly remove the peep sight insert during low light conditions, which is ideal for hunting since larger peep diameters will allow more light to pass through, improving the sight picture. The point of impact on a distal target will not change when the peep sight insert is replaced because the insert is always centered in the peep sight housing. Accordingly, the archer can shoot with confidence either with or without the peep sight insert.
[0049] A tool 122 can also be provided as part of the kit 120 for facilitating the installation and removal of the peep sight inserts. As shown, the tool 122 preferably has a generally cylindrical shape and includes a handle section 124 , a wedge section 126 extending rearwardly from the handle section, and drive sections 128 , 130 and 132 extending forwardly from the handle section. The wedge section 126 includes a curved contact surface 134 extending in an axial direction and a wall 136 extending in a radial direction from the contact surface. The curved contact surface preferably has a shape that complements the shape of the front and rear flanges of the peep sight inserts 110 , 92 and 118 . The handle and drive section 128 are preferably separated by a step 138 . Likewise, the drive sections 130 and 132 are separated by steps 140 and 142 , respectively. The diameters of the drive sections 128 , 130 and 132 preferably correspond to the aperture sizes of the peep sight inserts 118 , 92 and 110 , respectively.
[0050] Turning now to FIGS. 19-21 , a method of installing a peep sight insert into a peep sight housing the tool 122 is illustrated. Although the method will be described using the peep sight insert 92 , it will be understood that it applies to all inserts. As shown in FIG. 19 , the insert 92 is first positioned in the aperture of the peep sight housing 20 at an angle such that the front flange 98 is partially inserted into the aperture opening 22 ( FIG. 2 ) using the wedge section 126 of the tool 122 . Once the entire front flange 98 of the insert 92 is inserted into the aperture opening 22 as shown in FIG. 20 , the tool 122 is reversed and the appropriate drive section (in this case drive section 130 ) corresponding to the size of the insert aperture (in this case aperture 108 in FIG. 15 ), is inserted into the aperture, as shown in FIG. 21 . The tool is then pushed forward as shown by arrow 150 until the front flange 98 and rear flange 100 are seated against the peep sight housing 20 . Although this method has been shown installing the insert in the forward direction from the rear of the peep sight housing 20 , the insert can alternatively be installed in the rearward direction from the front of the peep sight housing.
[0051] Referring now to FIGS. 22-24 , a method of removing a peep sight insert from a peep sight housing the tool 122 is illustrated. Although the method will be described using the peep sight insert 92 , it will be understood that it applies to all inserts. As shown in FIG. 22 , the drive end of the tool 122 is positioned between the peep sight housing 20 and the rear flange 100 of the insert 92 . This can also be accomplished with the wedge section 126 of the tool. The tool is then pushed down and through the insert aperture 108 ( FIG. 15 ) with the appropriate drive section 130 , as shown in FIG. 23 . The tool is then pushed forward, as represented by arrow 152 in FIG. 23 , until the insert 92 is removed from the peep sight housing 20 , as shown in FIG. 24 . Although this method has been shown removing the insert in the forward direction from the rear of the peep sight housing 20 , the insert can alternatively be removed in the rearward direction from the front of the peep sight housing.
[0052] It will be understood that the term “preferably” as used throughout the specification refers to one or more exemplary embodiments of the invention and therefore is not to be interpreted in any limiting sense. In addition, terms of orientation and/or position as may be used throughout the specification denote relative, rather than absolute orientations and/or positions.
[0053] It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. For example, although the peep sight housing, peep sight inserts and their corresponding apertures have been shown as circular in shape, it will be understood that such components can be of other shapes without departing from the spirit and scope of the invention. It will be understood, therefore, that the present invention is not limited to the particular embodiments disclosed, but also covers modifications within the spirit and scope of the invention as defined by the appended claims.
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A peep sight assembly for an archery bow includes a peep sight housing adapted for connection to a bow string of an archery bow and a plurality of interchangeable peep sight inserts for installation in the peep sight housing. Each peep sight insert has a different aperture size and/or color for accommodating different users and/or shooting conditions. Mutually engageable sloped surfaces on the peep sight housing and the peep sight inserts provide a large contact area for frictionally holding the inserts within the housing. Outer flanges on the peep sight also assist to hold the inserts within the housing.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part application and claims priority to U.S. patent application Ser. No. 13/342,104, filed on Jun. 7, 2011 and Provisional Application 61/617025, filed on Mar. 28, 2012. Both pending applications are hereby incorporated by reference in their entireties for all their teachings.
FIELD OF TECHNOLOGY
[0002] This disclosure generally relates to synthesis and characterization of novel copper oxide-doped zinc oxide nanoparticles (CuO-doped ZnO nanoparticles) at ambient temperature and pressure; and using the said nanoparticles for photo-catalytically degrading cyanide present in soil or water as toxic contaminant.
BACKGROUND
[0003] Zinc oxide (ZnO), a II-VI semiconductor with broad range of applications due to its unique properties. In addition, its relatively low cost, superior chemical and mechanical stability (Look D. C. 2001), the availability of large-area substrates with desirable c-axis preferential growth nature and technological compatibility with the conventional silicon process (Lee et al., 2001) make it very desirable compound for many applications.
[0004] Alteration of ZnO's specifications, electronic and optical properties in particular, can be made by doping it with transition metals such as manganese, iron, cobalt, nickel, copper and lanthanides (europium, erbium, and terbium).
[0005] The Cu-doped ZnO semiconductor research was mainly directed to catalytic applications such as methanol synthesis (Bao et al. 2008), production of hydrogen by partial oxidation of methanol (POM) (Schuyten et al. 2009), carbon monoxide oxidation (Taylor et al. 2003), degradation of textile dye pollutants within aqueous solutions (Satish Kumar et al. (2011) and dilute magnetic semiconductors for spintronic devices (Kim et al. 2010, Wang et al. 2007).
[0006] Copper forms in different bonding states within ZnO lattice such as metallic)(Cu 0 , monovalent (Cu I 2 O) and divalent (Cu II O), depending on the annealing conditions (temperature and oxygen pressure), where the fully oxidized divalent state Cu 2+ is favored when the above conditions are promoted otherwise other states would be present.
[0007] There is a need for an easier method to make nanoparticles in an efficient way for industrial use.
SUMMARY
[0008] The instant invention describes a novel method for synthesizing CuO-doped ZnO nanoparticles and their use for photocatalytic degradation of cyanide using the CuO-doped ZnO nanoparticles. The CuO-doped ZnO nanoparticles are used as catalysts for photocatalytically degrading cyanide in aqueous solutions.
[0009] In one embodiment, method of synthesizing CuO-doped ZnO nanoparticles at room temperature from zinc nitrate hexahydrate, copper nitrate trihydrate and cyclohexylamine (CHA) in aqueous solution is described. In another embodiment, various mole ratios of zinc nitrate hexahydrate, copper nitrate trihydrate and cyclohexylamine are described. The mole ratio of copper nitrate trihydrate to zinc nitrate hexahydrate to cyclohexylamine ranges from 1:23:48 to 1:117:236. In one embodiment, once copper nitrate trihydrate, zinc nitrate hexahydrate and cyclohexylamine were mixed together , were stirred for a week, and precipitate is harvested. The precipitate, in another embodiment, is filtered and dried. The dried precipitate was then calcined at 500° C. for three hours. Thus the calcined precipitate was the CuO-doped ZnO nanoparticles to be used for photocatalytic degradation of cyanide.
[0010] In one embodiment, a co-precipitation method using a moderate base of cyclohexylamine (CHA) without using any organic template or surfactant at ambient temperature and pressure was performed. In another embodiment, the resultant CuO-doped ZnO nanoparticles produces copper-substituted ZnO wurtzite lattice structure nanoparticles, regardless of doping concentration of weight percents of copper oxide at 1-4 percent.
[0011] In another embodiment, characterizations of several properties of the novel CuO-doped ZnO nanoparticles were performed. These characterizations were performed to prove the purity and efficacy of the prepared CuO-doped ZnO nanoparticles as well as to demonstrate the current methods efficiency and effectiveness.
[0012] In one embodiment, the CuO-doped ZnO nanoparticles with different weight loading percentage of CuO were used to photo-catalytically degrade cyanide present solution or solids.
[0013] The novel method of synthesizing CuO-doped ZnO nanoparticles and method of using them in the photocatalytic degradation of cyanide in aqueous solutions, disclosed herein, may be implemented in any means for achieving various aspects. Other features will be apparent from the accompanying figures and from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Example embodiments are illustrated by way of example and no limitation in the tables and in the accompanying figures, like references indicate similar elements and in which:
[0015] FIG. 1 shows calcined CuO-doped ZnO nanoparticles of various CuO doping.
[0016] FIG. 2 shows X-ray diffraction (XRD) patterns of CuO/ZnO samples with varying copper oxide concentration before ( 2 A) and after calcination ( 2 B, 2 C).
[0017] FIG. 3 shows the scanning electron microscopy (SEM) micrographs ( 3 A) and the element analysis ( 3 B) for the calcined CuO-doped ZnO nanoparticles.
[0018] FIG. 4 shows high resolution TEM micrographs for the calcined CuO-doped ZnO nanoparticles.
[0019] FIG. 5 shows the UV-Vis absorption spectra for copper oxide doped ZnO nanoparticles before and after calcination.
[0020] Other features of the present embodiments will be apparent from the accompanying figures, tables and from the detailed description that follows.
DETAILED DESCRIPTION
[0021] Several embodiments for a process of synthesizing, characterization and method of using CuO-doped ZnO nanoparticles in the photo-catalytic degradation of cyanide are disclosed. The CuO-doped ZnO nanoparticles are used as a catalyst in the solution to degrade cyanide.
[0022] Synthesis of CuO-doped ZnO Nanoparticles:
[0023] Materials- Copper nitrate trihydrate (98-103%, Fluka), zinc nitrate hexahydrate (pure, POCH), and cyclohexylamine (GC>99%, Merck) were commercially available and were used without further purification. Deionized water (18.2 MΩ.cm) was obtained from a Milli-Q water purification system (Millipore).
[0024] Method of Making and Characterization of the Undoped ZnO and CuO-doped ZnO Nanoparticles:
[0025] As described previously (U.S. patent application Ser. No. 13/342,104) and incorporated herein in its entirety zinc nitrate hexahydrate was mixed with cyclohexylamine in water in 1:2 mol ratio at room temperature to prepare undoped ZnO precipitate as ZnO nanoparticle, which was calcined at 500° C. for three hours.
[0026] Calculated amounts of zinc nitrate hexahydrate, copper nitrate trihydrate, and cyclohexylamine were mixed according to the mol ratios as shown in Table 1. For each mixture, metal nitrate precursors were first mixed and dissolved in 500 ml of deionized water at room temperature, under continuous magnetic stifling. The addition of cylcohexylamine resulted in a very light blue precipitate. Depth of blue color increased with increasing the copper content. The reaction mixtures were left stifling for one week. The precipitates were filtered off through F-size fritted filters, and then were copiously washed with deionized water. The precipitates were dried under vacuum for one day. After drying, the precipitates were mixed with 300 ml water and were magnetically stirred for one day for the removal of any impurity. The precipitates were filtered off, air-dried, and then calcined at 500° C. for three hours. Brown solids were obtained after calcination. The depth of brown color increased with increasing the copper oxide content from 1 to 4% (specific concentration)( FIG. 1 ).
[0000]
TABLE 1
Mole ratio of copper nitrate to zinc nitrate to
CHA for preparing the catalyst precursors.
Precursor (wt %)
Cu 2+ : Zn 2+ : CHA mol ratio
1
1:117:236
2
1:47:97
3
1:31:65
4
1:23:48
[0027] Materials Characterization: Inductively-coupled plasma (ICP) was used to determine the copper and zinc component in the calcined CuO-doped ZnO nanoparticles, obtained at 500° C. X-ray diffraction (XRD) patterns were recorded for phase analysis and crystallite size measurement on a Philips X pert pro diffractometer, operated at 40 mA and 40 kV by using CuK α radiation and a nickel filter, in the 2 theta range from 2 to 80° in steps of 0.02° , with a sampling time of is per step. The crystallite size was estimated using Scherer's equation. XRD patterns were recorded for Cu 2+ -doped ZnO nanoparticles before and after calcination.
[0028] The morphology CuO-doped ZnO nanoparticles (size and shape) was investigated using a field emission scanning electron microscope (FE-SEM model: FEI-200NNL) and a high resolution transmission electron microscope (HRTEM model: JEM-2100F JEOL). Carbon-coated copper grids were used for mounting the samples for HRTEM analysis. Elemental microanalysis of the surface was performed by energy dispersive X-ray spectroscopy (EDX), which is coupled to FE-SEM.
[0029] UV-Vis absorption spectra for Cu 2+ -doped ZnO materials before and after calcination were recorded on a Perkin Elmer Lambda 950 UV/Vis/NIR spectrophotometer, equipped with 150 mm snap-in integrating sphere for capturing diffuse and specular reflectance.
[0030] Photocatalytic Evaluation: All the experiments were carried out using a horizontal cylinder annular batch reactor. A black light-blue florescent bulb (F18W-BLB) was positioned at the axis of the reactor to supply UV illumination. Reaction suspension was irradiated by UV light of 365 nm at a power of 18 W. The experiments were performed at room temperature by suspending 0.02 wt % of CuO-doped ZnO sample into 300 ml, 100 ppm potassium cyanide at pH 8.5, adjusted by ammonia solution. This specific pH value was chosen on the basis of previous investigation, revealed the preferred adsorption of OH − ion over CN − ion at higher pH values, while hydrogen cyanide, HCN, elevates at pH≦7 according to the following equation:
[0000] CN − ( aq )+H 2 O (l) =HCN (g) +OH − (aq)
[0031] The reaction was carried out isothermally at 25° C. and a sample of the reaction mixture was taken after 120 minutes. The CN − content in the solution after reaction time was analyzed by volumetric titration with AgNO 3 . The removal efficiency of CN − has been measured by applying the following equation:
[0000] % Removal efficiency=(C o −C)/C o ×100, where C o the original cyanide content and C the retained cyanide in solution.
[0032] The physical observation of the Cu 2+ -doped ZnO nanoparticles samples after calcination ( FIG. 1 ) was evident for increasing the copper oxide content through the increase in color depth. Table 2 confirms that the theoretical and experimental, obtained by ICP, CuO content in the calcined samples were in good agreement.
[0000]
TABLE 2
Theoretical and experimental results of CuO
content in the CuO-doped ZnO catalysts.
Theoretical
Experimental
Sample
(wt %)
(wt %)
1% CuO/ZnO
1
0.7
2% CuO/ZnO
2
1.9
3% CuO/ZnO
3
2.9
4% CuO/ZnO
4
3.9
[0033] FIG. 2 shows the XRD spectra of the CuO/ZnO samples with varying the copper concentration from 1 to 4 weight percent before ( 2 A) and after calcination ( 2 B). No indication of any copper secondary phases was observed upon incorporation of copper for all the samples. The absence of secondary phases could be attributed either to the complete solubility of copper within ZnO, which is higher than the reported solubility limit value of 1% and the 3% reported in the literature. The low solubility was attributed to the high covalent character in Cu-O bonding, resulted from the high localization of 3D state on copper. It is also likely that the high dispersion of copper phases within ZnO phase prevented its detection by XRD technique. However, this possibility was excluded on the basis of XRD results, explained below, and on the basis of the TEM results. The other possibility of not detecting any copper phase due to its amorphous nature was also ruled out on the basis of the TEM results, which showed the crystal planes.
[0034] The shift of the ZnO peaks (for instance 100, 002, and 101) to higher 28 is a result of replacing Zn 2+ (0.060 nm) by the smaller Cu 2+ ions (0.057 nm) in the wurtzite lattice. The shift in the uncalcined samples was more pronounced than the calcined samples due to the decrease in defects, resulting from copper substitution upon calcinations ( FIG. 2C ). No copper phases were detected by XRD for the uncalcined or the calcined samples which confirms complete substitution of Cu 2+ in the ZnO wurtzite lattice even at room temperature. The average crystallite size of CuO-doped ZnO catalysts was estimated by Scherrer equation for the crystallographic phases (100), (002), and (101). The average crystallite size was not affected by the CuO wt % content (1 wt %: 32.48 nm; 2 wt %: 33.34 nm; 3 wt %: 33.47 nm; 4 wt %: 33.60 nm).
[0035] The importance of having complete solubility in our CuO/ZnO catalyst systems is to produce a coupled system instead of having two independent ZnO and CuO composites such as those systems used in hetrojunctions that may not be in harmony with each other and minimize the charge transfer from one to another.
[0036] FIG. 3A shows the SEM micrographs for the calcined CuO-doped ZnO samples. The same morphology was observed in all samples irrespective of CuO wt %. The particles were agglomerated in rice-like shape. The elemental microanalysis of the surface (quality) by EDX ( FIG. 3B ) confirmed the purity of the calcined samples and the presence of copper, zinc, and oxygen on their surfaces. However, the surfaces are rich in zinc, which is consistent with the oxygen-deficiency for the n-type ZnO. In addition, the copper peak intensity increased with increasing the copper oxide content from 1 to 4%, as shown in EDX result ( FIG. 3B ).
[0037] FIG. 4 shows high resolution TEM micrographs for the calcined CuO-doped ZnO samples. All the samples show similar morphology and particle size irrespective of CuO wt % doping. The particles have different shapes such as rectangular- and round-like. The average size of the nanoparticles ranged from 5 to 20 nm. The lattice fringes, in addition, match those of ZnO only, which supports the results obtained from XRD, indicating the replacement of Zn 2+ Ions by Cu 2+ ions in the wurtzite lattice of ZnO.
[0038] FIG. 5 shows the UV-Vis absorption spectra for the copper oxide doped ZnO samples before and after calcination. The incorporation of Cu 2+ is responsible for ZnO E g reduction, i.e. red shift. As shown in Table 3, a slight shift in the E g of ZnO with increasing the content of CuO from 1 to 4 wt % was observed.
[0000]
TABLE 3
Band gap energy of the Cu 2+ -doped ZnO
samples before and after calcination.
Eg/eV
Eg/eV
Sample
(Uncalcined)
(Calcined)
1% CuO/ZnO
3.24
3.21
2% CuO/ZnO
3.22
3.20
3% CuO/ZnO
3.22
3.19
4% CuO/ZnO
3.21
3.19
[0039] The E g s of the uncalcined and calcined samples were almost comparable. This result might imply that Cu 2+ substituted Zn 2+ in ZnO wurtzite lattice at room temperature, which was also supported by X-ray results. However, the small red shift in the E g s of the calcined samples could be due to the enhancement of copper substitution upon calcinations.
[0040] The red shift in the calcined samples was less compared to the reported E g (2.9 eV) for CuO/ZnO nanoparticle, which was prepared physically by wet impregnation method and attributed to the stoichiometry deficiency of ZnO due to impregnated CuO [13]. The E g reduction (band offsets) in our solid solution system may be attributed to the following effects:
1) The strong d-p coupling between copper and oxygen moves O 2p orbital up, that narrows the direct fundamental E g of ZnO. 2) Creation of impurity energy band, especially at higher concentrations, above the ZnO valance band maximum (VBM) which creates a mixture of direct and indirect transitions.
[0043] Effect of CuO Doping on Photocatalytic Activity
[0044] Table 4 shows the effect of CuO doping on photocatalytic performance, which was investigated by changing the doping wt % from 0 to 4 under the aforementioned reaction conditions as above. The results showed that the un-doped ZnO catalyst gave a reasonable photocatalytic activity. However, the CuO-doped ZnO catalysts exhibited better activity with increasing the CuO content from 1 to 3 wt %. Nevertheless, increasing the CuO content to 4 wt% did not enhance the photocatalytic activity. This finding might be due to the identical E g of both 3% and 4 wt % CuO-doped ZnO catalysts.
[0000]
TABLE 4
The effect of CuO wt % on photocatalytic activity
Sample
% of cyanide degradation
ZnO
56
1% CuO/ZnO
89
2% CuO/ZnO
93
3% CuO/ZnO
97
4% CuO/ZnO
97
[0045] The enhancement in photocatalytic degradation of cyanide ion with increasing the CuO wt % content could be attributed to the inhibition of electron-hole pair recombination and efficient separation of the charges. Such easy transfer of electrons from CuO to ZnO is due to the close match of work function between CuO and ZnO (5.3 eV).
[0046] The instant Cu-doped ZnO nanoparticles showed enhancement in the photocatalytic performance due to E g reduction. Furthermore, the narrow E g of CuO (1.7, 1.33 eV) results in efficient separation of charges, which were photo-generated in the copper oxides/zinc oxide under UV light illumination and suppressed their recombination. The mechanism of the photo- generated charges separation is due to their transfer between the two semiconductor materials (p-type copper oxides/n-type zinc oxide) as follows; the photogenerated electrons transfer from the conduction band (CB) of CuO to that of ZnO, while the photogenerated holes immigrate in the opposite direction from the valance band (VB) of ZnO to that of CuO. Consequently, more electrons are accumulated in the conduction band of ZnO while more holes are accumulated in the valence band of CuO.
[0047] Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the various embodiments. In addition, the specification and drawings are to be regarded in an illustrative rather than as in a restrictive sense.
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A simple, room-temperature method of producing CuO-doped zinc oxide nanoparticles was established by reacting zinc nitrate hexahydrate, copper nitrate trihydrate and cyclohexylamine (CHA) at room temperature. These nanoparticles may be used for photocatalytic degradation of cyanide in aqueous solutions. The degradation of cyanide is effective because electrons transfer from the p-type copper oxide to the n-type zinc oxide.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application the National Phase Application of International Application No. PCT/MX2003/000027 filed Mar. 14, 2003.
TECHNICAL FIELD
[0002] This invention in a general way relates to the medical area in procedures where it is required to inject a dense or viscous fluid through a needle, in a particular way the viscous material is the polymethylmethacrylate. It is used in procedures like percutaneous vertebroplasty, kyphoplasty or other surgical events of the field. It has applications in other areas where it is required to apply at distance a dense and viscous liquid.
BACKGROUND OF THE INVENTION
[0003] Percutaneous vertebroplasty is a minimally invasive interventional radiological procedure that consists on injecting bone cement (Polymethylmethacrylate, PMMA) in the vertebral body, by trans-pedicular or oblique approach through a bone biopsy needle.
[0004] It was developed in France in 1984 for the treatment of aggressive or painful haemangiomas of vertebral bodies. For its analgesic effect, its use was quickly extended for the treatment of lytic metastatic lesions or myeloma and mainly in fractures or vertebral collapse due to osteoporosis, The procedure is indicated in those cases that are presented with severe and disabling pain that doesn't respond to conservative measures such as: corset use, analgesic and anti-inflammatory treatment or bed rest.
[0005] Most of the patients with this suffering are between the 6th and 8th decade of life. In this group of advanced age, the immobilization resulting from vertebral fractures has severe consequences in their general medical conditions, it predisposes them to cardiopulmonary, intestinal, circulatory complications, etc. Besides pain, the psychological effects can be devastating, it deteriorates the quality and reduces the expectation of life.
[0006] Vertebroplasty is a procedure that is carried out in hospital facilities that requires specialized medical personnel. It is performed in a hemodinamia room or cath lab, and it requires of the use of radiological equipment with high resolution fluoroscopy, mounted in a C arm. Currently, this injection is carried out in a manual and direct way and the operator is exposed to ionizing radiation every time that he/she practices a vertebroplasty. The injection of bone cement is made with fluoroscopic control, connecting an insulin syringe to the needle. This implies that the surgeon is in direct contact with the patient and therefore, overexposed to primary or secondary ionizing radiation during the lapse of the procedure of the vertebroplasty.
[0007] The primary radiation is the X ray beam coming from the X ray tube and received by the patient in a direct way, The secondary radiation it the one resulting on the deviation of the primary beam in the patient's body tissues and doesn't contribute to the formation of a diagnostic image, it is spread in all directions and it is the main source of exposure of medical personnel.
[0008] The insulin syringe is used since a small diameter barrel is required to have less resistance for the manual injection of high viscosity bone cement, each syringe is filled approximately in half or two thirds of its capacity to avoid bending or breaking the plunger when exercising the required injecting pressure that may be considerable, The volume needed to obtain the expected results varies from 3 ml up to 9 ml, therefore, 5 to 18 syringe exchanges are necessary, this favors the solidification of the polymethylmethacrylate and it can prevent to inject the wanted quantity.
[0009] If larger diameter syringes are used, the manual pressure is insufficient due to the density and viscosity of the bone cement; and becomes necessary the employment of a mechanical device to be able to exercise the required pressure. At the state of the art, there are commercially available devices such as pressure gun type or threaded plunger mechanisms connected directly to the needle that deposits the cement in the bone or through a high pressure short tube. The use of a long tube would have considerable resistance to the flow of the cement, favoring its solidification.
[0010] In most of these devices the syringe is not interchangeable, it is loaded with the total volume to inject and therefore, are of larger diameter and the increased resistance to the flow of the cement becomes worse with time due to solidification of cement.
[0011] On the other hand, the conventional hypodermic syringes are not designed for high pressure injection, the plunger and the fingers supporting wings bend easily.
[0012] The devices of the previous technique solve only the mechanical problem of injecting the dense and viscous cement through the needle but they are focused on exercising the necessary pressure directly on the patient or at a very short distance of the radiation source. They don't allow the operator to maintain an appropriate distance to reduced exposure to secondary radiation at acceptable levels according with the international radiological protection norms.
[0013] On the other hand, some mechanical devices do not allow control or manual sensibility of the exercised pressure and speed of the injection of the cement, important factors in the prevention of undesirable leaks and complications. Some devices that apply cement in the current state of the art are for example:
[0014] The patent application of the United States of America No, 2003/0018339, for Higueras et al, published Jan. 23, 2003, it discloses an application device for the controlled injection of hone cement, mounted in a syringe loaded with the cement, as a cartridge, which is discharged by a threaded metallic plunger placed in the other end of the device, it is useful for controlling the pressure exercised on the plunger of the syringe but it is a short device in which the operator is near the patient; It also contains the total load of cement.
[0015] On the other hand, due to the viscosity of the cement and quantity keeps certain dynamic memory that doesn't allow sudden interruption of the injection.
[0016] The patent application of the United States of America No. 2002/0156483, for Voellmicke et al, published Oct. 24, 2002, discloses a vertebropiasty device and bone cement, it contains two compartments, one for mixture of the cement and the other for storage and injection into the bone. This dual camera device for blending and injection, consists of a lodging camera with a plunger moving in an axial way, the cameras are in communication by a check valve that only allows the passage of the cement in one direction. An extra force can be exercise on the plunger by means of a lever that increases the mechanical force and therefore the pressure in the injection camera, This is a device in which it is necessary to work the piston of the blending camera and the piston of the injection camera to empty one and fill the other one alternatively. It is a short device, it is necessary to be near the patient and doesn't reduce the exposure to secondary ionizing radiation.
[0017] The patent application of the United States of America No, 2002/0099384, for Scribner et al, published Jul. 25, 2002, discloses a system and method to treat vertebral bodies. It is a special syringe with two concentric plungers. The first camera that has a first transverse section and a second smaller camera than the first one. Both cameras communicate to each other. The first camera includes a gate to receive the material inside the filling instrument, the second camera includes a gate to discharge the contained material. A first plunger suited to pass through the first camera and displace the material. A second plunger to pass through the interior of the first plunger's concentric hole and reach the interior of the second camera to displace the material through the exit in the second camera to inject into the needle toward the interior of the vertebral body. Although this device provides control in the injection of the bone cement, the operator is too near the patient.
[0018] In general the injection devices have a bolster that impels the viscous fluid by means of a manual trigger moved by a screw mechanism (inclined plane), there are others that have a gun like body such as the device of the Patent Application of the United States of America. 2002/0049448. for Sand et al, published Apr. 25, 2002, It has a tubular body that stores a viscous flowing material (bone cement), it is a longitudinal body with a providing end and a driving end, a plunger housed inside the tubular body that displaces the flowing material along the longitudinal axis of the tubular body, the driving mechanism has a handle like a gun to hold with a hand, while injecting with the other hand by means of the plunger that advances due the pressure exerted by a threaded mechanism. These mechanisms with big deposits have the inconvenience that the cement can end up solidifying in the conduit at the time of application and impede to apply the total amount of cement inside the affected vertebral body. On the other hand, with the excess of pressure generated by these devices, the cement could leak outside of the vertebral body, since the fluid (PMMA), for its viscosity, possesses a remaining flowing memory that may be difficult to control.
[0019] The Patent of the U.S. Pat. No. 6,348,055, for Preissman, published Feb. 19, 2002, protects a bone cement applying device with screw mechanism in which the preparation of the total volume of cement is made, this mechanism has an intermediate stabilizer that avoids the turns of the whole device during the application of pressure to the fluid. The stabilizer is a lever perpendicular to the screw body that can be sustain with a hand, while with the other hand exercises the pressure to inject the cement inside the vertebral body, This device is also operated very near the patient and therefore, the operator is exposed to secondary ionizing radiation. Another inconvenience is that if the cement solidifies in the system and has not reached the vertebral body in the proper amount, it is necessary to make another preparation previous placement of another needle in a different and appropriate position for the new requirement.
[0020] The Patent Application of the United States of America No. 2002/0010431, for Dixon et al, published Jan. 24, 2002, discloses a screw device for high pressure with a threaded axis that impels a plunger inside a camera full with viscous bone cement. This device has the inconvenience that one doesn't have manual sensitivity and control of the pressure exercised, it is not easy to exchange the syringes with the bone cement. As a matter of fact, it is the only syringe of the cartridge.
BRIEF SUMMARY OF THE INVENTION
[0021] Among the several objects of the present invention, a better control of the pressure in the placement of bone cement or other viscous materials in the bone is provided. The invention facilitates the injection of viscous filler in trabecular bone or a cavity formed in the vertebral body.
[0022] Another object of the present invention it is to provide a hydraulic device to treat vertebral fractures and reduce the pain, stabilize the vertebral body, to obtain higher resistance to compression, avoid further collapse and at the same time, to allow early mobilization of the patients and improve their quality of life.
[0023] It is still another object of the present invention, to provide a device for the injection of viscous material in the vertebral body that allows the operator to keep and appropriate distance (1.0 m to 1.5 m) in order to reduce exposure to ionizing radiation at acceptable levels within the international norms.
[0024] It is also another object of the present invention, to provide a hydraulic press like device using syringes of unequal caliber (3 and 10 ml) to exercise hydraulic pressure at distance transmitted from a proximal, manual syringe of smaller caliber, through the polyethylene tube until the distal or injecting syringe.
[0025] It is another object of the present invention to provide a cylinder of pressure with mechanical advantage complementary to an hydraulic system of syringes for injection at distance of polymethylmethacrylate suspension in the cancellous bone of a vertebral body. This way, the overexposure of the operator to ionizing radiation is reduced.
[0026] It is still another object of the present invention to provide a hollow cylinder or body of pressure in the shape of an inverted syringe to form a hydraulic device that allows manual control on the volume and velocity of injection polymethylmethacrylate (PMMA) and also immediate interruption of the pressure applied on the fluid.
[0027] It is still an object of the present invention, to provide a device that prevents the movements or abnormal displacements of the needle during the injection and syringes exchange (1 or 2 exchanges may be necessary), it reduces time loss and allows to maintain the bone cement loaded syringes in a recipient or cold atmosphere to slow time of solidification.
[0028] It is another object of the present invention, to provide a device that uses syringes from 3 to 5 ml that require smaller injection pressure, and can be exchanged easily with a single 90° rotation movement, Hub Lock type.
[0029] It is still an object of the present invention, to provide a device for injection of viscous material that can be manufactured of plastic, aluminum or any other disposable light-weighted material for single use or suitable for re-sterilization, sturdy enough to support the pressure of injection.
[0030] It is another object of the present invention to provide a flexible hydraulic, light-weighted device that prevents the movements or unwanted displacements of the needle during the injection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The FIG. 1 , represents the connection outline of the novel hydraulic press like device for injection at distance, of the present invention.
[0032] The FIG. 2 , represents an injection device with a screw type threaded plunger of the previous technique.
[0033] The FIG. 3 , represents a device of injection of the previous technique, which has a recipient to make the mixture, another to exercise the injecting pressure, each recipient contains a check valve in their exit holes to avoid re-flow
[0034] The FIG. 4 , represents a device of injection of the previous technique, which contains a larger capacity syringe in which the total amount of bone cement mixture is placed to inject, impelled by a threaded plunger.
[0035] The FIG. 5 represents the device object of the present invention corresponding to the transverse view of the piston together with the rubber cap.
[0036] The FIG. 6 represents the smaller, manual syringe for control of the device with the plunger and rubber cap.
[0037] The FIG. 7 , it represents the syringe of force, the conduit ( 7 ) that transmits the pressure to the larger diameter device (B), and the way to place the plunger (A) of the injecting syringe that contains the material and the injection needle.
[0038] The FIG. 8 , represents a hydraulic press, theoretical basic principles of the present invention.
[0039] The FIG. 9 , represents the pressure transmitted in the tube and the exit force generated, which pushes the plunger that injects the material through the needle.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The present describes a new device and method to treat affections of the bones, specifically, in the treatment of osteoporotic or fractured vertebral bodies.
[0041] These bone structures have different pathological states of diverse ethiology (trauma, osteoporosis, primary bone tumors or metastases, etc.). An alternative of treatment to stabilize and to consolidate this structures consists on the injection of a bio-materials such polymethylmethacrylate in the interior of the vertebral body for healing purpose.
[0042] The injection of biomaterials such as bone cement is carried out by means of a hydraulic device exerting pressure on small caliber conventional syringes connected directly to the needle; since the cement has the property of becoming hard quickly.
[0043] The theoretical basic principle for the operation of the device of the present invention consists on the amplification of the hydraulic pressure generated at distance and transmitted by the hydraulic tube.
[0044] In reference to the FIG. 8 , the most frequent application to the Law of Pascal is the hydraulic press that consists of two asymmetric columns of liquid. This principle is applied in mechanical devices of engineering areas, this columns are different in the size or diameter of the transverse section. In accordance with the Law of Pascal, a pressure applied in one of the columns is transmitted entirely and in all directions. Therefore, if a force F 1 is applied on the area piston A 1 , it will cause an exit force F 0 that acts on an area A 0 of the piston. This way, the entrance pressure is the same to the exit pressure, that is to say:
[0000]
F
1
/A
1
=F
0
/A
0
[0045] The ideal mechanical advantage of the device is similar to the relationship of the exit force with regard to the entrance force.
[0000]
VM=F
0
/F
1
=A
0
/A
1
[0046] Where a small entrance force can be multiplied (A 0 /A 1 times) to produce a larger exit force (F 0 ), using an exit piston with a larger area than that of the entrance piston. The exit force will be given by:
[0000]
F
0
F
1
A
0
/A
1
[0047] If friction is disregarded, in an ideal situation the entrance work should be the same to the exit work. Therefore, if the force F 1 travels a distance S 1 while the exit force F 0 travels a distance S 0 , there is equality.
[0000]
F
1
S
1
=F
0
S
0
[0048] The mechanical advantage can be expressed in terms of the distances traveled by the pistons:
[0000]
VM=F
0
/F
1
=S
1
S
0
[0049] It is observed that the mechanical advantage is obtained at expenses of the distance that the entrance piston travels.
[0050] In reference to the FIG. 9 that describes the body (B) and area ( 95 ) of the piston of larger area of the present invention, it is also represented the entrance of the pressure P 1 that is transmitted through the incompressible fluid, either water or oil, content in the flexible tube (not shown) that generates an exit force F 0 . The attachment ( 2 ) for the lateral wings of the injecting syringe that contains the bone cement acts as coupler to the device, the wings enter tightly in the internal peripheral groove ( 70 ) diametrically opposed inside the bolster(header) of the body of the device object of the present invention, with a turn of 90° either clockwise or counterclockwise. The plunger of the syringe enters in the longitudinal central space ( 95 ) of the body (B).
[0051] Returning to the FIG. 1 , the hydraulic device consists of four main parts arranged one after another in such a way that allows to inject at distance and in a controlled way (regarding the pressure) viscous materials such as polymehylmethacrylate used in percutaneous vertebroplasty for the reestablishment (without surgery) of patient with osteoporotic fractures.
[0052] The device here described is designed to inject at distance a polymethylmethacrylate suspension with viscous consistency, directly in the cancellous bone of the vertebral bodies by means of a syringe loaded with the bone cement attached to a bone biopsy needle. The device consists of four main parts, “injecting syringe” in vicinity to the patient, “pressure” exerting body, “hydraulic transmission tube” and “manual syringe”. in this, the fingers of the operator exercise the controlled force. This control is carried out by the operator's tact sensitivity. This device conforms a hydraulic system for polymethylmethacrylate injection at a variable distance from the patient (usually 1 m to 1.5 m).
[0053] The injection part is a commercially available, disposable 3 ml. hypodermic syringe (a) that is placed next to the patient, loaded with the bone cement that consists of a plunger ( 11 ) that pushes the material (CO) to be injected in the vertebral body trough a bone needle (CA), (not shown). This syringe couples tightly in a revolved way, by means of the opposed wings of support (b), in a peripheral groove in the internal face of the bolster ( 2 ) of the body of pressure, it is coupled by means of the opposed Wings (b) used as support for the fingers in an act of usual injection, these wings (b) are placed in the entrance guide and rotated, either clockwise or counterclockwise an angle of 90° to stay in tightly fixed to avoid inadvertent detachment and loss of the pressure. The injection needle is coupled rotating the threaded distal end (CA) in the usual way of common plastic syringes in order to avoid spillage of the material to be injected due to the high pressure exercised on the plunger (c) and its end ( 3 ). For exchange, the empty syringe is detached from the needle, and then from the pressure device by means of a 90° rotation, discarded ( 2 ) and replaced with another loaded syringe prepared in advance and stored in a cold environment to delay curing and hardening of the cement. The syringe (a) is of 3 or 5 ml capacity.
[0054] The part of pressure, consists of distal inverted syringe body ( 1 ) of larger diameter that the syringe at the proximal end of the complete device, It has a bolster ( 2 ) open to the atmospheric pressure that contains an internal peripheral groove where the opposed supporting wings of the injecting disposable hypodermic syringe are coupled (b) with a turn of 90°. Its interior is open to the atmospheric pressure and receives the plunger of the injecting syringe (c) in a extended position to make contact with the rigid surface of the piston ( 3 ), The piston moves tightly with respect of the internal wall of the device ( 1 ) by means of a rubber cap ( 4 ), to maintain a closed hydraulic space ( 5 ) The distal pressure is transmitted to the piston through the opening or mouthpiece ( 6 ) connected to the flexible tube of polyethylene or similar material ( 7 ) by means of the hydraulic fluid ( 10 ). The rigid surface of the piston ( 3 ) exercises pressure (which has been increased by the device) on the plunger ( 11 ) of the injecting syringe. The body ( 1 ) is manufactured of transparent plastic, aluminum or any other suitable light-weighted and rigid material. Other characteristics of the body will be described ( 1 ) with more detail in the FIGS. 5 , 7 and 9 .
[0055] The hydraulic tube for pressure transmission (the Pascal's Principle), is a tube or flexible hose of polyethylene or similar material of little weight, with appropriate diameter to couple in the distant and proximal ends of the syringes, the longitude is variable, most commonly of 1.0 m to 1.50 m, it is resistant to the internal pressure. The tube is loaded of water, oil or other non-compress fluid ( 10 ) to integrate together with the manual proximal syringe and the body of pressure closed hydraulic system.
[0056] The manual syringe ( 8 ), has a smaller diameter than the body of pressure ( 1 ) in a 2/1, 3/1 or 4/1 ratio that may vary according to the necessity of each case. According to the hydraulic press described in the FIG. 8 , the longitude of the manual syringe should be larger than that of the body of pressure ( 1 ) with the purpose of containing enough volume to displace the piston the, distance required to impel the plunger of the injecting syringe. this way, the quantity required of bone cement is deposited in the vertebral body.
[0057] The device works in the following way: a manual force is exercised on the plunger ( 9 ) of the manual syringe ( 8 ) in its extended position, the force exercises a pressure that is transmitted through the incompressible fluid ( 10 ) content in the flexible tube and in the camera ( 5 ) of the body of pressure ( 1 ). This pressure exercises an increased force on the plunger of the injecting syringe, due to the mechanical advantage of the relationship of areas or displacements formerly described. The plunger of the injecting syringe in turn, exert a force that impels (to) the material or cement to be injected in the patient's vertebral body through the bone biopsy needle. Once the total amount or content of the injecting syringe has been delivered, the plunger of the manual syringe is retracted to generate space inside the body of pressure ( 1 ) by retracting the piston to replace the emptied syringe with a loaded new syringe to continue the injection. Up to 10 ml. of bone cement is required to achieve an suitable filling of the fractured vertebral body, therefore, 3 to 4 syringe exchanges may be necessary.
[0058] The bone needle stays in place during the procedure that is to say, the movements or abnormal displacements of the needle during the injection are avoided, situation that implies several advantages: For the patient, since additional punctures are less frequent and for the operator with less problems of solidification of the cement.
[0059] Another advantage of the device is that the transmission of the pressure is immediate, that is to say, doesn't have a dynamic memory by effects of the increasing viscosity due to the solidification in the injection conduit specially with prolonged injections, prone to happen in the injecting devices of the previous technique that are loaded with the complete volume of cement to be placed. On the other hand, the threaded plunger doesn't allow tact sensibility regarding the exercised pressure and therefore favors unwanted leakage of the bone cement due to the dynamic memory of the material.
[0060] To this respect we have devices of the previous technique such as the ( 20 ) FIG. 2 that consists of a threaded plunger ( 23 ) that impels the contained cement in the camera ( 24 ) and a refilling deposit ( 22 ) that in turn feeds the camera by means of a plunger ( 21 ); A handle ( 25 ) that serves for support to the other hand of the operator to facilitate exercise the intense force so that the cement flows in a short tube ( 26 ) and it is injected through the needle ( 27 ).
[0061] The device ( 30 ) of the previous technique of the FIG. 3 contains two cameras ( 35 ) ( 32 ) connected by a valve check in the conduit ( 37 ). The bone cement is mixed In the camera ( 35 ) and impelled to the injection camera ( 32 ) by means of a plunger( 36 ), once in the injection camera the cement is impelled by the piston ( 38 ) of a plunger ( 34 ) moved by a lever that provides the required force ( 33 ), forcing the cement through the opening ( 31 ) that in turn contains a valve check that closes in the recharge operation.
[0062] The FIG. 4 illustrate another device ( 40 ) of the previous technique for injection of polymethylmethacrylate. In this one the threaded plunger ( 41 ) has a crank ( 42 ) in the end to facilitate impel the total content of the syringe ( 45 ), and supporting elements ( 43 ) ( 44 ) for the other hand of the operator in the action of injection of the bone cement.
[0063] The FIG. 5 , represents a cut profile and front view the body of pressure ( 50 ) that shows the groove of the bolster ( 2 ) where the injecting syringe that contains the bone cement is secured. Also presents the front view and profile of the piston ( 51 ) and the rubber cap ( 52 ) that avoids spillage of the hydraulic fluid in the action of transmission of the pressure. With this body of pressure, object of the present invention, is possible to transmit the pressure at distance and therefore reduces exposure of the operator to secondary ionizing radiation coming from the patient at the time of placement of the bone cement. This body of pressure complies with the characteristic of being light-weighted, may be disposable or reusable, manufactured of plastic, aluminum or other suitable material able to support sterilization.
[0064] The FIG. 6 , represents frontal and lateral views of the manual or impulsion syringe ( 60 ), and plunger ( 61 ) where the rubber cap is placed ( 62 ) to avoid leakage of the hydraulic fluid. The bone cement should be kept in a cold environment before it is applied so it is maintain fluid to avoid solidification in the needle.
[0065] In the FIG. 7 , the transverse cut of the cylindrical hollow body of pressure is described (B) that houses the plunger (A) of the injecting syringe secured in the peripheral groove ( 70 ) of this body of pressure, it is connected to the flexible tube ( 7 ) that transmits the hydraulic pressure ( 10 ), exercised from the manual or impulsion syringe (C) by means of its plunger ( 9 ). Here is illustrated the way the injecting syringe is attached to the body of pressure, Once introduced the plunger (A) in the opening of the body of pressure (B) the syringe is turned 90° in such a way that the body of the syringe is tightly secured to proceed with the injection of the bone cement.
[0066] The use of small diameter syringes in the application of the cement has the advantage of less resistance to flow, so a more viscous cement can be injected to reduce the possibilities of leakage from the vertebral body.
[0067] The experts in the technique expect other embodiments of the invention might exist, that is to say, embodiments of instruments built according to the teachings of the present invention, Because many of the characteristics of the embodiments are similar to those previously described, Peculiar embodiments of the invention have been illustrated and described in those that it will be obvious for those experts in the technique that several modifications or changes can be made without leaving the reach of the present invention. The above-mentioned tries to cover with the added claims so that the changes and modifications fall inside the reach of the present invention.
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The present invention relates to the medical field, in particular relates to the practice of percutaneous vertebroplasty where a pair of syringes in the distal extreme of a lengthened hydraulic device, are united by a camera of intermediate connection of larger diameter (pressure exerting body) or modified inverted syringe tube with a bolster, a hydraulic connecting tube of flexible material that transmits the pressure of the smaller diameter manual or impulsion syringe in the proximal extreme of the device toward the intermediate cylindrical larger diameter camera (pressure exerting body), this camera is in an inverted position with regard to the first syringe (fluid control), this intermediate camera has a moving piston longitudinal to the axis of the cylinder that is controlled with the first syringe (manual) and in cooperation with the atmospheric pressure. The injecting syringe loaded with bone cement is coupled with the bolster of the body of pressure, and to the needle that drives the cement toward the interior of the bone. The intermediate camera (pressure exerting body) together with the hydraulic tube and the manual syringe form a hydraulic press system (F/A=f/a) that allows to increase in a potential way the pressure exerted in the first syringe and to make the injection of polymethylmethacrylate (PMMA) at an approximate distance of 1.0 m to 1.5 m.
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BACKGROUND OF THE INVENTION
This invention relates generally to liquids. More specifically it relates to a device that separates oils from liquids.
It is well known that when preparing cooked meat, such as roasts, chicken, meat balls, etc., it is desirable to obtain gravies or sauces from the meat. Oil or fat mixes into the gravy or sauce when cooking the meat. It then becomes difficult to remove the fat by hand, before using the liquid. This situation is therefore in need of an improvement.
SUMMARY OF THE INVENTION
A principle object of the present invention is to provide a stock-sauce skimmer which can be used easily by anyone.
Another object is to provide a stock/sauce skimmer which can be stored away conveniently.
Further objects of the invention will appear as the description proceeds.
To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The Figures on the drawings are briefly described as follows:
FIG. 1 is a perspective view of the invention ready for use.
FIG. 2 is an exploded cross sectional view of the invention.
FIG. 3 is a perspective view of a valve element.
FIG. 4 is a perspective view of the invention on a collecting cup in storage.
FIG. 5 is an enlarged view of the collecting cup spout cover.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1, 2 and 3 in greater detail, the reference numeral 10 represents a separator device assembly, wherein there is a two cup heat-resistant glass (Pyrex) ewer 12 having a large cylindrical portion 14 with an open top 16, a handle 15 formed onto portion 14, a hip shaped molded ring 17 around lower circumference of portion 14, a funnel shaped middle portion 18 connected to a bottom small tube 20, and an inward tapered bulge 22 formed on the inner wall 23 of small tube 20. The lower portion of the small tube 20 is seated in a circular trough 24 formed by a one-piece thimble or sleeve 26 made of concentric outer and inner walls 28, 30 and floor 32. The outer wall 28 has threads 33 and the inner wall 30 of sleeve 26 having a lip 34 turned inward at the top forming a peripheral flange 36 with a centered aperture 38.
The bulge 22 fits snugly over the seam of contact between flange 36 and inner wall 23 and is welded or cemented to form a moisture-proof bond between the sleeve 26 and small tube 20.
A valve or stopper element 42 (best seen in FIG. 3) has a replaceable mushroom shaped boilable plastic chokestopper 44 mounted on cast metal shaft 46 having four fin shaped supports 48 and is placed under the flange 36 to open and close aperture 38.
A one piece molded plastic base 50 is also provided and has an upper vertical well or aperture 52 having threads 54, and a lower vertical well or aperture 56 having a narrowing tapered wall 58 with four vertical slots 60. The bottom of well 56 has a drip-proof lip rim 62 and a cylindrical foot 64 having a right-angle undercut 66 around the circumference of foot 64. Threads 54 mate with threads 33 on sleeve 26 and fin supports 48 on valve 42 fit into slots 60.
The rim 62 prevents liquids from trailing outwards along the underside of foot 64, and the undercut 66 permits snug seating of base foot 64 within the rim of collecting cup 68.
FIG. 4 shows the collecting cup 68 which has a large cylindrical portion 70, with an open top 72 having spout 74, a handle 76 formed onto portion 70 opposite spout 74, and a closed bottom or floor 78.
In FIG. 4 the ring 17 of the ewer 12 is placed upon the open top 72 of the collecting cup 68 and the undercut 66 of base 50 is placed upon the top 16 of ewer 12, so that base 50 now acts as a lid when the unit is to be stored.
A sealing device 79 has a small knobbed plastic stopper 80 that is attached to a thin lanyard 82 connects to an eyelet 84 on a plug 86. The stopper 80 is then placed into the well 52 of the lid 50 and the plug 86 (as best shown in FIG. 5) is placed into the spout 74 of the collecting cup 68 making it sanitary and completing the storage unit arrangment.
The operation of the stock/sauce skimmer is as follows:
Supports 48 of valve 42 are seated in slots 60 of tapered wall 58 in base 50. Pyrex cup 12 is screwed into aperture 52 of base 50 forming a free standing ewer. The undercut perimeter 66 of base foot 64 is mounted on open top 72 of collecting cup 68 and valve aperture 38 is closed by rotating ewer 12 (while holding base 50 stationary) until flange 36 is in firm contact with choke-stopper 44. Pan or pot liquids are poured into ewer 12. When oil is well defined at the top of liquids, separation is accomplished by rotating ewer 12 to open position (about 1/2 turn) raising choke aperture 38 from closed contact with choke-stopper 44. Liquids flow out rapidly into collecting cup 68 and further control is effected by careful rotation of ewer 12 on stationary base 50. When the surface line between liquid and oil enters bottom tube 20, the ewer and collecting cup assembly 10 may be lifted to eye level for final optimal separation of oil from liquids. The assembly 10 is lifted by the collecting cup handle 76 with thumb pressure on top of base foot 64 to stabilize seating of undercut 66 within open top 72 of cup 68 and further rotation of ewer 12 will bring flange 36 into firm contact with choke-stopper 44 to close centered aperture 38 and stop liquid flow.
While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it will be understood that various omissions, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing from the spirit of the invention.
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A stock/sauce skimmer device that separates oil from liquids having a ewer, a valve, a base and a collecting cup and when placed in storage the base becomes a lid and a sealing device is placed in the well of the lid and the spout of the collecting cup.
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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
The invention was made in part with Government support by the Army Research Laboratory under government contract number: DAAD17-03-C-0140. The Government has certain rights in the invention.
TECHNICAL FIELD
The present invention relates generally to semiconductor technology and, more particularly, to interconnect metallization using a stop-etch layer.
BACKGROUND OF THE INVENTION
Fabrication of electronic circuits may be divided into two stages. In the first stage, active and passive devices are fabricated on the wafer surface. In the second stage, metal systems necessary to connect these devices are added to the chip. The various processes for connecting these component parts together are generally referred to as “metallization.”
The inventor hereof has recognized that, particularly in power and radio frequency (RF) semiconductor devices, the coefficient of thermal expansion (CTE) of the interconnect metal should closely match that of the underlying semiconductor material in order to avoid catastrophic metal failures due to the expansion from the intense heat that is generated during operation of such devices. However, the CTEs of gold (Au), aluminum (Al), Copper (Cu), Nickel (Ni), and platinum (Pt), which are commonly used as interconnect metals, do not match those of certain semiconductor materials, such as Silicon Carbide (SiC) and Gallium Nitride (GaN).
Moreover, the inventor hereof has also recognized that prior-art metallization processes frequently result in non-uniformity across the wafer and/or die, and that such processes are often subject to machine and operator errors which are inherent to prior-art etching methods.
BRIEF SUMMARY OF THE INVENTION
Embodiments of the present invention are directed to systems and methods that reduce or eliminate device failure due to thermally induced metal fatigue, particularly in SiC and GaN-based devices. For example, a stop-etch layer (e.g., chrome (Cr)) may be deposited over a wafer surface followed by the deposition of interconnect metallization material (e.g., a mixture of titanium (Ti), titanium tungstate (TiW), titanium nitride (TiN), Molybdenum (Mo), and tungsten (W)) over the stop-etch layer. Preferably, at least one of the stop-etch layer and the interconnect metallization material have a CTE matched to that of the underlying semiconductor material. In one embodiment, a lithography operation may etch dielectric deposited on top of the CTE matched interconnect metal layers, thereby forming a dielectric mask or pattern. In another embodiment, a lithography operation may place resist material over certain areas of the CTE matched interconnect metal layers, thereby forming a resist mask or pattern. In another embodiment, additional interconnect metal layers can be deposited (e.g., gold (Au), platinum (Pt), aluminum (Al), copper (Cu), nickel (Ni), chrome (Cr)), with the top metal layer of the metallization stack chosen to stop etch chemicals. The portion of the additional interconnect metal layers situated on top of resist areas may then be lifted off by resist removal, thus forming a metal mask or pattern that stops the etch and protects the layers underneath it from etching action. Subsequently, the interconnect metallization material may be etched from the non-resist-mask, the non-dielectric-mask, or the non-metal-mask covered areas, with the etching stopping at the stop-etch layer. Finally, the stop-etch layer may be removed from the non-resist-mask, the non-dielectric-mask, or the non-metal-mask covered areas, thus producing the desired interconnect metallization pattern.
Some of the methods and systems described herein protect against the non-uniformity that is characteristic of prior-art etching processes. Moreover, certain embodiments of the present invention allows purposeful “over etching” of the metallization material in order to guarantee uniformity across different areas of the wafer and/or die. Other embodiments also safeguard against machine and/or operator errors inherent to prior-art “stop-watch” etching methods. Moreover, embodiments of the present invention further provide a method for a single lithographic step interconnect metallization that may use W (or a mixture of Ti, TiN, TiW, Mo and W) as the metallization material, thus resulting in the fabrication of more reliable SiC and GaN-based semiconductor devices. Many other advantages and benefits of the invention will be readily recognized by a person of ordinary skill in the art in light of this disclosure.
The foregoing has outlined rather broadly certain features and technical advantages of the present invention so that the detailed description that follows may be better understood. Additional features and advantages are described hereinafter. As a person of ordinary skill in the art will readily recognize in light of this disclosure, specific embodiments disclosed herein may be utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. Such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. Several inventive features described herein will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, the figures are provided for the purpose of illustration and description only, and are not intended to limit the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, reference is now made to the following drawings, in which:
FIG. 1 is a cross-sectional view illustrating a semiconductor device prepared for interconnect metallization;
FIG. 2 is a cross-sectional view illustrating a semiconductor device with a stop-etch layer deposited over the device;
FIG. 3 is a cross-sectional view illustrating a semiconductor device with a layer of interconnect metallization material deposited over the stop-etch layer;
FIGS. 4-7 are cross-sectional views illustrating processing steps for a semiconductor device where a resist mask or pattern, or a dielectric mark or pattern are formed;
FIGS. 8-11 are cross-sectional views illustrating processing steps for a semiconductor device where a metal mask or pattern is formed; and
FIG. 12 is flowchart illustrating an interconnect metallization method using a stop-etch layer.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, reference is made to the accompanying drawings that form a part hereof, and in which exemplary embodiments of the invention may be practiced by way of illustration. These embodiments are described in sufficient detail to enable a person of ordinary skill in the art to practice the invention, and it is to be understood that other embodiments may be utilized, and that changes may be made, without departing from the spirit of the present invention. The following description is, therefore, not to be taken in a limited sense, and the scope of the present invention is defined only by the appended claims.
Single lithographic step interconnect metallization systems and methods are disclosed herein representing exemplary embodiments of the present invention. Although certain embodiments discussed below utilize an Ion-implanted Static-Induction-Transistor (SIT) for illustration purposes, a person of ordinary skill in the art will readily recognize that the present invention is not limited to the fabrication of this particular device and may, in fact, be used in the fabrication of any semiconductor device. Moreover, while examples illustrated below may indicate specific materials and dimensions, a person of ordinary skill in the art will also recognize that certain variations and modifications may be made without departing from the spirit and scope of the present invention.
FIG. 1 shows a semiconductor device prepared for metallization, according to an exemplary embodiment of the present invention. Substrate and epitaxy 101 has several p+ and n+ doped regions 102 and 103 , respectively. First dielectric layer 104 is located over substrate or epitaxy 101 , and one or more dielectric layers 105 are located over first dielectric layer 104 . Any number of dielectric layers (including zero) 105 may be present. In one exemplary embodiment, substrate and epitaxy 101 may be silicon carbide (SiC) or gallium nitride (GaN). Additional dielectric layers 105 may be, for instance, phosphosilicate glass or PSG (i.e., silica (SiO 2 )), silicon nitride (i.e. Si 3 N 4 ), thermally grown oxide, and tetraethyl orthosilicate deposited SiO 2 (i.e. TEOS deposited SiO 2 ), whereas first dielectric layer 104 may be, for instance, borophosphosilicate glass or BPSG. In this example, source and gate metallization layers 108 are also shown. Areas 106 and 107 over the gate-bus region and n+ source fingers of the SIT, respectively, are open to receive interconnect metallization.
FIG. 2 shows the semiconductor device of FIG. 1 with stop-etch layer 201 , according to an exemplary embodiment of the present invention. In one exemplary embodiment, a layer of chrome (Cr) is deposited by physical-vapor-deposition (e.g., evaporation, e-beam evaporation, sputtering), or by chemical-vapor-deposition over the wafer, thereby creating stop-etch layer 201 . Preferably, stop-etch layer 201 has a CTE matched to that of the underlying semiconductor material. Layer 201 may, for example, have a thickness of about 200 A. Further, layer 201 may be capable of stopping sulfur hexafluoride (SF6) from etching portions of the device that are covered by it during a subsequent reactive-ion-etching (RIE) step. Layer 201 may also be designed to protect covered regions from other etching processes and/or agents.
FIG. 3 shows the semiconductor device of FIG. 2 with a layer of interconnect metallization material 301 deposited over stop-etch layer 201 , according to an exemplary embodiment of the present invention. For example, metallization material 301 may comprise titanium (Ti), tungsten (W), titanium nitride (TiN), titanium tungsten (TiW), molybdenum (Mo), or any combination thereof. In one exemplary embodiment, metallization material 301 is a mixture of titanium, nitrogen, and tungsten. Preferably, layer 301 has a CTE matched to that of the underlying semiconductor material. The thickness of metallization material layer 301 may vary according to the type of metallization material and/or deposition method used. For instance, when tungsten is chosen as metallization material, chemical-vapor deposition (CVD) may be used to create a W (17000 A) layer. In another example, physical-vapor-deposition (PVD or “sputtering”) may be used to create a Ti (200 A) layer or a TiW (1000 A) layer.
In one exemplary embodiment of the present invention, a lithography and a dielectric etch operation may pattern dielectric material over certain areas of the CTE matched interconnect metal layers, thereby forming a dielectric mask or pattern. In another embodiment, a lithography operation may place resist material over certain areas of the CTE matched interconnect metal layers, thereby forming a resist mask or pattern. There exemplary embodiments are described below with respect to FIGS. 4-7 , where layer 401 may be a dielectric or a resist material. In yet another exemplary embodiment, interconnect metal layers may be deposited in addition to resist material, where the top metal layer of the metallization stack may be selected to stop etch chemicals. This exemplary embodiment is described below with respect to FIGS. 8-11 .
Turning now to FIGS. 4-7 , cross-sectional views illustrating processing steps for a semiconductor device where a resist mask or a dielectric mask is formed are provided according to exemplary embodiments of the present invention. FIG. 4 shows the semiconductor device of FIG. 3 with patterned resist or dielectric layer 401 , which may block action by etching agents. FIG. 5 shows the semiconductor device of FIG. 4 under etching process 501 that may be, for example, a reactive-ion-etching (RIE) process, a wet chemical etching process, or a dry chemical etching process. FIG. 6 shows the semiconductor device of FIG. 5 after interconnect metallization material 301 has been uniformly etched in non-resist or non-dielectric covered areas. An etching agent such as, for example, sulfur hexafluoride (SF6), may be blocked by stop-etch layer 201 , thus protecting dielectric layer 105 and underlying layers from being undesirably etched. FIG. 7 shows the semiconductor device of FIG. 6 where resist or dielectric layer 401 and stop-etch layer 201 have been removed, for instance, with a chemical dip or exposure of the wafer to a very high energy RF process.
With respect to FIGS. 8-11 , cross-sectional views illustrating processing steps for a semiconductor device where a metal mask is formed are provided according to exemplary embodiments of the present invention. FIG. 8 shows the semiconductor device of FIG. 3 with patterned resist 401 and layers of material 802 and 803 , which may be deposited, for example, by physical vapor deposition (e.g., evaporation, e-beam evaporation, sputtering) or chemical vapor deposition. Resist 401 may be patterned onto the device in a lithographic step. Layers 802 (e.g., Ti/Pt) and 803 (e.g., Au) may be evaporated. In one exemplary embodiment, layer 803 is optional. In another embodiment, Ti/Pt layer 802 and/or Au layer 803 forms a metal mask which may block action by etching agents. FIG. 9 shows the semiconductor device of FIG. 8 after lift-off and under an etching process 901 that may be, for example, a reactive-ion-etching (RIE) process, a wet chemical etching process, or a dry chemical etching process. FIG. 10 shows the semiconductor device of FIG. 9 after interconnect metallization material 301 has been uniformly etched in non-metal-mask covered areas. Again, an etching agent may be blocked by stop-etch layer 201 , thus protecting dielectric layer 105 and underlying layers from being undesirably etched. FIG. 11 shows the semiconductor device of FIG. 10 where stop-etch layer 201 has been removed, for instance, with a chemical dip or exposure of the wafer to an RF process.
As described above, FIGS. 7 and 11 show the semiconductor devices of FIGS. 4 and 8 , respectively, with the resulting interconnect metallization. The present invention reduces the number of necessary processing steps in the fabrication process because it requires a single lithographic step and only one or zero corresponding metal lift-off steps depending on the desired composition of interconnect metal layers. Moreover, the present invention permits that the wafer be “over etched,” either purposefully (e.g., to achieve uniformity) or as a result of inadvertent mistake, without damage to the underlying wafer, die, and/or device. The stop-etch layer is later removed, thus resulting in a uniformly etched wafer.
FIG. 12 shows a flowchart of a single lithography step interconnect metallization method using a stop-etch layer according to one embodiment of the present invention. In step 1201 , a layer of stop-etch material (e.g., chrome (Cr)) is deposited over a wafer, thereby creating a stop-etch layer that is capable of stopping an etching process and/or etching agent from reaching the device. A layer of interconnect metallization material is deposited over the stop-etch layer in step 1202 . In step 1203 , a dielectric material is patterned over the interconnect metallization material. In another embodiment, a resist material is patterned over the interconnect metallization material in step 1203 . In yet another embodiment, this lithography step is accompanied by the deposition of at least one metal layer (e.g., Ti/Pt, Au, Al, Cu, Ni, Cr, etc.) and a lift-off. In step 1204 , an etching process is used to remove interconnect metallization material in non-covered areas of the wafer. Finally, in step 1205 , the stop-etch layer is removed, thus resulting in the desired interconnect metallization.
Although certain embodiments of the present invention and their advantages have been described herein in detail, it should be understood that various changes, substitutions and alterations can be made without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present invention is not intended to be limited to the particular embodiments of the process, machine, manufacture, means, methods, and steps described herein. As a person of ordinary skill in the art will readily appreciate from this disclosure, other processes, machines, manufacture, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, means, methods, or steps.
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Systems and methods for single lithography step interconnection metallization using a stop-etch layer are described. A method comprises depositing a stop-etch layer over a semiconductor device, depositing an interconnect metallization material over the stop-etch layer, performing a single lithography step to pattern a mask over the interconnect metallization material, etching the interconnect metallization material in non-masked areas, and removing the stop-etch layer. A system comprises means for depositing the stop-etch layer over a wafer, means for depositing an interconnected metallization layer over the chrome layer, means for patterning a mask over the interconnect metallization layer, means for etching the interconnect metallization layer, where the etching stops at the stop-etch layer, and means for removing the stop-etch layer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part of co-pending U.S. patent application Ser. No. 09/735,343, filed Dec. 11, 2000, and of co-pending U.S. patent application Ser. No. 10/016,169, filed 30 Nov. 2001.
[0002] U.S. Provisional Patent Application Ser. No. 60/170,270, filed 11 Dec. 1999, is incorporated herein by reference.
[0003] U.S. patent application Ser. No. 09/735,343, filed Dec. 11, 2000, is incorporated herein by reference, as is the published version of that patent application.
[0004] International Patent Application No. PCT/US00/33568, filed Dec. 11, 2000, is incorporated herein by reference, as is the published version (Int. Pub. No. WO 01/42125) of that patent application.
[0005] U.S. patent application Ser. No. 10/016,169, filed 30 Nov. 2001, is incorporated herein by reference, as is the published version of that patent application.
[0006] International Patent Application No. PCT/US01/48090, filed 30 Nov. 2001, is incorporated herein by reference, as is the published version (Int. Pub. No. WO 02/044073) of that patent application.
[0007] U.S. Provisional Patent Application Ser. No. 60/310,593, filed 7 Aug. 2001, is incorporated herein by reference.
[0008] U.S. Provisional Patent Application Ser. No. 60/270,334, filed 21 Feb. 2001, is incorporated herein by reference.
[0009] U.S. Provisional Patent Application Ser. No. 60/250,053, filed 30 Nov. 2000, is incorporated herein by reference.
[0010] U.S. Provisional Patent Application Ser. No. 60/394,988, filed 10 Jul. 2002, is incorporated herein by reference.
[0011] Priority of these patent applications is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0012] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0013] Not applicable
BACKGROUND OF THE INVENTION
[0014] 1. Field of the Invention
[0015] The present invention relates to cargo transfer systems. More particularly, the present invention relates to systems for transferring cargo between ocean-going vessels and land destinations or ocean-going vessels and barges or between ocean-going vessels, barges, and landside terminals, and including direct transfer from barges to rail without storing the goods landside.
[0016] 2. General Background of the Invention
[0017] At present large container vessels provide economies of scale by carrying very large numbers of intermodal containers and container derivative devices such as flat racks and open tops containers. Such large ships today carry more than 6000 twenty foot equivalent units (TEU) and still larger ocean-going vessels are foreseen. The containers carried by these large vessels are generated by several regional ports spread geographically over areas such as South East Asia, UK/North Europe or a US coastal region. This requires the large vessel to either make multiple port calls, some times once to discharge and later to double back to load, or by using a port in the region as a hub port where the large vessel proceeds to a landside terminal, from which containers are both landed for local distribution and transshipped to feeder vessels or barges and/or to trucks or rail cars, for distribution to other port destinations. The terminal operation required at landside hub ports is extensive and costly involving trucking from quay to storage in stacks and load out in a reverse operation at later dates to on carrying vessels.
[0018] Typically, import containers discharged from a large carrier vessel at a landside terminal are hauled from the dock side to stacked storage on the back side of the terminal or placed on wheeled chassis and parked for later haul back to cranes for loading to feeder vessels or to rail cars at distant sidings or transferred to trucks for delivery to other ports or inland locations.
[0019] Outbound containers are received at a landside terminal from rail sidings, often at remote locations or from drays and long haul trucks or feeder vessels and assembled on the backside of the terminal awaiting the arrival and readiness of the large carrier to load. Hundreds of acres of land are required for such operations in addition to the several handling operations involved.
[0020] The critical matter of road and rail infrastructure required for landside terminals to accommodate large vessels can take decades to develop and billions of dollars in cost. Environmental issues may also intervene. In Vietnam, a jack-up causeway was used to unload containers from ships. The causeway was used as a dock where trucks took the containers as they were unloaded and hauled away.
[0021] The Freeport Sulphur mine is a series of jack-up barges strung together.
[0022] Cranes for transferring containers from ships include gantry cranes and boom cranes.
[0023] The following patents documents are incorporated herein by reference:
[0024] U.S. Pat. Nos. 969,164; 1,193,587; 1,237,573; 1,346,068; 1,547,536; 2,308,743; 3,149,733; 3,183,676; 3,290,007; 3,367,119; 3,586,152; 3,606,251; 3,750,210; 3,945,450; 3,958,106; 3,967,457; 4,310,277; 4,363,411; 4,417,664; 4,456,404; 4,465,012; 4,482,272; 4,505,616; 4,544,137; 4,547,857; 4,568,232; 4,589,799; 4,627,768; 4,632,622; 4,652,177; 4,666,341; 4,678,165; 4,722,640; 4,762,456; 4,813,814; 4,916,999; 5,028,194; 5,139,366; 5,224,798; 5,456,560; 5,478,181; 5,515,982; 5,580,189; 5,733,092; 5,797,703; 5,807,029; DE 455 495; DE 1 079 299; DE 25 43 156; FR 588,542; GB 17,349; and all patent documents mentioned herein.
[0025] U.S. Pat. No. 4,762,456 discloses a cargo container loading and unloading operation where a floating crane is used to transfer containers between deep draft ships and shallow draft ships.
[0026] U.S. Pat. No. 4,363,411 (see col. 3, lines 44-53) discloses a loading/unloading crane system that is placed between the ocean and a lagoon to handle deep draft and shallow draft ships at the same time.
[0027] U.S. Pat. No. 4,465,012 discloses a floating crane transhipment device to accommodate movement of cargo between ships and barges.
[0028] U.S. Pat. No. 4,568,232 discloses a floating horizontal boom bulk unloader that allows shallow draft ships to be loaded and unloaded from a deep draft ship.
[0029] U.S. Pat. Nos. 4,310,277; 4,457,85; 4,544,137; 4,632,622; and 5,028,194 disclose cargo transfer systems supported on open sea platforms with one or more cranes.
BRIEF SUMMARY OF THE INVENTION
[0030] The apparatus of the present invention comprises a platform container transfer terminal that functions as an efficient hub port. Sea Point™ Terminal modules can be constructed to move intact across oceans for rapid erection in remote or strategic locations to provide high speed loading and unloading of large container vessels to lighters or feeder vessels and/or to/and facilities adjacent.
[0031] One embodiment of the present invention includes a container offloading facility made of jack-up barges. There can be, for example, four jack-up barges, each barge from 100 feet (30.5 m) to 700 feet (213.4 m) (e.g., 450 feet (137.2 m)) long and 25 feet (7.62 m) to 250 feet (76.2 m) (e.g., 100 feet (30.5 m)) wide, in an ocean-going hull design, with e.g. a 20 foot (6.1 m) hull depth, and placed end-to-end to provide a platform (e.g. 1800 feet (548.6 m) long). There can be multiple (for example, 4) cranes per platform. The facility could advantageously be placed at the mouth of a river (such as at the mouth of the Mississippi River) to provide a sea coast or near sea coast transfer port for large vessels.
[0032] The container cranes used with the facility of the present invention can include a boom on the backside which is much longer than a conventional backside boom on a land terminal. This facilitates loading the feeder vessels or barges while at the same time offloading the ocean-going container or cargo ships (and vice versa).
[0033] The present invention also comprises a method of transporting goods, comprising using a jack-up barge to transfer goods from an ocean-going vessel to a barge or other shallower-draft feeder vessel.
[0034] The present invention also comprises a method of transporting goods, comprising using a pile-supported platform deck on which cranes operate to transfer goods from an ocean-going vessel to a barge or other type feeder vessels.
[0035] The present invention can be constructed as a floating mobile terminal or as a fixed terminal on pile or material foundation. The Sea Point™ platform concept consists of a platform structure erected in a semi-sheltered location such as at the mouth of a river, bay, sound or inlet with sufficient water depth, natural or dredged, to accommodate ocean-going vessels on one side and feeder vessels or barges on the opposite side. The platform may be constructed on pilings in the manner of a pile-supported dock, as an artificial island built up of material, or as floating modules with spud legs which can be towed intact to remote transoceanic locations and combined for rapid jack-up assembly as one platform made from multiple modules at the chosen site. Floating modules with jack-up supporting legs that can be embedded in the solid bottom material allows almost immediate erection of the platform to its desired height ready to accommodate container transfers between large carriers on one side and feeder vessels or barges on the opposite side. Towable jack-up platform modules are particularly attractive for military rapid deployment needs and could be a valuable element of U.S. prepositioned forces or reserve fleet components.
[0036] The platform ( FIG. 1 ) serves as the base for container handling cranes one version of which has been designed to have an extreme reach on the large vessel side as well as on the feeder side so that even a postpanamax vessel (over 105 feet (32 m) wide) up to 200 feet (61 m) wide can be loaded or discharged by the container crane boom on the large vessel side to or from barges or feeders docked two or more (e.g., four) wide up to +200 feet (61 m) off the feeder vessel side. These container cranes using state-of-the-art hoisting speed at lifting capacity and with high horizontal travel speeds can, in one transfer cycle, lift two or more loaded containers at a time and rapidly transfer them to or from stowed positions on the feeders. Feeder vessels or barges being shorter and less wide and deep than large container carriers can be berthed on the platform side opposite the larger vessels in multiple sets ( FIG. 2 ) so that distribution to multiple destinations can be served quickly by loading some feeders with specifically destined containers and dispersing them immediately upon completion of discharge. Simultaneously, outbound cargo would be brought to Sea Point™ by separate feeder vessels or barges and placed along side the platform feeder side to be transferred to the large vessel as soon as the loaded feeders are taken away from the dock.
[0037] During loading or discharge at a Sea Point™ transfer platform, outport destined containers may be landed to transfer cars stationed under the crane legs on designated road ways that may run in opposite directions in order to distribute such containers to other cranes serving feeders for their destinations ( FIGS. 3 and 4 ). This would be accomplished by vehicles (for example, light tractors) hauling these containers (e.g., on cars or chassis) to those cranes loading the desired feeders, reducing the necessity for stacking or grounding containers on the platform during cargo operations. The container crane can also be designed to have two separate cabs with traveling trolleys that move outward from a center raised platform located between the legs of the crane; this provides rapid transfer from each side that will speed up the loading and discharge cycles substantially ( FIGS. 3 and 4 ).
[0038] A pile-supported platform or a platform on a built-up material (spoil or otherwise) island can be used as the foundation for the transfer platform of the present invention, which in cases where mobility is of no value, would be a cheaper mode of construction.
[0039] Other configurations of transfer cranes have certain advantages where alternative container cells on the large vessels and/or the feeder vessels are served by special crane arrangements as shown, for example, in FIGS. 5-8 .
[0040] The delivery to various Port terminals by feeder barges or feeder vessels permits each port terminal to be designed to discharge the less costly unmanned vessel units, direct to rail car and truck lanes located along the dockside within the reach of port cranes' terminal side. Extended landside booms on port cranes can accomplish this efficiently and provide added opportunity by placing containers directly on stacks in the terminal yard saving costly terminal handlings and reducing significantly the acreage required for each container terminal. The Sea Point™ platform can also be placed so as to provide offloading from large vessels to feeders and to adjacent terminal docks by locating the platform in water at a distance of about 100 feet (30.5 m) from the land terminal thus allowing one or more (e.g., two) feeder vessels to be berthed between the Sea Point™ platform and land terminal. The long (e.g., 200 foot (61 m)) reach of the crane's booms on each side of the platform would allow transfers between the land terminal, feeder vessels and the large vessel as desired.
[0041] The critical matter of road and rail infrastructure required for landside terminals to accommodate large vessels can take decades to develop and billions of dollars in cost. Environmental issues may also intervene. In contrast a Sea Point™ transfer platform can be fabricated for erection in appropriate water depth locations in less than two years time and its size is unlimited. Ideally, Sea Point™ platforms can also be phased in to provide an initial length and width to handle, for instance, the next half decade of expected use and then expanded to any greater length or width when required.
[0042] The present invention comprises a method of transporting goods, comprising:
[0043] providing a jack-up barge;
[0044] providing a crane on the jack-up barge;
[0045] transferring goods from an ocean-going vessel to a barge or other shallower-draft feeder vessel using the crane on the jack-up barge. Preferably, the jack-up barge is positioned at the mouth of a river.
[0046] The present invention also comprises a system for transshipping containerized cargo, comprising:
[0047] a jack-up barge;
[0048] a crane on the jack-up barge for transferring goods from an ocean-going vessel to a barge or other shallower-draft feeder vessel using the crane on the jack-up barge.
[0049] The present invention further comprises a system for transshipping containerized cargo, comprising:
[0050] a plurality of jack-up barges connected together end-to-end to form a transshipping platform;
[0051] cranes on the jack-up barges for transferring goods from ocean-going vessels to barges or other shallower-draft feeder vessels using the cranes on the jack-up barges. Preferably, the jack-up barges are each about 450 feet (137.2 m) long and about 100 feet (30.5 m) wide, with about a 20 foot (6.1 m) hull depth and an ocean-going hull design. Preferably, there are at least four cranes. Preferably, there is also an upper transfer platform above the transshipping platform. Preferably, there are also cargo transfer roadways on the transshipping platform.
[0052] The platform is preferably at least 100-200 feet (30.5-61 m) long, more preferably at least 300 feet (91.4 m) long, even more preferably at least 400 feet (121.9 m) long, and most preferably at least 500 feet (152.4 m) long; the platform is preferably 20-1000 feet (6.1 m-305 m) wide, more preferably 40-500 feet (12.2 m-152.4 m) wide, and most preferably 60-200 feet (18.3-61 m) wide.
[0053] The present invention also comprises a gantry having one or more boom cranes.
[0054] The ability for a port to enhance all of its cargo vessel operations and particularly feeder and rail-on-dock operations by fitting existing or new ship-to-shore gantries with a boom crane is the primary benefit of the invention. The attached cranes can be considered a movable accessory thereby allowing the terminal operator to change the configuration of the gantry to optimize his cranes for different cargo operations, including containers, bulk, palletized and break bulk cargo.
[0055] The gantries of the present invention with boom cranes attached thereto have utility, for example, in terminals operating as transfer hubs for water-borne vessels, working from the transfer rack and the barges or small feeder ships on the back side of the platform or pier and larger ships on the ship side of the platform or pier.
[0056] A preferred embodiment of the present invention is apparatus including a gantry, a gantry crane attached to the gantry, and at least one rotating boom crane attached to the gantry. There can be at least two rotating boom cranes attached to the gantry. There is preferably at least one boom crane attached to the ship side of the gantry. There can be at least one boom crane attached to the back side of the gantry.
[0057] In one embodiment of the invention, there are three rotating boom cranes attached to the gantry. In one embodiment of the invention, there are four rotating boom cranes attached to the gantry. At least one of the boom cranes can be a rotating horizontal slewing boom crane
[0058] The gantry can be a ship-to-shore gantry. A boom crane and frame can be attached to the ship-to-shore gantry.
[0059] The apparatus of the present invention can include a boom crane, a frame for supporting the boom crane, and means for attaching the frame to a ship-to-shore gantry.
[0060] The boom crane in any embodiment could be a slewing boom crane attached to the gantry, or a luffing boom crane attached to the gantry.
[0061] In some embodiments, there can be at least one luffing boom crane attached to the gantry and at least one slewing boom crane attached to the gantry. In other embodiments, there can be two luffing boom cranes attached to the gantry and two slewing boom cranes attached to the gantry.
[0062] The apparatus of the present invention includes a platform container transfer terminal that functions as an efficient hub port.
[0063] More information about the invention can be found in the papers attached to U.S. Provisional Patent Application No. 60/394,988, filed 10 Jul. 2002.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0064] 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:
[0065] 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:
[0066] FIG. 1 is a side view of a first embodiment of the apparatus of the present invention;
[0067] FIG. 2 is a top view of the first embodiment of the apparatus of the present invention;
[0068] FIG. 3 is a side view of a second embodiment of the apparatus of the present invention;
[0069] FIG. 4 is a top view of the second embodiment of the apparatus of the present invention;
[0070] FIG. 5 is a side view of a third embodiment of the apparatus of the present invention;
[0071] FIG. 6 is a top view of the third embodiment of the apparatus of the present invention;
[0072] FIG. 7 is a side view of a fourth embodiment of the apparatus of the present invention;
[0073] FIG. 8 is a top view of the fourth embodiment of the apparatus of the present invention.
[0074] FIG. 9 is a plan view showing two gantries of the present invention;
[0075] FIG. 10 is a side elevational view showing a gantry of FIG. 9 ;
[0076] FIG. 11 is a plan view showing a gantry of the present invention with two attached boom cranes;
[0077] FIG. 12 is a side elevational view showing another embodiment of the present invention, a boom crane and frame attached to a new or existing ship-to-shore gantry;
[0078] FIG. 13 is a plan view showing the gantry and boom cranes of FIG. 12 ;
[0079] FIG. 14 is a front elevational view showing the gantry and boom cranes of FIG. 12 ;
[0080] FIG. 15 is a view similar to FIG. 14 , but showing an embodiment of the invention including a rope luffing jib crane;
[0081] FIG. 16 is a plan view showing the gantry and boom cranes of FIG. 12 adjacent barges; and
[0082] FIG. 17 is a plan view showing the gantry of FIG. 12 adjacent barges, but with a single attached boom crane;
[0083] FIG. 18 is a plan view of another embodiment of the present invention;
[0084] FIG. 19 is an elevation of the embodiment of the present invention shown in FIG. 18 ;
[0085] drawings of some embodiments of the present invention are shown in the papers (incorporated herein by reference) attached to U.S. Provisional Patent Application No. 60/394,988, filed 10 Jul. 2002.
DETAILED DESCRIPTION OF THE INVENTION
[0086] The Sea Point™ platform apparatus 10 ( FIGS. 1 and 2 ) of the first embodiment of the present invention comprises a platform structure 20 erected in a semi-sheltered location such as at the mouth of a river, bay, sound or inlet with sufficient water depth, natural or dredged, to accommodate ocean going vessels 31 , 32 on one side and feeder vessels or barges 41 , 42 , 43 , 44 , 45 on the opposite side. For example, the platform apparatus of the present invention can be installed in the Mississippi River near Venice, La., US, adjacent the West bank at mile 12.2 above head of passes.
[0087] Platform apparatus 10 ( FIGS. 1 and 2 ) is similar to platform apparatus 100 ( FIGS. 3 and 4 ) but lacks upper transfer platform 65 and the double trolley system of platform apparatus 100 . Both platform apparatus 10 and platform apparatus 100 include a helicopter pad (heliport) 75 at one end thereof.
[0088] The platform 20 may be constructed on pilings in the manner of a pile-supported dock or as modules 21 , 22 , 23 with spud legs 24 which can be towed, floating, intact to remote transoceanic locations for rapid jack-up assembly as one terminal made from multiple modules 21 , 22 , 23 at the chosen site. Floating modules 21 , 22 , 23 with jack-up supporting legs 24 that can be embedded in the solid bottom material allow almost immediate erection of the platform 20 to its desired height ready to accommodate container transfers between large carriers 31 , 32 on one side and feeder vessels or barges 41 , 42 , 43 , 44 , 45 on the opposite side. Towable jack-up platform modules 21 , 22 , 23 are particularly attractive for military rapid deployment needs and could be a valuable element of U.S. prepositioned forces or reserve fleet components. As shown in the drawings, the platform 20 is set out an appropriate height above the water line 81 of water 80 , with spud legs 24 extending below the mud line 91 and through mud 90 .
[0089] The platform 20 ( FIG. 1 ) serves as the base for container handling cranes 51 , 52 , 53 , 54 that can be designed to have an extreme reach on the large vessel side as well as on the feeder side so that a panamax vessel 31 105 feet (32 m) wide, or a postpanamax vessel 32 up to 200 feet (61 m) wide can be loaded or discharged by the container boom on the large vessel side to or from feeders 41 , 42 , 43 , 44 , 45 docked two or more wide up to about 200 feet (61 m) off the feeder vessel side. These container cranes 51 , 52 , 53 , 54 using state of the art lifting speed and capacity and horizontal travel speeds can, in one transfer cycle, lift two or more loaded containers 55 at a time and rapidly transfer them to or from stowed positions on the feeders. Cranes 51 , 52 , 53 , 54 can be similar to standard gantry container handling cranes, and similar in construction to the cranes shown in U.S. Pat. Nos. 4,363,411; 4,568,232; and 4,762,456. Cranes 51 , 52 , 53 , 54 each include crane legs 56 , gantries 58 supported on legs 56 , bracing 57 which interconnects legs 56 and which connects legs 56 to gantries 58 , and trolley stops 59 to prevent the trolleys 71 from falling off of the ends of the gantries 58 .
[0090] Feeder vessels or barges 41 , 42 , 43 , 44 , 45 being shorter and less wide than large container carriers 31 , 32 can be berthed on the platform side opposite the larger vessels 31 , 32 in sets ( FIG. 2 ) so that distribution to multiple destinations can be served quickly by loading the feeders with specifically destined containers and dispersing immediately upon completion of discharge. Simultaneously, outbound cargo would be brought to Sea Point™ by separate feeder vessels or barges 41 , 42 , 43 , 44 , 45 and placed alongside the platform to be transferred to the large vessels 31 , 32 as soon as the empty feeder is taken away from the dock. It is also possible to use one vessel/barge as a carrier for export and import transferred containers.
[0091] During loading or discharge at a Sea Point™ transfer platform, outport destined containers 55 may be landed to one or more transfer cars 61 stationed under the crane legs 56 on designated road ways 62 that may run in opposite directions so as to distribute such containers 55 to cranes serving feeders for their destinations ( FIG. 3 ). This would be accomplished by vehicles (such as light tractors 76 —see FIG. 7 ) hauling these containers on cars or chassis 61 to cranes loading the desired feeders, reducing or eliminating any necessity for stacking or grounding containers on the platform during cargo operations. The container cranes 51 , 52 , 53 , 54 can also be designed to each have two separate cabs and traveling trolleys 71 that move outward from a center raised transfer rack 65 ; this provides rapid transfer from each side that will speed up the loading and discharge cycles substantially (see FIG. 3 ). As shown in FIG. 3 , containers 55 can rest on transfer rack 65 while waiting to be transferred between ships 31 , 32 , and barges 41 , 42 , 43 , 44 , or 45 . Adjacent transfer rack 65 are openings 66 to allow containers 55 to move from the cranes 51 , 52 , 53 , 54 to road ways 62 .
[0092] The delivery to various port terminals by feeder barges or feeder vessels 41 , 42 , 43 , 44 , 45 permits each port terminal to be designed to discharge these less costly vessel units 41 , 42 , 43 , 44 , 45 , direct to rail car and truck lanes located along the dockside within the reach of port cranes' terminal side. Extended landside booms on port cranes can accomplish this efficiently and provide added opportunity that save several costly terminal handlings and reduces significantly the acreage traditionally required for each container terminal. The Sea Point™ platform apparatus can also be placed so as to provide offloading from large vessels to feeders and to adjacent terminal docks by locating the platform in water at a distance of about 100 feet (30.5 m) from the land terminal thus allowing one feeder vessel to be berthed between the Sea Point™ platform and land terminal. The reach (e.g. 200 feet-61 m) of the crane on each side of the platform would allow transfers between the land terminal, feeder vessels and the large vessel as desired.
[0093] The platform apparatus 110 of the third embodiment of the present invention is shown in FIGS. 5 and 6 . Apparatus 110 includes a platform 120 supported by piles 124 imbedded in mud 90 . Two container handling gantry cranes 151 and 152 are shown in FIG. 6 . Crane 151 includes a gantry 153 , a boom crane 141 with lifting hoist, and pedestal type boom cranes 143 and 144 with lifting hoists. Crane 152 includes a gantry 154 , a boom crane 142 with lifting hoist, and pedestal type boom cranes 145 and 146 with lifting hoists.
[0094] The circles in FIG. 6 show the reach of the various cranes. As can be seen in FIG. 6 , there are two storage stacks of containers 55 out of reach of the cranes (these containers 55 can be moved around by light tractors 76 —see FIG. 7 ), and various stacks of containers 55 are shown which can be reached by more than one crane. In FIG. 6 , the barges 41 , 42 , 433 , and 44 can be partially unloaded onto platform 120 before ship 32 arrives to minimize dock time of ship 32 .
[0095] The platform apparatus 200 of the fourth embodiment of the present invention is shown in FIGS. 7 and 8 . Apparatus 200 includes a platform 220 on which are mounted two container handling gantry cranes 251 and 252 . Crane 251 includes a gantry 253 , a boom crane 241 with lifting hoist, and telescopic boom cranes 243 and 244 with lifting hoists. Crane 252 includes a gantry 254 , a boom crane 242 with lifting hoist, and telescopic boom cranes 245 and 246 with lifting hoists.
[0096] The circles in FIG. 8 show the reach of the various cranes. As can be seen in FIG. 8 , there are four mobile harbor cranes 231 , 232 , 233 , and 234 . The containers 55 out of reach of the fixed cranes can be moved around by light tractors 76 —see FIG. 7 —or by the mobile harbor cranes 231 , 232 , 233 , and 234 . FIG. 8 shows a causeway 225 from platform 220 to shore (not shown). This causeway 225 allows platform 220 to be supplied from shore as well as by barge and ship.
[0097] The various cranes shown in FIG. 8 , the light tractors 76 , and cars 61 move containers 55 among ship 32 , feeder vessels 342 and 344 , and barges 345 and 346 .
[0098] In FIG. 8 , the barges 345 and 346 can be partially unloaded onto platform 220 before ship 32 arrives to have empty slots available for the ship containers to minimize dock time of ship 32 .
[0099] In FIG. 8 , the gantry trolleys 71 unload above-hatch containers until the first hatch is cleared. Hatch covers are removed and cargo containers are unloaded to the bottom of the cell. Once a cell has been cleared, the cargo operations using trolleys to load and unload containers with each trolley move. The gantry trolleys 71 and the boom cranes 241 and 242 work the ship cargo. The gantry trolleys 71 deliver containers to the fixed container racks 65 . The trolleys 71 may also land containers 55 on the shuttle cars 61 or on the platform 220 along the ship 32 .
[0100] The cranes 243 , 244 , 245 , 246 attached to the barge side of the gantries 253 , 254 load from rack 65 to barges/feeder vessels 342 , 344 and back. These cranes may also work to and from the dock transfer areas and the shuttles 61 .
[0101] The boom cranes 241 , 242 unload containers to the shuttle cars 61 or to the dock transfer areas.
[0102] The mobile harbor cranes 231 , 232 , 233 , and 234 are set to work the barges 345 and 346 and feeder vessels 342 and 344 and stack.
[0103] All of the cranes are preferably equipped with anti-collision controls.
[0104] The critical matter of road and rail infrastructure required for landside terminals to accommodate large vessels can take decades to develop and billions of dollars in cost. Environmental issues may also intervene. In contrast a Sea Point™ transfer platform can be fabricated for erection in appropriate water depth locations in no more than two years time and size is unlimited. Ideally, Sea Point™ platforms can also be phased in to provide an initial size to handle, for instance, the next half decade of expected use and then expanded to any greater size when required.
[0105] Some embodiments of the present invention combine a gantry crane with one or more rotating boom cranes to increase cargo productivity economically.
[0106] The addition of one or two boom cranes to the ship side of the gantry allows a substantial increase in cargo productivity with a minimal cost.
[0107] Adding one or two boom cranes to the back side of a gantry will substantially increase the productivity of the gantry's ship unloading trolley. The increased reach of a boom allows terminal operators to efficiently load and unload barges, small feeder ships, trucks (terminal or road) and trains depending upon the terminal design.
[0108] FIGS. 9 and 10 show a container vessel 720 along a dock 30 with two gantry cranes 410 and 510 . Gantry 510 has two ship side boom cranes 11 and 12 working to and from transfer areas 13 and 14 . Trolley 15 of gantry 510 works to and from the ship 720 and transfer rack 16 . Back boom cranes 17 and 18 of gantry 510 work between transfer rack 16 and the container storage stack 19 . Back boom cranes 17 and 18 also work between transfer areas 13 and 14 and the container storage stack 19 . Operations of gantry 410 are similar, though as shown gantry 410 has a single ship side boom crane 112 . Like gantry 510 , gantry 410 has two back boom cranes 117 and 118 . Trolley 115 and cranes 112 , 117 , and 118 all work with a transfer rack 116 .
[0109] In some terminals, one might use gantries similar to gantries 510 and 410 , but without back boom cranes (see gantry 210 in FIG. 11 , showing two ship side boom cranes 211 and 212 ). In such a terminal, cargo transferred between vessel 221 and dock 230 might be handled with terminal tractors (not shown). Other vehicles such as AGV's (automated guided vehicles) and over-the-road approved trucks and trailer chassis can be used depending upon the terminal operations.
[0110] FIG. 11 shows a 9-container wide ship 221 with one gantry 210 configured with two ship-side boom cranes 211 and 212 . Gantry 210 with two attached pedestal cranes 211 and 212 working a 9-container wide ship 221 gives simultaneous access to 53 cells versus a standard gantry's access of only 9 cells. Two standard gantries working as close as possible to each other cannot access the ship's bay between them without both cranes gantrying to new positions. The improved gantry 210 with two boom cranes 211 and 212 reaches seven adjacent bays without moving the gantry. A small terminal using the improved gantry 210 can handle ships efficiently and allow a more flexible ship stowage plan.
[0111] In FIG. 11 , the hatched area shows a reach into 53 cells on a 9-wide ship 221 using a 100′ (30.5 m) boom reach.
[0112] Gantry cranes similar to gantry cranes 510 and 410 might be used on a platform or finger pier handling cargo between ships (or larger barges) and feeder vessels or barges. In this example the terminal operates as a transfer hub for water born vessels, and the gantry cranes might each have a single ship side boom crane and two back boom cranes (the ship side boom cranes could be positioned distant from one another on the gantries).
[0113] Gantry cranes 510 and 410 might be used to transfer cargo between a dock and a container vessel along the dock In such a situation, gantry cranes 510 and 410 would work between a ship or barge and the storage stack, trucks and trains.
[0114] One or more of the boom cranes attached to the gantry cranes of the present invention can be horizontal slewing boom cranes (not shown in the drawings).
[0115] The examples mentioned herein show some of the benefits that can be achieved by combining a gantry with a boom crane. The examples do not show all of the possible applications. Some of the other possible benefits are for terminals that specialize in mixed cargo including containers, bulk and break bulk cargoes in bags, pallets, coils etc.
[0116] FIGS. 12-17 show an embodiment of the present invention, a boom crane and frame to be attached to a new or existing ship to shore gantry. This embodiment of the present invention allows the attachment of a boom crane to a new or existing gantry without substantially increasing wheel loads of the existing gantry. The boom cranes' stability benefits from the attachment. The invention shown in FIGS. 12-17 will allow the addition of one or two boom cranes to an existing gantry without significant structural change to the existing gantry and rail system. A conventional ship-to-shore gantry with one or more attached boom cranes increases cargo productivity economically and improves the efficiency of moving both containerized and non-containerized cargoes between vessels and land side truck/rail-on-dock transport at terminals. The invention improves the transfer of containers or other cargo between ships and feeder vessels or barges.
[0117] FIGS. 12 and 13 show a conventional ship-to-shore gantry 310 with two pedestal-type boom cranes 311 and 312 on separate frames 321 and 322 attached to the main gantry 310 . Other boom cranes such as harbor cranes, jib cranes, telescopic and any other crane with a boom can be attached. The crane frames 321 and 322 can be (and preferably are) built to match the main gantry rail gauge and portal beam clearance. The wheels 343 (see FIGS. 14 and 15 ) of the boom crane frames 321 and 322 can be freewheeling. Hoist, luffing and sluing power for the attached cranes 311 and 312 can be provided in several ways. The main gantry power supply can be sized to provide the additional power needed for the attached cranes 311 and 312 . The attached cranes 311 and 312 may also have a built in diesel/electric or diesel/hydraulic power system located over the back wheels of the crane frames 321 and 322 . A separate cable reel or other power conveyance method can be used for the attached cranes 311 and 312 when power is supplied from a utility or a generating plant in the port area. A container ship 320 is shown in FIGS. 12 and 13 . A trolley 315 is best seen in FIG. 12 .
[0118] FIGS. 14 and 15 show different methods used to attach the crane frames 321 , 322 to the main gantry 310 . The attachment points can be built on both sides of the frame 321 , 322 ( FIG. 15 ) and on the main gantry 310 thereby allowing a crane to be moved and attached to either side of a gantry 310 . The design will be engineered to distribute the attached crane weight to the separate crane frame wheels 343 without adding significant weight to the main gantry wheels 353 . The number of wheels for the crane frame 321 , 322 can be designed to keep the wheel weights within the rail design limits of the facility. The attachment points on the main gantry 310 are located to provide crane stability in the “East/West” direction along the dock 330 . The “North/South” crane stability results from the separate crane frame. A structural analysis of the existing gantry and the dynamic forces of the operations will determine the best points for the attachment.
[0119] FIG. 14 shows the preferred location of slip pins 344 and fixed pins and a detail of a slip pin.
[0120] The braces should be engineered to be as high as possible for crane stability. In FIG. 15 , attachment points 361 are provided on frame 441 for opposite side installation. In FIG. 15 , a rope luffing jib crane 411 replaces the hydraulic ram luffing crane 311 of FIGS. 12-14 . Also, the separation of frame 441 from gantry 310 is greater than the separation of frame 322 from gantry 310 to give added stability and reach to crane 411 .
[0121] FIGS. 16 and 17 show the modified gantry 310 positioned over two standard hopper barges 420 , 520 . For barge and similar operations where the vessel(s) being loaded are without ballast and trim pumps, the modified gantries 310 are substantially more productive because the barge trim can be maintained during operations without gantrying up and down the length of the barge. Hopper barges 420 , 520 can be 35 feet (10.7 m) wide and 195 feet (59.4 m) long, for example.
[0122] FIG. 17 shows a rail-on-dock operation 430 . The boom crane 311 provides better reach to temporary stacks, trucks and train. The improved reach gives a terminal operator added flexibility to plan rail-on-dock operations efficiently.
[0123] In FIG. 17 , a temporary storage stack 419 is indicated below the truck lanes 428 . Three trucks 424 , 426 , and 427 are on the truck lanes 428 . Railroad cars 461 or other like container-carrying means are on track 462 .
[0124] The present invention has particular utility in the systems and methods disclosed in International Publication No. WO 01/42125 A1, which is incorporated herein by reference.
[0125] FIGS. 18 and 19 show Sea Point System Components of another embodiment of the present invention.
[0000] Platform
[0126] Deck 601
[0127] MPC (multi-purpose container) Island 602
[0128] Deck Extensions 603
[0129] Causeway 604
[0130] Causeway truck turn-around 605
[0131] Mooring Dolphins 606
[0000] Lift Equipment
[0132] Over the Ocean vessel
Gantry crane(s) with trolley's and hatch storage 607 Sea Point gantry crane(s) (trolley gantry cranes with one or two “boom” cranes attached and hatch storage 608 Harbor crane(s) fixed or mobile 609 . The harbor cranes operate over the ship or barges. CBW type “boom” crane(s) mounted on separate gantry frames with hatch storage 610 .
[0137] Over the Barges
MPC cranes with horizontal slewing booms. 611 Harbor cranes fixed or mobile 609
Horizontal Conveyance Equipment
[0140] Bi-directional draw bar multi-trailers 612 and yard tractors 613 with automatic hitches.
[0000] Miscellaneous
[0141] Container scanning equipment 614
[0142] Fixed Barge shift equipment (winches and sliders) 615
[0143] Push boats 616
[0000] Facility Operating System
[0144] Software
[0145] Control and monitoring hardware
[0146] The use of a bi-directional drawbar double trailer (multi-trailer) 612 with an automatic hitch improves the present invention's operating flexibility, reduces labor, reduces vehicle traffic and supports cargo operations at the platform extension 603 .
[0147] The bi-directional trailer allows a tractor 613 to pull into a narrow platform extension (about 50′ wide) 603 . The truck without trailer can then make a U-turn and the trailer can be pulled out from the other drawbar on the opposite end. This system can be used in several areas of the platform to create additional barge docking locations where the barges can be shifted independently of the other barges. A single MPC barge crane 611 on a 50 ′ wide platform extension 603 can reach four barges and at least two trailers. The ability to rapidly shift strings or sets of barges independently of each other without interrupting the MPC cranes' cargo operations of the remaining barges is essential to service the largest ship loads without slowing the facility's productivity.
[0148] A separate MPC platform island 602 and mooring points 606 for the outer lane of barges gives each MPC 611 crane the ability to reach every cell in four barges and two trailer lanes on the main platform 601 . The barges in each of the four lanes can be shifted without interrupting the cargo operations to the three remaining barge lanes.
PARTS LIST
[0149] The following is a list of parts suitable for use in the present invention:
10 platform apparatus of a first embodiment of the present invention 11 ship side boom cranes 12 ship side boom cranes 13 transfer area 14 transfer area 15 trolley 16 transfer rack 17 back boom crane 18 back boom crane 19 container storage stack 20 platform structure of platform apparatus 10 and 100 21 jack-up module 22 jack-up module 23 jack-up module 24 spud legs 30 dock 31 ocean-going vessel 32 ocean-going vessel 41 barge going to port C 42 barge going to port A 43 barge going to port B 44 barge going to port A 45 barge going to port D 51 container handling crane 52 container handling crane 53 container handling crane 54 container handling crane 55 loaded containers 56 crane legs 57 bracing 58 gantries 59 trolley stops 61 transfer cars 62 road ways 65 transfer rack of platform apparatus 100 66 openings adjacent rack 65 71 cabs and traveling trolleys 75 helicopter pad (heliport) 76 yard tractor 80 water 81 water line 90 mud 91 mud line 100 platform apparatus of the second embodiment of the present invention 110 platform apparatus of the third embodiment of the present invention 112 ship side boom crane 115 trolley 116 transfer rack 117 back boom crane 118 back boom crane 120 platform 124 piles for platform 120 141 boom crane with lifting hoist 142 boom crane with lifting hoist 143 pedestal type boom crane with lifting hoist 144 pedestal type boom crane with lifting hoist 145 pedestal type boom crane with lifting hoist 146 pedestal type boom crane with lifting hoist 151 container handling crane 152 container handling crane 153 gantry of crane 151 154 gantry of crane 152 200 platform apparatus of the fourth embodiment of the present invention 210 gantry 211 ship side boom crane 212 ship side boom crane 221 vessel 220 platform 225 causeway from platform 220 to shore 230 dock 231 mobile harbor crane 232 mobile harbor crane 233 mobile harbor crane 234 mobile harbor crane 241 boom crane with lifting hoist 242 boom crane with lifting hoist 243 telescopic boom crane with lifting hoist 244 telescopic boom crane with lifting hoist 245 telescopic boom crane with lifting hoist 246 telescopic boom crane with lifting hoist 251 container handling crane 252 container handling crane 253 gantry of crane 251 254 gantry of crane 252 310 conventional ship-to-shore gantry 311 pedestal-type boom crane 312 pedestal-type boom crane 315 trolley 320 container ship 321 frame 322 frame 330 dock 341 slip pins 342 feeder vessel 343 wheels 344 feeder vessel 345 barge 346 barge 353 main gantry wheels 361 attachment points 410 gantry crane 411 rope luffing jib crane 419 temporary storage stack 420 standard hopper barges 424 truck 426 truck 427 truck 428 truck lanes 430 rail-on-dock operation 441 frame 461 railroad cars 462 track 510 gantry crane 520 standard hopper barges 601 deck 602 MPC island 603 deck extensions 604 causeway 605 causeway truck turn-around 606 mooring dolphins 607 gantry crane with trolleys and hatch storage 608 Sea Point gantry crane (trolley gantry cranes with one or two “boom” cranes attached and hatch storage) 609 Harbor crane, fixed or mobile 610 CBW type “boom” crane mounted on separate gantry frames with hatch storage 611 MPC cranes with horizontal slewing booms 612 bi-directional draw bar multi-trailers 613 yard tractors with automatic hitches 614 container scanning equipment 615 fixed barge shift equipment (winches and sliders) 616 push boats 720 container vessel
[0281] In all plan views, the circles and partial circles show the maximum outreach of the boom crane whose base is at the center of the partial circle.
[0282] Various features have been shown in various figures herein. Feature appearing in one figure can be used with apparatus in other figures. For example, though jack-up legs are shown in FIGS. 1 and 3 , and pilings are shown in FIGS. 5 and 7 , the platform in FIGS. 1 and 3 can be supported by pilings and the platform in FIGS. 5 and 7 can be supported by jack-up legs. Likewise, cranes appearing in one figure can be used with the apparatus shown in other figures. Also, various features shown in the various patents cited herein can be incorporated into the apparatus of the present invention.
[0283] More information about the invention can be found in the papers attached to U.S. Provisional Patent Application No. 60/394,988, filed 10 Jul. 2002.
[0284] Any suitable materials, such as steel, can be used to construct the apparatus of the present invention. For example, reinforced concrete can be used for the platform deck.
[0285] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise.
[0286] 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 platform container transfer terminal ( 10 ) functions as an efficient hub port. Sea Point™ Transfer station modules ( 21, 22, 23 ) can be moved intact across oceans for rapid erection in remote or strategic locations to provide high speed loading and unloading of large container vessels ( 31, 32 ) to lighters or feeder vessels ( 41, 42, 43, 44, 45 ) and/or to facilities adjacent. A gantry crane ( 510 ) combined with one or more rotating boom cranes ( 11, 12, 17, 18 ) increases cargo productivity economically. There can be two luffing boom cranes attached to the gantry and two slewing boom cranes attached to the gantry. One can retrofit an existing gantry by attaching a boom crane and frame to a ship-to-shore gantry.
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The present invention relates in general to the art of self observation by means of a plurality of mirrors, and it relates in particular to a new and improved system of mirrors which enables the observation of one's own eyes and adjacent facial areas as well as to a method of using a system of mirrors to observe one's own eyes during for example, the manipulation of an opthalmic contact lens in one's own eye.
BACKGROUND OF THE INVENTION
Manipulation of contact lenses in the eyes during insertion of the lenses but more particularly during removal of the lenses requires considerable dexterity, and unless performed properly, can easily scratch and otherwise damage the external surface of the cornea or schlera. For example, the standard procedure recommended by eye care specialists for removing soft contact lenses from the eyes involves pulling down the lower eyelid with the middle finger, and looking up to elevate the pupil while simultaneously using one index finger to slide the lens downwardly off the cornea and onto the schlera portion of the eyeball. Then, while still looking up and holding the lower eyelid down the wearer must squeeze the opposite side edges of the lens between his thumb and index finger to cause the lens to buckle outwardly thereby to break the suction between the eye and the lens. The lens may then be removed with the index finger and thumb. This is a relatively difficult procedure when performed in front of a simple mirror inasmuch as the wearer's hand is necessarily within the line of sight of the eye and close to the eye, wherefor it causes the eyelids to blink in a reflex action. Moreover, since the normal effect of blinking is to cause the pupil to return to its central or straight ahead position, the chance of damage to the eyeball is accentuated. Although most people can train themselves in a matter of weeks to avoid blinking during this procedure, many persons can never do so, and moreover, reflex blinking with the concomitant danger of scratching the cornea and/or schlera is almost always a problem for persons who are learning to wear contact lenses.
I have also found that reflex blinking which is occasioned by positioning one's hand or the like in proxmity to the eye and close to the line of sight thereof makes it difficult for many persons to apply eye cosmetics, such as masccara to the eyelashes and eye liner to the eyelids. While the possibility of eye damage is not so great as when manipulating lenses in the eyes, such uncontrolled blinking does present a serious inconvenience for many people.
SUMMARY OF THE INVENTION
Briefly, there is provided in accordance with one aspect of the present invention a new and improved method of self observation of the eyes which facilitates the manipulation of contact lenses on the eyeball and which facilitates the application of cosmetics to the eyelids and closely adjacent facial areas. This method involves the use of three mirrors which are oriented relative to the eye in such a way that the eye is observed from a direction which is angularly displaced from the line of sight of the eye. When using this method to look at one's own eye, a contact lens can be easily manipulated with the fingers inasmuch as the fingers do not obstruct the line of sight of the eye, and reflex blinking does not occur. In like manner mascara and other eye makeup can easily be applied because the problem of uncontrolled blinking is alleviated.
In accordance with another aspect of the invention there is provided a new and improved device including a plurality of mirrors arranged in a manner for use in carrying out the heretofore discussed method of self observation of the eyes and adjacent facial areas. This device is relatively small and compact, and thus portable, may be collapsible for convenient storage when not in use, may be positioned in proximity to the eyes of the user to minimize the effects of inherent visual impairments of the user such as myopia, and has a relatively large viewing area to permit the user to adjust the effective distance between the eyes and the area being viewed to accommodate for other inherent visual impairments such as hyperopia and to provide adequate room, for example, for positioning the fingers for manipulaton of a lens.
GENERAL DESCRIPTION OF THE DRAWINGS
The present invention will be better understood by a reading of the following detailed description taken in connection with the accompanying drawings wherein:
FIG. 1 is a perspective view of a device embodying the present invention, which device is illustrated in the closed, storage position;
FIG. 2 is a cross sectional view taken along the line 2--2 of FIG. 1;
FIG. 3 is an elevational view showing the device of FIG. 1 in use;
FIG. 4 is an end view taken from the right hand side of FIG. 2;
FIG. 5 is a schematic diagram which is useful in understanding the operaton of instruments embodying this invention; and
FIG. 6 is a front view of another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring particularly to FIGS. 1, 2 and 3, an instrument for viewing the facial areas in the vicinity of one's own eyes is generally identified by the reference character 10 and includes a pair of body members 12 and 14 which are hingedly connected together on a shaft 16. A detent type closure 18 is provided between the body members 12 and 14 at the end opposite the shaft 16. In FIGS. 1 and 2 the instrument 10 is shown in the closed storage condition with the body members 12 and 14 snapped together. The body members 12 and 14 respectively include interfitting apertured lug portions 20 and 22 through which the shaft 16 extends and a pair of abutment surfaces 24 and 26 which precisely position the body members 12 and 14 in predetermined angular relationship when the body members are fully opened with the abutting surfaces 24 and 26 in juxtaposed relationship.
A mirror support plate 30 is mounted at an angularly adjustable position within the body member 12 by any suitable means such for example, as a ball and socket connector 32 and side brace members 33 which frictionally abut the side edges of the plate 30. A mirror 34 is mounted to the lower face of the mirror support plate 30 as viewed in FIG. 2 whereby its position is adjustably fixed within the body member 12.
Fixedly mounted within the cover member 14 between a pair of upstanding ribs 36 and 38 is a mirror 40. A second mirror support platform 42 carrying a mirror 44 between a pair of ribs 46 and 48 is hingedly mounted to the body member 14 on a shaft 50. More particularly, a plurality of integral lugs 52 are provided on the interior of the body member 14 adjacent to the left hand end as viewed in FIG. 2 and are provided with aligned apertures through which the shaft 50 extends. The mirror support 42 is provided with an elongated hole through which the shaft 50 extends. The rib 38 on the body member 14 and a lug portion 54 on the mirror support 42 hold the mirror 44 in displaced relationship from the mirror 40 when the unit is in the collapsed condition. An interference fit is provided between the lugs 52 and the adjacent portion of the mirror support 42 so that the resiliency of the lugs 52 hold the mirror support in the set position as shown, for example, in FIG. 3. The mirror support 42 is provided with an abutment shoulder 56 which in the fully open usable position of the instrument engages the inner end wall of the cover 14 to set the mirror 42 in the precise predetermined position relative to the mirrors 40 and 34 for the reasons described in greater detail hereinafter.
In order to use the instrument 10 to observe one's own eyes and adjacent facial areas the body member 12 is opened so as to position the shoulder 24 against the shoulder 26, and the body member 14 is positioned in the relatively upright position as illustrated in FIG. 3. With the mirror support 42 in the fully opened position, as also shown in FIG. 3, the entire device 10 is positioned relative to the eyes A of the user such that rays of light emanating from the lower portion of the schlera are reflected from the mirror 34 to the mirror 42 and are from there reflected to the mirror 40 to the pupil of the eye. By positioning the instrument 10 somewhat above the straight ahead line of vision of the eye A the pupil is positioned at the top of the eye as required in the normal placement and removal of contact lenses therein and the eye is observed from an apparent position well below the eye. Preferably, the line of sight is displaced from the line of observation by an angle of between about 30° and 35°. Consequently, when the fingers are placed in proximity to the eye for manipulating a contact lense or eye makeup applicator they are not in the direct line of vision of the eye and do not, therefore, cause the reflex blinking heretofore described. Although the fingers may and will normally be in the overall field of vision of the eye A i.e., in the path from the schlera to mirror 34, the other eye nevertheless sees the fingers and the lens or cosmetic applicator throughout the process.
An important feature of the present invention is that the rays of light which are directed to the pupil of the eye A from the mirror 40 have been reflected at acute angles from each of the mirrors 34, 44 and 40. Consequently, the vertical field of vision is not appreciably foreshortened as would be the case if the reflective angles were obtuse angles. Also, the mirror 34 which initially collects the light from the eye A and adjacent facial areas is the largest, the mirror 44 being the second largest and the mirror 40 being the smallest. It will be understood that these mirrors all have the same width which may be approximately two and one-half inches which is sufficient to provide an adequate horizontal field of vision for observing one eye and its adjacent facial areas with the other eye.
With reference to FIG. 5, I have found that assuming an average vertical field of view of ten degrees for the normal eye, a mirror 40 having a vertical dimension of about one and one-half inches, a mirror 44 having a front to rear dimension of about one and three quarter inches, and a mirror 34 having a front to rear dimension of about three inches provides a good proportional sizing of the mirrors to enable the normal user to position the instrument sufficiently far from the eye as to provide adequate space in which to place the hands for manipulation of lenses or eye makeup applicators. In this regard the mirrors 40 and 42 should be positioned at a relative included angle of about 58° and the included angle between the planes of the mirrors 40 and 34 should be between 37° and 42°. It will be understood that these angles may be changed to some extent but the tests I have made to date indicate these are the optimum angles where a sufficiently large field of view of the eye and adjacent facial area is to be provided for the normal person.
In order to enable the observation of a relatively large facial area with a relatively small instrument, either or both of the mirrors 34 and 40 can be concave magnifying mirrors. It must be understood, however, that the use of such magnifying mirrors will introduce some distortion, but for some applications this distortion may be acceptable This is the case, for example, where the instrument is to be used by persons having hyperopia.
Referring to FIG. 6, there is shown an embodiment of the invention which incorporates means for facilitating the proper positioning of the instrument relative to the eye to be observed. As shown, a reference mark 60 in the form of an X is provided near the bottom of the center of the mirror 34 and a loop 61 descends from the left hand side of the foreward edge of the mirror 44. A second reference mark 63 in the form of a dot is provided in the left hand upper corner of the mirror 40.
In use, the mark 60 is placed about four inches from the nose of the user and using the left eye only, the mark 63 is lined up with the opening in the loop 61. With the instrument 10 thus located, the eye and adjacent facial areas will be observed in the manner described above.
Again referring to FIG. 3, the purpose for providing limited angular adjustment of the mirror 34 is shown. As may there be seen, the angular position of the mirror 34 relative to the mirrors 40 and 44 may be changed to enable the distance between the eye and the mirror 34 to be changed to accommodate for acute myopia and hyperopia. The solid line position of the eye in FIG. 3 provides a focused image for a normal eye. The dotted line position of the eye provides a focused image for acutely nearsighted eyes. It will be seen from FIG. 3 that the line of sight and the direction of observation remain substantially the same as the angle of the mirror 34 is adjusted and the position of the eye is changed accordingly.
The ball and socket connector 32 also enables the mirror 34 and its associated support plate 30 to be readily snapped out of the body member 14 and replaced with a magnifying mirror where desired.
While the present invention has been described in connection with particular embodiments thereof, it will be understood by those skilled in the art that many changes and modifications may be made without departing from the true spirit and scope of the present invention. Therefore, it is intended by the appended claims to cover all such changes and modifications which come within the true spirit and scope of this invention.
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A three mirror arrangement for an observer viewing himself from a direction offset from the line of sight and a method of so viewing with manipulation of a contact lens is disclosed. The mirrors may be held in a collapsible arrangement and the two mirrors generally facing the observer may be curved.
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RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royalty.
FIELD OF THE INVENTION
The present invention relates generally to nanomaterials and, more specifically, to grafted and functionalized carbon nanotubes and nanofibers.
BACKGROUND OF THE INVENTION
One-dimensional, carbon-based, nano-structured materials, which are formally derived from the rolling up of single or multiple graphene sheets into tubular structures, are generally divided into three categories (based on diameter dimensions): single-wall carbon nanotubes (“SWNT”) having diameters ranging from 0.7 nm to 3 nm; multi-wall carbon nanotubes or CNT having diameters ranging from 2 nm to 20 nm; and carbon nanofibers (“CNF”) having diameters ranging from 40 nm to 100 nm. The length of vapor grown carbon nanofibers (“VGCNF”) may range from 30 μm to 100 μm. While the length of SWNT and CNT is difficult to determine because of a strong proclivity to aggregate or form ropes, the lengths of SWNTs and CNTs are generally considered to be two-orders of magnitude shorter than VGCNFs.
Carbon nanomaterials have captivated wide-spread attention in the advanced materials research community because of the predicted extraordinary thermal, mechanical, and electrical properties. To take advantage of their predicted mechanical properties, several studies have been performed on CNT or CNF and reported their reinforcement effects in various thermoplastics and thermoset matrices.
Great strides have been made in the functionalization of SWNT to impart solubility and processing options. Similar to fullerene derivatization chemistry, the general nature of chemical reactions utilized in conventional CNT functionalization are compatible with the electron-deficient character of the carbon nanotubes. This generalization is understandably applicable to the reaction chemistry involving the perfect graphene framework. However, defect sites, (for example, the pre-existing sp 2 C—H bonds), of these graphene-based nanomaterials may behave differently.
Graphene-based nanomaterials have such broad applications because of particular thermal, electrical, mechanical, and photonic properties. Therefore, graphene-based nanomaterials are actively investigated with respect to their structural reinforcement, energy/electron transport or storage capabilities, and interactions with electromagnetic waves.
The chemical medication of graphene-based surfaces and edges is usually quantitatively assessed by using the combination of thermogravimetric analysis (“TGA”) and elemental analysis. Experimentally, under TGA conditions, organic functional groups are thermally degraded at temperatures well below the thermal degradation of carbon nanomaterials (much greater than 600° C.). Therefore, the total amount of the specific organic group in the original test sample can be estimated by the associated weight loss. Such estimation is referred to as degree of functionalization (DF or τ and expressed in terms of atom %). It follows that a rough, empirical formula for the functionalized carbon nanomaterial sample may be derived and elemental analysis based on this empirical formula is used for its confirmation. For example, when VGCNF is functionalized via a Friedel-Crafts acylation reaction, the DF for VGCNF is estimated to be 3 atom %, that is to say, on average for every 100 carbon atoms of a single nanofibers, there are 3 functional group grafted.
Therefore, it would be desirable to transfer one or more of these properties to polymeric matrices, for example, it is desirable to transfer such electrical, mechanical, and optical properties to bulk materials via the chemical modification of nanomaterial surfaces and edges to promote or enhance specific interactions or bonding strength between the matrix and the functionalized nanomaterial.
SUMMARY OF THE INVENTION
The present invention overcomes the foregoing problems and other shortcomings, drawbacks, and challenges of modifying nanomaterial surfaces for improving transfer of properties to bulk materials. While the invention will be described in connection with certain embodiments, it will be understood that the invention is not limited to these embodiments. To the contrary, this invention includes all alternatives, modifications, and equivalents as may be included within the spirit and scope of the present invention.
One embodiment of the present invention is directed to a functionalized nanomaterial, which includes a nanomaterial comprising a carbon nanotube or a carbon nanofiber. At least one ketoxime group is coupled to a first location on the nanomaterial, and at least one amide group is coupled to a second location on the nanomaterial.
Yet another embodiment of the present invention is directed to a method of synthesizing a ketoxime- and amide-functionalized nanomaterial. The method includes converting a keto-carbonyl group, which is coupled to the nanomaterial to an oxime group. The oxime group then undergoes a Beckmann Rearrangement to an amide group.
Other embodiments of the present invention are directed to a method of synthesizing a ketoxime- and amide-functionalized nanomaterial. The method includes grafting, with a Friedel-Crafts acylation, the keto-carbonyl group onto the nanomaterial. The keto-carbonyl group is converted to an oxime group and undergoes a Beckmann Rearrangement to an amide group.
Yet another embodiment of the present invention is directed to a functionalized nanomaterial of which the nanomaterial comprises a carbon nanotube or a carbon nanofiber. At least ketoxime group is coupled to the nanomaterial.
According to still another embodiment of the present invention, a functionalized nanomaterial includes a nanomaterial comprises a carbon nanotube or a carbon nanofiber. At least amide group is coupled to the nanomaterial.
Another embodiment of the present invention includes a functionalized nanomaterial having at least one external surface and at least one edge. The nanomaterial is a carbon nanotube or a carbon nanofiber. At least one primary amine group is coupled to the at least one external surface of the nanomaterial. At least one primary amine group is coupled to the at least one edge of the nanomaterial. At least one primary carboxylic acid group is coupled to the at least one external surface of the nanomaterial. And, at least one primary carboxylic acid group is coupled to the at least one edge of the nanomaterial.
Additional objects, advantages, and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be leaned 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.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with a general description of the invention given above, and the detailed description of the embodiments given below, serve to explain the principles of the present invention.
FIG. 1 is a flowchart illustrating a method of functionalizing CNTs according to one embodiment of the present invention.
FIG. 2 is a flowchart illustrating a Beckmann rearrangement of an oxime group of the CNTs of FIG. 1 .
FIG. 3 is a schematic representation of a chemical reaction between a model compound 4-(2,4,6-trimethylphenoxy)benzophenone and hydroxylamine hydrochloride.
FIG. 4 illustrates a schematic representation of the Beckmann rearrangement of a first isomer product from the reaction of FIG. 3 .
FIG. 5 illustrates a schematic representation of the Beckmann rearrangement of a second isomer product from the reaction of FIG. 3
FIGS. 6A-6B illustrates a schematic representation of a chemical reaction between a CNT and hydroxylamine hydrochloride with Beckmann rearrangement of the oxime group.
FIGS. 7A-7C illustrates exemplary R groups of the products in FIGS. 6A-6B .
FIG. 8 illustrates a schematic representation of a convention chemical reaction for functionalizing a CNT.
FIG. 9 illustrates a schematic representation of a chemical reaction, according to another embodiment of the present invention, between a CNT and hydroxylamine hydrochloride with Beckmann rearrangement of the oxime group
It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the sequence of operations as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes of various illustrated components, will be determined in part by the particular intended application and use environment. Certain features of the illustrated embodiments have been enlarged or distorted relative to others to facilitate visualization and clear understanding. In particular, thin features may be thickened, for example, for clarity or illustration.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the figures, and in particular to FIG. 1 , a flowchart 20 illustrating a method of synthesizing ketoxime- or amide-functionalized graphene-based nanomaterials according to one embodiment of the present invention are shown, respectively.
In Block 22 of FIG. 1 , carbon nanotubes (“CNTs”) are grafted with keto-carbonyl groups via Friedel-Crafts (F-C) acylation in optimized PPA/P 2 O 5 using methods described in U.S. application Ser. No. 10/963,469, entitled NANOCOMPOSITES FROM IN-SITU POLYMERIZATION OF 3-PHENOXYBENZOIC ACID IN THE PRESENCE OF VAPOR-GROWN CARBON NANOFIBERS; U.S. application Ser. No. 12/233,423, entitled NANOCOMPOSITES FROM IN-SITU POLYMERIZATION OF 3-PHENOXYBENZOIC ACID IN THE PRESENCE OF VAPOR-GROWN CARBON NANOFIBERS, and issued as U.S. Pat. No. 7,960,471 on Jun. 14, 2011; and U.S. application Ser. No. 12/079,083, entitled CARBON NANOFIBERS AND NANOTUBES GRAFTED WITH A HYPERBRANCHED POLY (ETHER-KETONE) AND ITS DERIVATIVES, and issued as U.S. Pat. No. 8,173,763 on May 8, 2012, the disclosure of each incorporated herein by reference, in its entirety. The surface keto-carbonyl group may then be then converted to an oxime group (Block 24 ) and followed by effecting a Beckmann rearrangement in sulfuric acid ( FIG. 26 ).
FIG. 2 is a flowchart further illustrating the Beckmann Rearrangement 26 , with exemplary schemes as applied to a model compound (2,4,6-trimethylphenoxy)benzophenone in FIGS. 3-5 and to CNT in FIGS. 6A and 6B . In Block 28 , the compound, whether 4-(2,4,6-trimethylphenoxy)benzophenone 30 of FIG. 3 or keto-carbonyl grafted CNT 32 of FIG. 6A from the reaction noted above with respect to FIG. 1 ) is reacted with hydroxylamine hydrochloride in pyridine/ethanol at an elevated temperature (for example, 90° C.). With not wishing to be bound by theory, it is believed that when an unsymmetrical ketoxime is involved, the Beckman Rearrangement is expected to form two structural isomers in the amide product. Accordingly, and as shown in FIG. 3 , 4-(2,4,6-trimethylphenoxy)benzophenone 30 reacts with hydroxylamine hydrochloride to afford two oxime isomers 34 , 36 . Otherwise, and if a symmetric ketoxime is involved, then a single ketoxime-functional CNT product is formed, such as oxime-CNT 38 of FIG. 6A .
If desired, the products 34 ( FIG. 3 ), 36 ( FIG. 3 ), 38 ( FIG. 6A ) may be collected under filtration and dried (Optional Block 40 ), and before undergoing molecular rearrangement (Block 42 ) in a hot acid solution to form corresponding aromatic amide products 44 ( FIG. 4 ), 46 ( FIG. 5 ), 48 ( FIG. 6B ). The relative yield of a first product 44 ( FIG. 4 ) and a second product 46 ( FIG. 5 ) may be, for example, 83.1% to 16.9%. The degree of functionalization of the amide-CNT 48 ( FIG. 6B ) may be, for example, 1.3 atoms per 100 carbon atoms.
There are two isomeric forms of secondary amide moieties bonded to graphene surfaces of CNTs or CNFs, including C graphene C bond or a direct C graphene-N bond and corresponding to C-amide and N-amide, respectively. Conventional synthesis methods, illustrated in FIG. 8 , invariably produce C-amide functionalized CNTs and CNFs. However, synthesis according to embodiments of the present invention, and as shown in FIG. 9 , provides a near-quantitative yield of N-amide (98%) or mixture of N-amide (ranging from 72% to 86%) and C-amide (ranging from 14% to 28%) functionalized CNTs and CNFs, depending on the nature of R group in the starting keto-functionalized carbon nanomaterials.
The following examples illustrate particular properties and advantages of some of the embodiments of the present invention. Furthermore, these are examples of reduction to practice of the present invention and confirmation that the principles described in the present invention are therefore valid but should not be construed as in any way limiting the scope of the invention.
EXAMPLE 1
Confirmation of Functionalized Amide-CNT
Functionalization of the amide-CNT 48 ( FIG. 6B ) was confirmed by comparing the FT-IR spectra of corresponding products, generally designated as keto-CNT. The corresponding products included Oxime-CNT-R and Amide-CNT-R, wherein R may be one compound selected from the group illustrated in FIGS. 7A-7C [4-(2,4,6-trimethylphenoxy)benzoyl (“TMPB”); 1-pyrene; and pentyl, respectively].
When R is TMPB, the corresponding Keto-CNT-R showed a ketone-carbonyl characteristic peak at 1664 cm −1 , which is absent in the resulting Oxime-CNT-R having characteristic CN and N—O stretches at 1604 cm −1 and 996 cm −1 , respectively. After rearrangement, the amide-carbonyl peak at 1647 cm −1 and associated N—H stretch at 3321 cm −1 appeared in the Amide-CNT-R spectrum.
To determine the ratio of these isomers, Amide-CNT-R was hydrolyzed in potassium hydroxide/ethanol under refluxing condition. After work-up, a mixture of the hydrolysis product 50 , carboxylic acid 52 , and amine 54 in solution was separated from the solid product and injected into a GC-MS instrument for analysis. GC peak locations were compared with those of known compounds. The ratios of carboxylic acid 52 and amine 54 were obtained by integration of both GC peak areas.
The hydrolysis of Amide-CNT-R resulted in 98% of 4-(1,3,5-trimethylphenoxy)benzoic acid 52 and only 2% of 4-(1,3,5-trimethylphenoxy)aniline 54 . It is believed that the carboxylic acid 52 is dominant because anti-Oxime-CNT is encountering much less steric hindrance than its syn-counterpart and the predominant presence of syn-configuration of the ketoxime moiety as the result of the OH group moving away from the nonpolar graphene surface. The significant implication of this observation is that despite being part of a bulky graphene system, the surface sp 2 carbon may be an active participant in the molecular rearrangement of the pendant.
EXAMPLE 2
4-(2,4,6-Trimethylphenoxy)benzonitrile
2,4,6-Trimethylphenol (6.00 g, 44.1 mmol), 4-fluorobenzonitrile (5.34 g, 44.1 mmol), potassium carbonate (7.30 g, 52.8 mmol), a mixture of NMP (100 mL), and toluene (60 mL) were placed into a 250 mL three-necked, round-bottomed flask equipped with a magnetic stir-bar, nitrogen inlet, and a condenser. The reaction mixture was then heated and maintained at a temperature of about 140° C. for 8 hr under nitrogen. The dark solution was filtered while warm, and the filtrate was poured into distilled water containing 5% hydrochloric acid. The solution was separated into organic and aqueous layers. The organic layer was diluted with dichloromethane and separated. The solvent was removed from the dichloromethane extract to dryness. The resulting light brown oily residue was freeze-dried to afford 10.1 g (97% yield):
Analytical calculation for C 16 H 15 NO: C, 80.98%; H, 6.37%; N, 5.90%; 0, 6.74%.
Found: C, 80.31%; H, 6.37%; N, 5.75%; 0, 6.46%. FT-IR (KBr, cm −1 ): 2226 (CN stretch).
Mass spectrum (m/e): 237 (M + 100% relative abundance), 222, 204, 194. 1 H NMR (CDCl 3 , ppm) δ 2.05 (s, 6H, CH 3 ), 2.30 (s, 3H, CH 3 ), 6.81-6.84 (d, 2H, Ar), 6.91 (s, 2H, Ar), 7.53-7.56 (d, 2H, Ar). 13 C NMR (CDCl 3 , ppm) δ 16.10, 20.79, 115.48, 129.07, 129.15, 129.88, 130.48, 134.25, 147.84, 150.03, 161.44.
EXAMPLE 3
4-(2,4,6-Trimethylphenoxy)benzoic acid
4-(2,4,6-Trimethylphenoxy)benzonitrile (10.0 g, 42.0 mmol), and phosphoric acid (100 mL) were placed into a 250 mL three-necked round-bottomed flask equipped with a magnetic stir-bar, nitrogen inlet, and a condenser. The reaction mixture was then heated and maintained at a temperature of about 150° C. for 8 hr. After cooling down to room temperature, the mixture was poured into distilled water containing 5% hydrochloric acid. The resulting precipitates were collected by suction filtration, air-dried, dissolved in warm heptane, and filtered. The filtrate was allowed to cool to room temperature to afford 4.5 g (42% yield) of white crystal: m.p. 236-238° C.
Analytical calculation for C 16 H 16 O 3 : C, 74.98%; H, 6.29%; 0, 18.73%.
Found: C, 74.76%; H, 6.67%; 0, 18.56%. FT-IR (KBr, cm −1 ): 1650 (C═O stretch), 3385 (O—H stretch).
Mass spectrum (m/e): 256 (M + , 100% relative abundance), 255. 1 H NMR (DMSO-d 6 , ppm) δ 2.00 (s, 6H, CH 3 ), 2.67 (s, 3H, CH 3 ), 6.74-6.77 (d, 2H, Ar), 6.98 (s, 2H, Ar), 7.82-7.86 (d, 2H, Ar). 13 C NMR (DMSO-d 6 , ppm) δ 15.80, 20.41, 113.80, 127.65, 129.69, 129.81, 130.12, 134.47, 147.95, 159.95, 167.06.
EXAMPLE 4
4-(2,4,6-Trimethylphenoxy)benzophenone
2,4,6-Trimethylphenol (2.72 g, 20.0 mmol), 4-fluorobenzophenone (4.00 g, 20.0 mmol), potassium carbonate (3.32 g, 24.0 mmol), a mixture of DMAc (40 mL), and toluene (10 mL) were placed into a 250 mL three-necked, round-bottomed flask equipped with a magnetic stir-bar, nitrogen inlet, and a Dean-Stark trap with a condenser. The reaction mixture was then heated and maintained at a temperature of about 140° C. for 6 hr with nitrogen flow. The brown mixture was filtered while warm, and the filtrate was poured into distilled water containing 5% hydrochloric acid. The solution was phase-separated into an organic layer and an aqueous layer. The organic layer was diluted with dichloromethane and separated. The solvent was removed from the CH 2 Cl 2 extract to dryness to afford 6.00 g (95%) of a light brown oily residue, which solidified upon standing at room temperature: m.p. 52-54° C.
Analytical calculation for C 22 H 29 O 2 : C, 83.52%; H, 6.37%; 0, 10.11%.
Found: C, 83.15%; H, 6.51%; 0, 10.52%. FT-IR (KBr, cm −1 ): 3058, 2919, 2859, 1655 (C═O), 1597, 1500, 1307, 1278, 1235, 1165, 847, 700.
Mass spectrum (m/z): 316 (Ml, 100% relative abundance), 239, 105, 91, 77.
1 H NMR (CDCl 3 , ppm) δ 2.09 (s, 6H, CH 3 ), 2.31 (s, 31-1, CH 3 ), 6.82-6.84 (d, 21-1, Ar), 6.92 (s, 2H, Ar—H), 7.44-7.48 (t, 2H, Ar—H), 7.54-7.58 (t, 1H, Ar—H), 7.75-7.80 (overlapped d, 4H, Ar—H). 13 C NMR (CDCl 3 , ppm) δ 16.16, 20.76, 114.28, 128.15, 129.69, 129.73, 130.63, 130.73, 131.93, 132.70, 134.98, 138.08, 148.22, 161.67, 195.46.
EXAMPLE 5
4-(2,4,6-Trimethylphenoxy)benzophenone oxime
4-(2,4,6-Trimethylphenoxy)benzophenone 30 ( FIG. 3 ) (3.16 g 10 mmol), hydroxylamine hydrochloride (3.50 g, 50 mmol), pyridine (20 mL), and ethanol (50 mL) were placed into a 250 mL three-necked, round-bottomed flask equipped with a magnetic stir-bar, nitrogen inlet. The reaction mixture was then heated and maintained at a temperature of about 90° C. for 8 hr with nitrogen flow. Most solvents were removed by a rotavap, water (100 mL) was added, and the resulting mixture extracted with ethyl acetate. The organic layer was separated, washed with water 3 times, and finally dried over magnesium sulfate. After filtration to remove MgSO 4 , the filtrate was evaporated to dryness and dried in oven at 100° C. overnight to afford 3.15 g (99%) of white solid, m.p. 175.1-175.4° C. FT-IR (KBr, cm −1 ): 3228 (Br, OH), 3060, 2916, 1601, 1507, 1479, 1328, 1201, 994, 835, 765, 692.
EXAMPLE 6
4-(2,4,6-Trimethylphenoxy)-N-phenylbenzamide and N-[4-(2,4,6-Trimethylphenyoxy)phenyl]benzamide
4-(2,4,6-Trimethylphenoxy)benzophenone oxime (0.50 g, 1.5 mmol) and sulfuric acid (10 mL, 85%) were added into a 50 mL three-necked, round-bottomed flask equipped with a magnetic stir-bar and nitrogen inlet. The mixture was heated at a temperature of about 100° C. for 1 hr. After cooling down to room temperature, the resulting mixture was poured into ice. The precipitate was collected to afford 0.43 g (86%) of white powder. FT-IR (KBr, cm −1 ): 3319 (amide, N—H), 3059, 2918, 2857, 1649 (amide, C═O), 1599, 1503, 1440, 1321, 1241, 1167, 751, 691.
EXAMPLE 7
Functionalization of CNTs with 4-(2,4,6-trimethylphenoxy)benzoic acid
4-(2,4,6-Trimethylphenoxy)benzoic acid (0.50 g, 1.95 mmol), CNT (0.50 g of Graphistrengh® C100, Arkema, Colombes Cedex, France), and poly(phosphoric acid) (83% assay, 40 g) were place into a 250 mL resin flask equipped with a high torque mechanical stirrer and nitrogen inlet and outlet and stirred with dried nitrogen purging at 130° C. for 24 hr. P 2 O 5 (10 g) was then added in one portion. The initially dark mixture became dark brown after 24 hr. The temperature was maintained at 130° C. for 72 hr. After cooling down to room temperature, water was added to the reaction vessel and the content was poured into a beaker of water (about 1 L). The resulting precipitates were collected, washed with (1) diluted ammonium hydroxide; (2) Soxhlet-extracted with water for three days and (3) with methanol for three days; (4) and dried over phosphorus pentoxide under reduced pressure at 100° C. for 72 hr to give 0.60 g (95%) of dark brown solid. FT-IR (KBr, cm −1 ): 3435, 2922, 2856, 1659 (keto C═O), 1594, 1389, 1230, 1152, 913.
EXAMPLE 8
Functionalization of MWCNTs with 1-pyrenecarboxylic acid
Keto-CNT-Re ( FIG. 6B ), wherein R is the 1-pyrene of FIG. 7B , was synthesized from 1-pyrenecarboxylic acid (0.50 g, 2.03 mmol) and MWCNT (0.50 g) using the same procedure as was described in Example 7 to afford 0.57 g (91% yield) of dark brown solid.
Analytical calculation for C 122.1 H 11.7 O 1.3 (based on the assumption that for every 100 carbon, there are 1.3 1-pyrenecarbonyl groups attached): C, 97.82%; H, 0.79%; 0, 1.39%.
Found: C, 97.56%; H, 0.88%; 0, 1.42%. FT-IR (KBr, cm −1 ): 3036, 1641 (C═O), 1512, 1277, 840.
EXAMPLE 9
Functionalization of MWNTs with 1-hexanoic acid
Keto-CNT-R ( FIG. 6B ), wherein R is the pentyl of FIG. 7C , was synthesized from 1-hexanoic acid (0.50 g, 4.31 mmol) and MWCNT (0.50 g) using the same procedure as was described in Example 7 to afford 0.49 g (88%) of dark brown solid.
Analytical calculation for C 107.8 H 14.3 O 1.3 (based on the assumption that for every 100 carbon, there are 1.3 hexanoyl groups attached): C, 98.32%; H, 1.30%; 0, 1.56%.
Found: C, 97.94%; H, 1.26%; 0, 1.63%. FT-IR (KBr, cm −1 ): 2928, 2863, 1648, 1458, 1202.
EXAMPLE 10
Conversion of Keto-CNT-R to Oxime-CNT-R
Keto-CNT-R ( FIG. 6B ), wherein R is the TMPB of FIG. 7A , keto-carbonyl grafted CNT 32 ( FIG. 6A ) (0.50 g), hydroxylamine hydrochloride (2.00 g, 28.6 mmol), pyridine (20 mL), and ethanol (1000 mL) were added into a 250 mL three-necked, round-bottomed flask equipped with a magnetic stir-bar, nitrogen inlet. The reaction mixture was then sonicated for 1 hr and heated to a temperature of about 90° C. for 2 d. The solution was then poured into water. The black precipitate was collected by filtration, washed with ethanol, and dried in an oven at 100° C. overnight to afford 0.51 g (99%) of black powder. FT-IR (KBr, cm −1 ): 3420 (oxime O—H), 2920, 1501, 1604 (oxime C═N), 1228, 1163, 996 (oxime N-0).
EXAMPLE 11
Conversion of Oxime-CNT-R to Amide-CNT-R
Oxime-CNT-R (0.20 g), wherein R is the TMPB of FIG. 7A , and sulfuric acid (10 mL) were placed into a 50 mL three-necked, round-bottomed flask equipped with a magnetic stir-bar and nitrogen inlet. The reaction mixture was then sonicated for 1 hr and heated at 100° C. for 1 d. The solution was then poured into ice water. The black precipitate was collected by filtration, washed in water, and dried in oven at 100° C. overnight to afford 0.18 g (90%) of black powder. FT-IR (KBr, cm −1 ): 3321 (amide N—H), 2920, 1647 (amide C═O), 1601, 1499, 1324, 1227, 1154.
EXAMPLE 12
Hydrolysis of Amide-CNT-R
Amide-CNT-R (0.20 g), wherein R is the TMPB of FIG. 7A , and ethanol (10 mL) were placed into a 50 mL three-necked, round-bottomed flask equipped with a magnetic stir-bar and nitrogen inlet. The reaction mixture was then sonicated for 1 hr and potassium hydroxide (2.0 g, 3.6 mmol) was added. The mixture was heated under refluxing for 1 d and then poured into water in a beaker. Dilute HCl solution (2N) was added until pH was about 6-7, followed by addition of ethyl acetate, and the resulting heterogeneous mixture was magnetically stirred. Upon standing, the top organic layer of mixture was separated from the lower aqueous phase with solid particles at the bottom of the beaker and dried over sodium sulfate. After filtration, the solid was dried to afford 0.12 g (75%) of black power (CNT-R′, where R′ is NH 2 or COOH). The ethyl acetate extract of the filtrate was rotary-evaporated to dryness to afford 0.03 g (76%) of white crystalline products included carboxylic acid 52 ( FIG. 6B ) and amine 54 ( FIG. 6B ), which were then dissolved in acetonitrile and injected into GC-MS sample port for quantitative identification.
EXAMPLE 13
Hydrolysis of Amide-CNT-R
Hydrolysis of Amide-CNT-R, wherein R is the 1-pyrene of FIG. 7B , was performed using the same procedure as was described in Example 12 using Amide-CNT-R (0.16 g), ethanol (10 mL), and potassium hydroxide (2.0 g, 3.6 mmol) to afford 0.09 g (82%) of black power (CNT-R′, where R′ is NH 2 or COOH), and the ethyl acetate extract filtrate was rotary-evaporated to dryness to afford 0.03 g (75%) of yellow crystals (mixture of carboxylic acid 52 and amine 54 ), which were then dissolved in acetonitrile and injected into GC-MS sample port for identification and quantification.
EXAMPLE 14
Hydrolysis of Amide-CNT-R
Hydrolysis of Amide-CNT-R, wherein R is the pentyl of FIG. 7C , was performed using the same procedure as was described in Example 12 using Amide-CNT-R (0.16 g), ethanol (10 mL), and potassium hydroxide (2.0 g, 3.6 mmol) to afford 0.10 g (78%) of black power (MWCNT-R′, where R′ is NH 2 or COOH), and the ethyl acetate extract was rotary-evaporated to remove the solvent to afford 0.02 g (76%) of a colorless liquid (carboxylic acid 52 and amine 54 ), which was then dissolved in acetonitrile and injected into GC-MS sample port for identification and quantification.
EXAMPLE 15
Hydrolysis of Amide-CNT-R
GC-MS analysis and associated plots were obtained on a CP-3800 Gas Chromatographer and TQ-Mass Spectrometer (Varian Medical Systems, Inc., Palo Alto, Calif.). A “25 min” method was used for all the samples, wherein operational parameters included an injector temperature of 250° C.; column helium flow rate of 1.0 mL/min; and flame ionization detector (FID) temperature of 250° C. The column oven temperature was held at 50° C. for 0.5 min after each analyte had been injected. The oven temperature was then raised, at the rate of 20° C./min to 300° C./min for 12.5 min and held at 300° C. for 12 min.
The carboxylic acid 52 ( FIG. 6B ) and amine 54 ( FIG. 6A ) reference compounds were specially synthesized. Other reference compounds included 1-aminopentane (1-pentylamine), 1-hexanoic ac id, 1-aminopyrene, and 1-pyrenecarboxylic acid. The reference compounds, 4-(1,3,5-trimethoxyphenoxy)benzoic acid and 4-(1,3,5-trimethoxyphenoxy)aniline were prepared as described in Example 3 and Example 16, respectively.
TABLE 1
R group designation
N-amide (%)
C-amide (%)
TMPB (FIG. 7A)
98
2
1-pyrene (FIG. 7B)
86
14
pentyl (FIG. 7C)
100
0
EXAMPLE 16
Synthesis of 4-(1,3,5-trimethoxyphenoxy)aniline for GC-MS analysis
2,4,6-Trimethylphenol (7.50 g, 55.0 mmol), 4-fluoronitrobenzene (7.10 g, 50.0 mmol), potassium carbonate (7.60 g, 55.0 mmol), and N,N′-dimethylformamide (100 mL) were placed into a 250 mL three-necked, round-bottomed flask equipped with a magnetic stir-bar and nitrogen inlet. The reaction mixture was agitated at room temperature for 24 hr with nitrogen flow. The brown mixture was filtered, and the filtrate was poured into distilled water. The solution phase-separated into an organic layer and an aqueous layer. The organic layer was diluted with ethyl acetate and separated. The solvent was removed by rotary evaporation. The semi-solid was purified by a column (basic alumina) chromatography with a 1:9/ethyl acetate:hexane mixture as eluent to eventually afford 7.31 g (58.4%) of 1,3,5-trimethyl-2-(4-nitrophenoxy)benzene as a colorless liquid, which, upon standing in a refrigerator, was solidified to a light yellow solid m.p. 46-48° C.
Analytical calculation for C 15 H 15 NO 3 : C, 70.02%; H, 5.88%; N, 5.44.
Found: C, 69.87%; H, 5.78%; N, 5.45%.
Mass spectrum (m/z): 257. 1 H NMR (DMSO-d 6 , ppm) δ: 1.98 (s, 6H, CH 3 ), 2.24 (s, 3H, CH 3 ), 6.88-6.89 (d, 2H, Ar—H), 6.97 (s, 2H, Ar—H), 8.17-8.19 (d, 2H, Ar—H). 13 C NMR (DMSO-d 6 , ppm) δ: 15.58, 22.28, 114.9, 126.33, 128.6, 129.8, 135.1, 141.7, 147.5, 162.5.
1,3,5-Trimethyl-2-(4-nitrophenoxy)benzene (4.0 g, 15.6 mmol) was then dissolved in ethyl acetate (100 mL) and palladium on activated carbon (0.20 g) was placed in a hydrogenation bottle. The bottle was tightly secured on a Parr hydrogenation apparatus, flushed four times with hydrogen gas, and pressurized to 60 psi. After agitation at room temperature for 12 hr under the hydrogen pressure of 60 psi, the solution was filtered through Celite. The filter cake was washed with ethyl acetate, and the filtrate was evaporated to dryness on a rotary evaporator and the resulting crude product was recrystallized from ethanol/water to afford 3.25 g (92%) of light brown crystals: m.p. 94-95° C.
Analytical calculation for C 15 H 17 NO: C, 79.26%, H, 7.54%, N, 6.16%,
Found: C, 79.19%, H, 7.55%, N, 5.95%.
Mass spectrum (m/z): 227. 1 H NMR (DMSO-d 6 , δ in ppm): 1.99 (s, 6H, CH 3 ), 2.22 (s, 3H, CH 3 ), 4.63 (s, 2H, NH 2 ), 6.39-6.41 (d, 2H, Ar—H), 6.45-6.48 (d, 2H, Ar—H), 6.89 (s, 2H, Ar—H).
EXAMPLE 17
Table 2, below, summarizes a degree of functionalization determined based on thermogravimetric analysis and elemental analysis results of pristine and functionalized MWCNTs. The superscript “a” in Table 2 indicates a value less than the detection limit. The subscript “b” in Table 2 indicates the theoretical calculation of C %, H %, and N % were based on the assumption that for every 1000 carbons there are 13 (i.e., degree of functionality or τ=1.3 at. %, based on reported TGA and elemental results) functional groups (C n H m N p O q ) attached from the following equation:
C % = ( 100 + τ * n ) * 12.01 100 * 12.01 + τ ( 12.01 n + 1.01 m + 14.01 p + 16.00 q ) ; H % = τ * m * 1.01 100 * 12.01 + τ ( 12.01 n + 1.01 m + 14.01 p + 16.00 q ) ; N % = τ * p * 14.01 100 * 12.01 + τ ( 12.01 n + 1.01 m + 14.01 p + 16.00 q ) ; and O % = τ * q * 16.00 100 * 12.01 + τ ( 12.01 n + 1.01 m + 14.01 p + 16.00 q ) ,
where the subscripts n, m, p, and q are the numbers of carbon, hydrogen, nitrogen, and oxygen, respectively, in one functional group. The atomic weights of carbon, hydrogen, nitrogen, and oxygen are 12.01 g/mol, 1.01 g/mol, 14.01 g/mol, and 16.00 g/mol, respectively.
Returning again to Table 2, the superscript “c” indicates a CNT content calculated as follows:
CNT
Content
=
100
*
12.01
100
*
12.01
+
τ
(
12.01
+
16
+
1.01
*
15
+
2
*
16.00
)
.
The superscript “d” in Table 2 indicates a residual weight percent at a temperature ranging from 550° C. to 600° C. from TGA thermograms in air.
TABLE 2
Sample
DF
CNT Content (%)
Elemental
No.
τ
Calculated
Found d
Analysis
C (%)
H (%)
N (%)
MWCNT
0
100
95.10
Calculated
100
0
0
Found
95.10
0.40
<0.1 a
Keto-
1.3
79.4 c
79.4
Calculated for
95.94
1.30
0
CNT-
C 120.8 H 19.5 O 2.6 b
TMPB
Found
94.67
1.26
<0.1 a
Keto-
1.3
80.1 c
80.1
Calculated for
97.82
0.79
0
CNT-l-
C 122.1 H 11.7 O 1.3 b
pyrene
Found
97.56
0.88
<0.1 a
Keto-
1.3
90.3 c
90.3
Calculated for
97.35
1.09
0
CNT-
C 107.8 H 14.3 O 1.3 b
pentyl
Found
97.22
1.12
<0.1 a
Oxime-
1.3
78.4 c
78.2
Calculated for b
94.72
1.37
1.19
CNT-
C 120.8 H 20.8 N 1.3 O 2.6
TMPB
Found
94.65
1.39
1.22
Oxime-
1.3
79.1 c
79.0
Calculated for b
96.57
0.86
1.20
CNT-
C 122.1 H 13.0 N 1.3 O 1.3
pyrene
Found
96.43
0.89
1.24
Oxime-
1.3
89.0 c
89.7
Calculated for b
95.94
1.17
1.35
CNT-
C 107.8 H 15.6 N 1.3 O 1.3
pentyl
Found
95.81
1.13
1.32
Amide-
1.3
78.4 c
78.2
Calculated for b
94.72
1.37
1.19
CNT-
C 120.8 H 20.8 N 1.3 O 2.6
TMPB
Found
94.65
1.41
1.17
Amide-
1.3
79.1 c
79.2
Calculated for b
96.57
0.86
1.20
CNT-
C 122.1 H 13.0 N 1.3 O 1.3
pyrene
Found
96.43
0.82
1.15
Amide-
1.3
89.0 c
89.6
Calculated for b
95.94
1.17
1.35
CNT-
C 107.8 H 15.6 N 1.3 O 1.3
pentyl
Found
96.10
1.15
1.32
As described in detail herein, chemical attachment of ketone-oxime (or simply ketoxime) moieties onto the surfaces of multi wall carbon nanotubes (MWCNT) and carbon nanofibers (CNF) via sequential Friedel-Crafts acylation in polyphosphoric acid and condensation with hydroxylamine is described according to various embodiments of the present invention. Additional embodiments of the present invention are directed to methods to obtain one-dimensional carbon nanomaterials with directly bound secondary amide (—CONHR) and primary amine (—NH 2 ) via a tandem application of Beckmann Rearrangement in aqueous sulfuric acid and alkaline hydrolysis reaction.
While the present invention has been illustrated by a description of one or more embodiments thereof and while these embodiments have been described in considerable detail, they are not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope of the general inventive concept.
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Ketoxime- and amide-functionalized nanomaterials. The nanomaterials including a nanomaterial comprising a carbon nanotube or a carbon nanofiber. At least one ketoxime group coupled to a first location on the nanomaterial, and at least one amide group coupled to a second location on the nanomaterial.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a divisional of U.S. application Ser. No. 09/601,180 filed Sep. 15, 2000 now U.S. Pat. No. 6,616,695 is a national stage entry of PCT/FR99/00183 filed on Jan. 29, 1999.
BACKGROUND OF THE INVENTION
The invention relates to implants for replacing at least part of a vertebra, for example after ablation of the vertebra.
The document EP-0 567 424-A1 discloses an implant of this kind comprising an intermediate body and two bearing parts adapted to bear against the vertebral plates of vertebrae adjacent the space left by a vertebra that has been removed. Each bearing part is assembled to one end of the intermediate body by a screw connection so that rotation of each bearing part relative to the body varies the total length of the implant. However, it takes a relatively long time to assemble the various components of the implant. What is more, given the number of parts capable of relative movement, adjusting the length of the implant is relatively complicated and takes a long time, which increases the duration of the surgery. Finally, manufacturing the implant entails defining a large number of accurate surfaces enabling relative movement of the parts. Manufacture is long and costly.
U.S. Pat. No. 5,723,013 relates to an implant for replacing a vertebra that is made up of two implant parts sliding one within the other. The two parts are in mutual contact through teeth enabling the length of the implant to be increased by distraction of the two parts. The length cannot be reduced, however. The length of the implant can be adjusted simply and quickly. However, fine adjustment of the length of the implant is not possible.
SUMMARY OF THE INVENTION
An object of the invention is to provide an implant that is quick to install during surgery and that enables fine adjustment of its length.
To achieve the above object, the invention provides an implant for replacing at least part of a vertebra, the implant having two parts adapted to be joined together and enabling a total dimension of the implant to be adjusted, each part having a fixed dimension homologous to the total dimension of the implant, characterized in that the parts form a screw connection with each other.
Accordingly, during surgery, the total dimension of the implant is adjusted by moving only the two parts of the implant relative to each other. Adjustment is therefore simple and fast. Similarly, assembling the mobile parts of the implant before or during the operation is simple and fast. What is more, the number of surfaces enabling relative movement of the parts is reduced. Because the surfaces concerned are very accurate surfaces, fabrication of the implant is easy and its cost is low. The screw connection enables fine adjustment of the length of the implant.
At least one of the parts is advantageously in one piece.
This further reduces the number of parts to be assembled.
At least one of the parts is advantageously in more than one piece.
This facilitates obtaining some shapes of the part concerned.
Each part advantageously has at least one lateral opening and the openings can be superposed to receive a fixing member.
This facilitates superposing the openings, in particular when he two parts are relatively mobile by virtue of a screw connection.
At least one of the openings is advantageously elongate.
The elongate opening is advantageously rectilinear and parallel to a direction of measuring the total dimension of the implant.
One part advantageously has an elongate opening and the other part advantageously has at least one circular opening.
One part is advantageously a female part adapted to receive the other part and including a body and a flange which can be moved relative to the body to immobilize the other part by wedging it.
Accordingly, the wall of at least one of the two parts does not necessarily have to have an orifice to receive a member for fixing the two parts together. The wall of each part can therefore be apertured as much as may be required to show the implant clearly on X-rays and to favor the growth of bone with a view to its osteointegration.
The flange is advantageously mobile by virtue of elastic deformation of the female part.
The flange and the body advantageously each have a conduit to receive a member positioning the flange relative to the body.
The conduits are advantageously parallel to a direction in which the other part is received into the female part.
The flange advantageously comprises an uninterrupted collar.
The collar is advantageously in a plane perpendicular to a direction in which the other part is received into the female part.
At least one of the parts advantageously has a toothed end forming an end of the implant.
Other features and advantages of the invention will become apparent in the course of the following description of two preferred embodiments of the invention, which description is given by way of non-limiting example only.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIGS. 1 and 2 are perspective views of a first embodiment of an implant according to the invention respectively before and after assembly;
FIG. 3 is a side view of one variant of the first embodiment;
FIG. 4 is a perspective view of a second embodiment of an implant according to the invention before assembly; and
FIGS. 5 and 6 are two side views of the implant shown in FIG. 4 after assembly.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2 , in a first embodiment of the invention the implant 2 has two parts 4 , 6 .
Each part 4 , 6 includes a cylindrical tubular one-piece body 8 , 10 that has an axis 9 . The body 8 , also referred to as the male body, is adapted to penetrate into the body 10 , also referred to as the female body, in a direction parallel to the axis 9 . The male body 8 is threaded externally and the female body 10 is threaded internally to cooperate with the male body and provide a screw connection. A side wall of the male body 8 has identical rectilinear elongate openings or slots 12 of constant width that are parallel to each other and to the axis 9 . Each extends more than half the length of the body 8 in a direction parallel to the axis 9 . They are distributed all around that axis. A side wall of the female body 10 has a series of circular fixing openings or slots 14 that are identical to each other and lie in a common plane perpendicular to the axis 9 and in the vicinity of a proximal edge of the female body through which the male body 8 penetrates into the female body 10 . The circular openings 14 are threaded. The diameter of the circular openings 14 is equal to the width of the elongate openings 12 . The female part 6 has a fixing screw 16 adapted to cooperate with the circular openings 14 to provide a screw connection.
The female body has an end wall including circular openings 18 at a distal edge of the female body that is opposite the proximal edge in the axial direction 9 . The distal edge of the female body has teeth 19 extending away from the proximal edge. The wall of the female body 10 has other circular openings 18 which are not threaded between the distal edge and the fixing openings 14 .
The wall of the male body 8 has an internal thread in the vicinity of a distal edge opposite the proximal edge adapted to penetrate into the female body. The male part 4 includes a cap 22 comprising a threaded cylindrical wall for fixing it by means of a screw connection to the threaded distal edge of the male body. The cap 22 has an end wall perpendicular to the axis 9 and including circular openings 18 and teeth 19 directed away from the male body 8 . The threads of the cap 22 and of the distal edge of the male body 8 are just long enough to rigidly fix the cap 22 onto the male body 8 in an axial abutting relationship so that the cap can be separated from the body 8 by very slightly rotating it about the axis 9 , for example by rotating it through one or two turns. When the cap 22 is not abutted on the distal edge, it is connected to the body 8 with play. The various positions of the cap 22 relative to the body 8 when their threads are in mesh do not significantly change the length of the male part 4 along the axis 9 because the threads have a very small inclination to the axis 9 . The male and female parts have respective fixed lengths m and f parallel to the axis 9 .
To assemble the implant 2 , the cap 22 is fixed to the body 8 to constitute the male part 4 . The male part 4 is then inserted in the female part 6 with their respective threads meshing. Both threads are very long to provide a wide choice as to the length over which the male part 4 penetrates into the female part 6 . Because of the screw connection, relative rotation of the male and female parts adjusts the total length L of the implant in the direction parallel to the axis 9 . The length L corresponds to the distance between the two vertebral plates between which the implant is to be installed. When the length L suited to the intervertebral space to be occupied is obtained, the screw 16 is inserted in one of the fixing openings 14 in the female body 6 which coincides with an elongate opening 12 in the male body 4 . If there is no such coincidence, all that is required to bring about such coincidence is to turn the two parts relative to each other by a very small fraction of one turn, thanks to the elongate shape of the openings 12 . The screw 16 is inserted as far as the corresponding elongate opening 12 , which prevents subsequent relative rotation of the two parts. Finally, the screw 16 is tightened until its head bears against the female body 6 . The adjustment of the distance L and the fixing of the screw 16 are carried out at least in part with the implant 2 in situ, occupying the space left by the vertebra that has been partly or totally removed. The distal edges of the male and female parts then bear against the respective vertebral plates of two vertebrae adjacent the latter space. The teeth 19 ensure a good grip of the implant 2 on the plates and facilitate osteointegration of the implant. All the openings 12 , 14 , 18 of the implant facilitate osteosynthesis for the purpose of osteointegration.
In the FIG. 3 variant, the distal edges carrying the teeth are in planes inclined to the plane perpendicular to the axis 9 to allow for the inclined configuration of the vertebral plates of some vertebrae.
Referring to FIGS. 4 to 6 , in the second embodiment, in which the reference numbers of corresponding components are increased by 100 , the two parts 104 , 106 of the implant provide a male-female coupling with a screw connection, as previously. Each distal edge and the teeth it carries are now in one piece with the corresponding body. The male part 104 is in one piece. The male part 104 and the female part 106 have no end walls and the ends of the implant associated with the distal edges are open.
The proximal edge of the female part 106 has a slot 130 in a plane perpendicular to the axis 109 and in the shape of a circular arc subtending an angle about the axis greater than 180°, for example equal to 200°. The slot 130 therefore delimits a flange 132 carrying the proximal edge and forming an uninterrupted circular collar which can move relative to the remainder of the body by elastic deformation of a junction part 133 connecting the remainder of the body to the flange. On either side of the slot 130 , and opposite the junction part, the flange and the body have respective facing lobes 134 projecting from the outside face of the female body 106 . The lobes 134 have respective conduits with a common axis 136 parallel to the axis 109 . The female part includes a screw 116 adapted to be inserted through the flange 132 into the two conduits to engage with a thread of the conduit in the body 110 , a head of the screw abutting on the lobe of the flange.
The lateral walls of the male and female bodies have triangular openings 138 that extend from one of the corresponding proximal and distal edges to the other. The triangular openings 138 on each male and female part are alternately inverted relative the axis 109 to define between them branches 140 connecting the distal edge to the proximal edge, both of which are circular and uninterrupted. These very large openings 138 ensure that the implant 102 is highly visible in X-rays and encourage osteointegration.
The length L of the implant is chosen by relative rotation of the two parts 104 , 106 , as previously. When the desired length L is reached, the screw 116 is tightened to move the flange 132 towards the body 106 by virtue of elastic deformation of the junction part 133 . Because of the screw connection between the flange 132 and the male body 104 and the screw connection between the male body 104 and the female body 106 , this movement over a very short distance achieves rigid wedging of the male and female parts relative to each other. Alternatively, the fixing by the screw 116 could be such that the wedging effect is achieved by movement of the flange 132 away from the female body 106 .
The implant 2 , 102 according to the invention enables a bone graft to be fitted between two vertebral plates when total or partial corporectomy and ablation of the overlying or underlying intervertebral discs have been carried out. Once adjusted to the size of the space to be filled, by choosing its length L, the implant 2 , 102 is filled with bone, generally taken from the patient. This achieves a graft and braces the spinal column.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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The invention concerns an implant for replacing a vertebra at least partially, consisting of two parts adapted to be mutually connecting while enabling the adjustment of the implant total dimension, each part having an invariable dimension homologous with the implant dimensions. The parts form a screw-nut connection with each other.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a spinneret having a non-circular cross-section capillary orifice and process for using this spinneret in the production of polyamide yarns having a circular cross-section. In particular, the invention relates to a spinneret for extruding polyamide filaments and forming yarns comprised of the same filaments.
2. Description of the Related Art
In the manufacture of polyamide multifilament yarns, especially nylon 66 yarns, the winding of the yarn must be stopped frequently to remove undesirable deposits found around the capillary exit side of the spinneret plate. If not removed these deposits build up to a thickness of a “few millimeters (per) week” according to Fourne ( Synthetic Fibers , Chapter 4, page 359, C. Hanser Publishers, Munich 1998.) Such deposits contributed to the filament bending or “kneeing.” The bending of a majority of the filaments, if not remedied, ultimately led to filaments breaks, yarn defects or unscheduled process interruptions and poor efficiency.
A remedy practiced in the art for filament bending or kneeing is to clean these deposits off the extrusion or spinneret plate on the capillary exit face. This cleaning process is also known as “spinneret wiping.” The cycle time between spinneret wiping events, where each event is necessitated by a build up of the undesirable deposits, is the spinneret wipe life. It is desirable from a process efficiency and continuity standpoint to have a longer spinneret wiping cycle or wipe life.
In general, the cross sectional shape of a filament is determined by the cross sectional profiled shape of the extrusion orifice. For example, in U.S. Pat. No. 5,432,002 a trilobate profile filament yarn is produced by means of a spinneret plate with multiple orifices of trilobate shape. Whereas, a circular profile filament yarn is produced by a spinneret plate, illustrated at 170 in FIGS. 1 a and 1 b with multiple orifices 100 of circular shape.
SUMMARY OF THE INVENTION
Applicants have observed that wiping cycles for production of trilobal profile filaments were in general longer times than those times observed for circular profile cross-section filaments. In particular, Applicants have observed that a non-circular cross-section spinneret capillary orifice (or extrusion orifice) with a cross-sectional area substantially the same as the area of a circular cross-section spinneret capillary, but having a perimeter measure greater than the perimeter of a circular cross-section spinneret capillary, provides greater time interval between spinneret plate wiping events. This non-circular cross-sectional shape of the extrusion capillary, when used to extrude filaments of circular cross-sectional shape, extends the spinneret wipe life by lessening the amount of thermal deposits. This thereby extends the time between wipe cycles. As a result of increased wipe life, the productivity of the process is increased.
Therefore, in accordance with the present invention, there is provided a melt extrusion spinneret plate having at least one capillary orifice for producing at least a single filament of circular cross sectional shape, said capillary orifice having a non-circular shape. Preferably, the capillary orifice has a profiled shape with at least five 5 radially arranged legs, and preferably up to twelve 12 legs. More preferred are eight radially arranged legs.
Further in accordance with the present invention, there is provided a process for making a nylon filament of circular cross sectional shape comprising the steps of: supplying a polymer to a spin beam where the melted polymer is passed to a spin pack and through a spinneret plate having at least a single capillary orifice of non-circular shape, extruding at least a polymer single filament with a jet velocity substantially the same as that jet velocity employed when using a circular cross-section capillary orifice, quenching the freshly extruded filaments with conditioned air, drawing the filament, and winding the filament.
Other objects of the invention will be clear from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a representation in plan view of a prior art spinneret plate having a plurality of circular cross section extrusion capillaries.
FIG. 1 b is a representation in elevation view of a prior art spinneret plate having a plurality of circular cross section extrusion capillaries.
FIG. 2 a is a representation in plan view of the invention spinneret plate having a plurality of non-circular cross section extrusion capillaries.
FIG. 2 b is a representation in elevation view of the invention spinneret plate having a plurality of non-circular cross section extrusion capillaries.
FIG. 3 a is a representation of a prior art spinneret plate with a single circular cross section extrusion capillary.
FIG. 3 b is a representation of an invention spinneret plate with a single non-circular cross section extrusion capillary.
FIG. 4 is a schematic representation of a process in which the invention spinneret plate is useful.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Throughout the following detailed description, similar reference characters refer to similar elements in all drawings or figures.
In accordance with the present invention, there is provided an apparatus comprising a melt extrusion spinneret plate comprising at least a single non-circular capillary orifice for making a nylon filament of circular cross sectional shape. A schematic representation of a single capillary orifice is shown in FIG. 3 b . The non-circular capillary orifice of the spinneret plate for producing a single filament of circular cross sectional shape has a perimeter of non-circular cross sectional shape. The perimeter is characterized by a perimeter measure p c , and an extrusion area, wherein, the perimeter measure p c , is greater than either of: 2πR and 2πr. The extrusion area for the non-circular cross sectional shape orifice is greater than πr 2 and less than πR 2 . Herein, r is the radius of the largest circle inscribed by the orifice perimeter and R is the radius of the largest circle circumscribing the orifice perimeter. This relationship is represented in FIG. 3 b.
In accordance with the present invention, the non-circular capillary orifice of the preferred melt extrusion spinneret plate has a perimeter measure p c of about 2 to about 10 times greater than either of 2πR and 2πr. The non-circular capillary orifice of the preferred melt extrusion spinneret plate has about 5 to about 12 radially arranged legs.
In accordance with the present invention, there is provided a process for making a nylon filament of circular cross sectional shape. A schematic representation of the filament spinning process is shown in FIG. 4 . The process comprises the steps of supplying a molten polymer to a spin beam (comprising elements 150 , 160 and 170 ) where a molten polymer is passed to a spin pack. The molten polymer is represented at 140 , typically the polymer has an RV in the range of 45 to 60, is conveyed to the spin beam. The polymer is then forwarded by a meter pump 150 and fed at a controlled rate to a spinning filter pack 160 .
The polymer is then extruded through a spinneret plate 170 , shown in FIGS. 2 a , 2 b and 4 . The spinneret plate has at least a single capillary orifice 110 . The capillary orifices correspond to each individual filament comprising the yarn (as represented in side elevation by FIG. 2 b and plan view by FIG. 2 a ). FIG. 3 b is a representation the capillary orifices of the present invention as compared to a circular capillary orifice of the prior art represented in FIG. 3 a . The non-circular cross-section spinneret capillary orifices (or extrusion orifice) of FIG. 3 b is designed to have a cross-sectional area substantially the same as that area of a circular cross-section spinneret capillary, represented in FIG. 3 a . At the same time, the perimeter measure p c of the invention non-circular cross-section orifice is greater than the perimeter measure 2πR of a circular cross-section spinneret capillary having a radius R. Additionally, the invention orifice is characterized, in the process of the invention, as allowing the polymer extrusion velocity to remain the same as that for a circular extrusion orifice, represented in FIG. 3 a , with a substantially similar extrusion area. The polymer extrusion velocity is the same as the filament exit velocity from the spinneret capillary. In general, for a certain polymer throughput G (e.g. in grams per minute) per capillary, the following equation applies:
G=ρ (melt) D 2 (capillary) (π/4) v (extrusion) Equation 1.
In this equation, ρ is the polymer melt density (e.g. for melted nylon 6,6@290° C. equal to 1.0 gram per cm 3 ), D (=2R) is the diameter (equal to twice the radius) of the capillary assuming a circular orifice, and v is the velocity of the filament. The extrusion velocity is given by the following equation:
v (extrusion) =G (4/π) D 2 (capiliary) ρ (melt) Equation 2.
In combination, the perimeter increase in the capillary orifice of the present invention with an unaltered extrusion velocity is thought to provide a longer length of time between spinneret plate wiping events. In a preferred embodiment the polymer is extruded at a jet velocity in the range of 20 centimeters per second to 80 centimeters per second.
In the process of the invention, the freshly extruded filaments are quenched with conditioned air in the known manner. In this step, the individual filaments 200 are cooled in a quench cabinet 180 with a side draft of conditioned air 190 and converged and oiled with a primary finish, known in the art, at 210 , into a yarn. The yarn is forwarded by feed roll 220 onto a draw roll pair 230 where the yarn is stretched and oriented to form a drawn yarn which is directed by roll 240 into a yarn stabilization apparatus 250 , commonly used in the art and here optionally employed as a yarn post-treatment step. Finally, the yarn is wound up as a yarn package at 270 , at a yarn speed in the range of 4500 to 6500 meters per minute, and preferably 5000–6000 meters per minute. The yarn RV measured is about 51 to about 54. During the course of winding at these speeds any need to interrupt the process for the purpose of cleaning the exit side face of the spinneret plate dramatically affects the productivity. Essentially all product which could have been wound up is sent to waste while the spinneret plate is wiped.
Using the spinneret plate of the invention, having extrusion orifices of non-circular cross section, to spin filaments of circular cross sectional shape provides a process with a reduced need for spinneret wiping due to bent filaments. The number of bent filaments at the exit side 175 of the face of the spinneret plate 170 with the present invention may be counted directly by observation and recorded for a typical eight-hour shift after spinneret plate wiping. The record is indicative of how robust the process is from a bent filament production rate. Similarly, the spinneret wipe life expressed as the time for 10% of all single filaments in the yarn bundle to appear bent at the exit side of the capillary on the spinneret plate face is also recorded. Measuring the time to 10% bent filaments is performed directly by observation and a direct count by an operator illuminating the spinneret plate face within the quench cabinet.
The yarn produced according to the process represented by FIGS. 4 is a drawn yarn with elongation of 22 to about 60%, the boiling water shrinkage is in the range of 3 to about 10%, the yarn tenacity is the range of 3 to about 7 grams per denier, and the RV of the yarn can be varied and controlled well within a range of about 40 to about 60. The yarn is a dull luster multifilament polyamide yarn. A preferred nylon filament of the invention is delustered with a pigment such as titanium dioxide in an amount of 0.03 to 3 percent by weight.
A derived parameter characterizing the superior properties of this yarn is called the Yarn Quality and found by the product of the yarn tenacity (grams per denier) and the square root of the % elongation, as in Equation 3.
YARN QUALITY=tenacity×(elongation) 1/2 Equation 3.
The Yarn Quality is an approximation to the measure of yarn “toughness.” As is known to those skilled in the art, the area under the yarn load elongation curve is proportional to the work done to elongate the yarn. Where tenacity is expressed in terms of force per unit denier, for example, and the elongation expressed as a per cent change per unit of length, the load elongation curve is the stress-strain curve. In this case the area under the stress-strain curve is the work to extend the yarn or the yarn toughness. The yarn quality improvement provides an apparel polyamide yarn which is more acceptable in varied applications. These applications may include, without limitation, warp knit fabrics, circular knit fabrics, seamless knit garments, hosiery products and light denier technical fabrics.
Test Methods
Yarn tenacity and the yarn elongation are determined according to ASTM method D 2256-80 using an INSTRON tensile test apparatus (Instron Corp., Canton, Mass., USA 02021) and a constant cross head speed. Tenacity is expressed as grams of force per denier, the elongation percent is the increase in length of the specimen as a percentage of the original length at breaking load.
Yarn Quality derived from tenacity and elongation and is calculated according to Equation 3.
Polymer relative viscosity RV is measured using the formic acid method according to ASTM D789-86.
EXAMPLES
Example of the Invention
In an example of the invention, a yarn of 40 denier (44 dtex) and 13 filaments was prepared from a nylon 66 polymer of 51.5 RV which contained 1.5% by weight TiO 2 . This polymer was melted in an extruder and fed to a spinning machine (shown schematically in FIG. 4 .) which was used to prepare the yarn, by a process of quenching in conditioned air, converging and treating the yarn with a primary spinning oil, drawing the yarn using unheated godets, stabilizing the yarn with a heated fluid, interlacing the yarn and winding on at a speed of about 5300 meters per minute. The spinneret plate had 13 non-circular cross-sectional shape cross-sectionally shaped capillaries with 9 radially protruding “legs”, as shown in FIG. 3 b . The perimeter measure of a single capillary, represented in FIG. 3 a , was 120 micrometers. Under these spinning conditions, the jet velocity of the polymer through this capillary was 100 feet per minute (50.8 cm per second). During the course of preparing the example yarns the spinneret plate 170 on the capillary exit face 175 (in plan view by FIG. 2 a .) required wiping each 10 hours of yarn winding since at least 10% of the filaments were bent. The yarn produced had a circular cross-sectional shape. The RV, the tenacity and elongation of the wound up 40-13 yarn was measured. The RV was 52.5. The tenacity and elongation measurements were used to calculate a “yarn quality” parameter using Equation 3. The parameter is related to the yarn toughness or work needed to draw the yarn and found here to be 33.1.
Comparative Example
In a comparative example of the prior art, a yarn of 40 denier (44 dtex) and 13 filaments was prepared by treating a nylon 66 polymer (51.5 RV) was melted in an extruder and fed to a spinning machine which was used to prepare the 40-13 yarn, by a process of quenching in conditioned air, converging and treating the yarn with a primary spinning oil, drawing the yarn using unheated godets, stabilizing the yarn with a heated fluid, interlacing the yarn and winding on at a speed of about 5300 meters per minute. The spinneret plate had 13 circular cross-sectionally shaped capillaries, as shown in FIG. 3 a . The perimeter measure of a single capillary, represented in FIG. 3 a , was 22 micrometers. Under these spinning conditions, the jet velocity of the polymer through this capillary was 100 feet per minute (50.8 cm per second). During the course of preparing this circular cross-sectionally shaped yarn the spinneret plate 170 on the capillary exit face 175 required wiping each 1.5 hours of yarn winding, since at least 10% of the filaments were bent. The tenacity and elongation of the wound up 40-13 yarn was measured exactly as in the example of the invention. The measured RV was of this yarn was 52.5 RV as before. The tenacity and elongation were used to calculate a “yarn quality” parameter, which was found to be 31.5 using Equation 3.
As a result of these modifications to the perimeter measure, an increase of about 6 times, and the shape of the spinneret plate capillaries an increased productivity spinning process is realized. Most importantly, the need to interrupt the process continuity is reduced to about 2 times per 24 hour period from that of 6 or more times per 24 hour period.
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A melt extrusion spinneret plate has at least one non-circular capillary orifice for producing at least a single filament of circular cross-sectional shape. This non-circular cross-sectional shape of the extrusion capillary, when used to extrude filaments of circular cross-sectional shape, extends the spinneret wipe life by lessening the amount of thermal deposits, which extends the time between wipe cycles. As a result of increased wipe life, the productivity of the process is increased.
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BACKGROUND OF INVENTION
[0001] Polymeric thin film electro-optical (EO) modulator devices based on guest nonlinear optical (NLO) chromophores dispersed in a polymeric material are known. The devices function because the NLO chromophores exhibit a high molecular hyperpolarizabity, which when aligned into an acentric dipolar lattice by an applied poling field, increases the EO activity. The performance of such devices is limited or diminished by the randomizing of the acentric order originally imposed on the lattice due to physical events within the polymeric material. These events include polymer creep, polymer glassy behavior above glass transition state, and chromophore/polymer phase segregation and aggregation.
[0002] One approach to surmount these problems includes using a polymeric material exhibiting a relatively high glass transition state well above the operating temperature of the device. However, this strategy has been limited because the NLO chromophore has been found to exert a plasticizing effect on the polymeric material, thereby lowering the glass transition temperature of the composite material relative the undoped polymer.
[0003] A second approach employs crosslinking the polymeric material to “fix” the orientation of the poled chromophores. Difficulty in controlling the reaction conditions during device fabrication has limited this approach. To be a viable approach, the crosslinking must not occur before poling is complete. Poling is generally conducted at temperatures at or about the glass transition temperature of the polymeric material. Therefore, the crosslinking needs to occur “on demand”.
[0004] There remains a continuing need for still further improvements in the polymeric materials used to maintain the oriented NLO chromophore lattice.
BRIEF DESCRIPTION OF THE INVENTION
[0005] In one embodiment, a method for crosslinking a polymer comprises reacting i) a crosslinkable polymeric material comprising olefin groups and ii) a crosslinking agent comprising electron deficient olefin groups, at a temperature at which crosslinking occurs.
[0006] In another embodiment, a method of fabricating a crosslinked polymer comprises mixing a crosslinkable polymeric material, a crosslinking agent, and a chromophore to form a mixture; forming a film from the mixture; aligning the chromophore; and heating the mixture to effect crosslinking reactions between the crosslinkable polymeric material and crosslinking agent.
[0007] In yet another embodiment, a method for crosslinking a polymer comprises reacting i) a polycarbonate copolymer prepared from a bisphenol compound comprising two olefin groups and a 4,4′-[1-methyl-4-(1-methylethyl)-1,3-cyclohexandiyl]bisphenol and ii) 1,1′-(methylenedi-4,1-phenylene)bismalimide, 1,4-phenylene bismalimide, 1,4-di-1H-pyrrole-2,5-dione)butane, or a combination thereof, at a temperature at which crosslinking occurs.
[0008] In another embodiment, a crosslinkable composition comprises a crosslinkable polymeric material comprising olefin groups; a crosslinking agent comprising electron deficient olefin groups; and a non-linear optical chromophore.
BRIEF DESCRIPTION OF DRAWINGS
[0009] FIGS. 1 a and 1 b include an idealized thermosetting of DABPA-co-BHPM polycarbonate copolymer via Ene and Diels Alder reactions;
[0010] FIG. 2 is a graphical representation of the thermal cure of DABPA-co-BHPM polycarbonate copolymer in the presence of BMI (first heat);
[0011] FIG. 3 is a graphical representation of the thermal cure of DABPA-co-BHPM polycarbonate copolymer in the presence of BMI (second heat); and
[0012] FIG. 4 includes exemplary NLO chromophores.
DETAILED DESCRIPTION
[0013] Described herein are polymeric materials that can be crosslinked to “fix” guest NLO chromophores oriented by electric field poling prior to crosslinking of the polymeric material. The chemical crosslinking reactions subsequent to the induction of acentric order by electric field poling leads to enhanced, long term, thermal stability of the polymeric EO films used to prepare EO devices. The stability is thought to be due to the crosslinks limiting polymer creep and subsequent loss of the chromophores' defined orientation.
[0014] Also disclosed herein is a method of crosslinking polymeric materials. The crosslinked polymeric material can maintain an ordered, acentric, dipolar chromophore lattice induced by electric field poling thereby providing both temporal and thermal stability of the EO films when incorporated into EO modulator devices. It has been found that polymeric materials comprising olefin groups can undergo crosslinking under thermal conditions in the presence of an electron deficient olefin-group-containing crosslinking agent. Not wishing to be bound by theory, it is believed that the olefin groups of the crosslinkable polymeric material react with the olefin groups of the crosslinking agent via an ene addition reaction to provide crosslinks. It is further believed that the resulting ene product can undergo a Diels Alder reaction with available olefin groups of the crosslinking agent to provide additional crosslinks.
[0015] FIG. 1 a provides an idealized crosslinking reaction scheme between a polycarbonate copolymer and 1,1′-(methylenedi-4,1-phenylene)bis-maleimide (BMI). The exemplary polycarbonate copolymer (DABPA-co-BHPM PC copolymer) shown is prepared from 2,2′-diallyl Bisphenol A (DABPA) and 4,4′-[1-methyl-4-(1-methylethyl)-1,3-cyclohexandiyl]bisphenol (BHPM). As shown in FIG. 1 b, when the resulting Ene reaction product contains an olefin alpha to an aryl group, these groups are thought to further undergo a Diels Alder reaction with the remaining free olefin of the crosslinking agent resulting in a crosslinked polymeric material.
[0016] The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. All ranges disclosed herein are inclusive and combinable.
[0017] The crosslinked polymeric material can be prepared from crosslinkable polymeric material and a crosslinking agent. The crosslinkable polymeric material comprises olefin groups within or pendent from the polymer backbone, and more specifically terminal olefin groups pendent from the polymer backbone (—CH═CH 2 as opposed to —CH═CH—). More specifically, the terminal olefins groups of the polymeric material are pendant from an aromatic group as an allylaromatic. For example, polycarbonates prepared from 2,2′-diallyl Bisphenol A (DABPA) contain allylaromatics having pendent olefin groups.
[0018] The crosslinkable polymeric material can include, for example, those of the following class: polycarbonates, polyamides, polyimides, polyetherimides, polyethylene sulfones, polyether sulfones, polyethylene ethers, polyethylene ketones, polyesters, polyacrylates, polyurethanes, polyarylene ethers, copolymers thereof, and the like.
[0019] The crosslinkable polymeric material generally comprises 1 to about 50 mole percent olefin functionality, specifically about 2 to about 10 mole percent, and yet more specifically about 2 to about 6 mole percent olefin functionality.
[0020] In one embodiment, the crosslinkable polymeric material is a polycarbonate copolymer exhibiting a high glass transition temperature and good film forming qualities. The polycarbonate copolymer can be prepared from a diol comprising at least one olefin group and 4,4′-[1-methyl-4-(1-methylethyl)-1,3-cyclohexandiyl]bisphenol (also identified as 1,3-bis(hydroxyphenyl)monoterpene or BHPM). Exemplary diols comprising at least one olefin group include 2,2′-diallyl Bisphenol A (DABPA), 4-(3-allyl-4-hydroxybenzyl)-2-allylphenol, bis(3-allyl-4-hydroxyphenyl)methanone, 4-(3-allyl-4-hydroxyphenylsulfonyl)-2-allylphenol, 4-(3-allyl-4-hydroxyphenylsulfinyl)-2-allylphenol, and the like.
[0021] In an exemplary embodiment, the polycarbonate copolymer is prepared from BHPM and DABPA having a mol fraction of DABPA from about 0.01 to about 1, specifically about 0.05 to about 0.75, and more specifically about 0.1 to about 0.4.
[0022] The crosslinking agent includes electron deficient olefin compounds comprising one or more adjacent electron withdrawing groups. Suitable electron withdrawing groups include carbonyl groups such as aldehyde, carboxylic acid, ester, amide, and ketone; nitrile groups; nitro groups; and the like. The crosslinking agent can comprise two, or more electron deficient olefin groups each comprising one or more adjacent electron withdrawing groups.
[0023] An exemplary group of crosslinking agents comprising electron deficient olefins include a compound comprising at least two maleimide groups linked via the nitrogen atom to a C 1 -C 30 hydrocarbylene group. Exemplary crosslinking agents include 1,1′-(methylenedi-4,1-phenylene)bismalimide (BMI); 1,4-phenylene bismalimide; 1,4-di-1H-pyrrole-2,5-dione)butane; and the like.
[0024] As used herein, “hydrocarbyl” and “hydrocarbylene” refer to a residue that contains only carbon and hydrogen. The residue may be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It may also contain combinations of aliphatic, aromatic, straight chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbon moieties. The hydrocarbyl or hydrocarbylene residue, when so stated however, may contain heteroatoms over and above the carbon and hydrogen members of the substituent residue. Thus, when specifically noted as containing such heteroatoms, the hydrocarbyl or hydrocarbylene residue may also contain carbonyl groups, amino groups, hydroxyl groups, or the like, or it may contain heteroatoms within the backbone of the hydrocarbyl or hydrocarbylene residue.
[0025] Stoichiometric ratios of the crosslinking agent to the amount of olefin groups from the backbone of the polymeric material can be used. Other amounts include 0.5 to about 10 equivalents of crosslinking agent per olefin group of the polymeric material, specifically about 1 to about 5 equivalents, and yet more specifically about 1 to about 2 equivalents of crosslinking agent per olefin group. Suitable nonlinear optical (NLO) chromophores that can be used to form EO films include those that exhibit good chemical stability under conditions of electric field poling. Exemplary NLO chromophores include so-called high-μβ chromophores comprising and electron donor group bound to a pi electron connective system, which is in turn bound to an electron acceptor group. A suitable NLO chromophore includes LM 46M (4-((1E)-2-(5-(4-(N-ethyl-N-(2-methoxyethyl)amino)styryl)-3,4-dihexylthiophen-2-yl)vinyl)-2-(dicyanomethylene)-2,5-dihydro-5,5-dimethylfuran-3-carbonitrile).
[0026] The NLO chromophore can be selected to minimize any potential reaction between the chromophore and the crosslinkable polymeric material and/or crosslinking agent. By selecting, for example, sterically hindered chromophores, it is possible to crosslink the polymeric material without compromising the pi electron connective system of the chromophores. Such a selection can be made by one of ordinary skill in the art without undue experimentation.
[0027] The chromophore may be used in amounts of about 10 to about 35 weight percent based on the polymer, specifically about 15 to about 30 weight percent, and yet more specifically about 20 to about 25 weight percent.
[0028] Prepared solutions of crosslinkable polymeric material, crosslinking agent, chromophore, and optional solvent can be formed as thin curable films on a substrate, such as polymeric or silicon substrates. The solvent of the solution can be removed by evaporation, optionally with heating and/or vacuum to result in a crosslinkable film. The crosslinkable film can be heated to temperatures sufficiently above the Tg of the crosslinkable polymeric material so that poling can be used to induce the formation of an acentric dipolar lattice while the material is in a glassy state. Once the chromophores have been poled, the temperature is increased to induce crosslinking via Ene or Ene and Diels Alder reactions between the crosslinkable material and crosslinking agent.
[0029] The thin crosslinkable films can be formed by spin casting, dipping, spray coating, silk screening, doctor blading, ink jetting, and the like to form a thin film of the composition, more specifically spin casting. Solvents that are suitable for film forming include those that can solubilize the polymeric material, but are inert to the components of the film. Substrates on which the films are form may be of any material including, for example, polymeric or silicon substrates.
[0030] In an exemplary embodiment, the crosslinked film can be prepared by mixing a crosslinkable polymeric material comprising pendent olefin groups, a crosslinking agent, and NLO chromophore with a suitable solvent to form a mixture. The mixture is then applied to a substrate, either by spin coating, casting, dipping, etc., and then the solvent is allowed to evaporate to leave a crosslinkable film comprising the crosslinkable polymeric material, crosslinking agent, and chromophore. The crosslinkable film is heated to at or slightly above the glass transition temperature of the film and an electromagnetic field is then applied to the crosslinkable film to cause a poling of the chromophore present therein. The chromophore molecules align relative to the direction of the applied field. While maintaining the electromagnetic field, the crosslinkable film is heated to temperatures sufficient to induce crosslinking of the olefin groups of the polymeric material with the crosslinking agent by Ene and possibly even Diels Alder reactions. The crosslinking fixes the aligned chromophore molecules thereby providing a cured film having non-linear EO properties. It is believed that the crosslinking will provide an increase in the lifetime of the device after poling by maintaining the chromophore orientation longer than the corresponding non-crosslinked polymers.
[0031] The crosslinking of the crosslinkable polymeric material and crosslinking agent occurs under mild conditions at temperatures at or just above the glass transition temperature of the crosslinkable film. These temperatures are sufficient to provide cure while at the same time low enough so that decomposition of the other components of the film does not occur. Temperatures suitable to induce crosslinking can be about 150 to about 350° C., specifically about 200 to about 300° C., and more specifically about 200 to about 275° C.
[0032] The time of heating to induce crosslinking is dependent upon the crosslinkable polymeric material employed and the crosslinking agent used. Exemplary reaction times to induce crosslinking can be about 2 to about 60 minutes, specifically about 3 to about 20 minutes, more specifically about 4 to about 10 minutes, and yet more specifically about 2 to about 5 minutes.
[0033] The crosslinked films comprising oriented NLO chromophores can be used for a variety of applications, including for example, electro-optical waveguide materials, Mach Zehnder modulators, optical switches, variable optical attenuators, narrow band notch and bandpass filters, digitally tuned gratings, optical frequency mixers, and electro-optical devices including organic light-emitting diodes and photo diodes.
[0034] In another embodiment, the crosslinkable polymeric material in combination with a crosslinking agent, but without the chromophores, can find use in non-EO applications as a coating material with on-demand cure.
EXAMPLES
Examples 1-4
Synthesis of DABPA-co-BHPM PC Copolymer
[0035] DABPA-co-BHPM PC copolymers comprising varying amounts of pendent olefin groups were prepared by reacting a mixture of 1,3-bis(hydroxyphenyl)monoterpene (BHPM, internally prepared), and 2,2′-diallylbisphenol A (DABPA, n=0.1, 0.2, 0.3, and 0.4, Aldrich Chemical Co., purified prior to use) with excess phosgene, and in the presence of pyridine or triethylamine. An amount of 1.5 mol percent of 4-Cumylphenol (Aldrich Chemical Co.) was used as a chain stopper.
[0036] Alternatively, the copolymers were prepared under interfacial phosgenation conditions using methylene chloride as the solvent, aqueous sodium hydroxide as the base and (0.1-1 mol %) triethylamine as the catalyst. The processes used for the preparation of the copolymers were not optimized and exhibited a slight excess of BHPM relative to the mole fraction of DABPA, presumably due to a difference in the monomer reactivity ratios under the condensation polymerization conditions used.
[0037] Table 1 summarizes the weight average molecular weight (M w ), the number average molecular weigth (M n ), and the polydispersity index (PDI, M w /M n ) for the DABPA-co-BHPM PC copolymers obtained by gel permeation chromatography (GPC).
TABLE 1 Mol Fraction M n M n Example DABPA M w (Exp) (Theory) M w /M n 1 0.1 11664 5598 23383 2.084 2 0.2 15148 5794 23279 2.615 3 0.3 17481 7142 23175 2.448 4 0.4 28354 8677 23071 3.268
[0038] A differential scanning calorimetry (DSC) study was undertaken to evaluate the thermal cross-linking of the DABPA-co-BHPM polycarbonate copolymers of Examples 1-4 using 1,1′-(methylenedi-4,1-phenylene)bismalimide as the crosslinking agent. The DSC thermal analysis was completed using a Perkin-Elmer DSC7 differential scanning calorimeter. 1,1′-(Methylenedi-4,1-phenylene)bismalimide (BMI, Aldrich Chemical Co.) was added without further purification to each polycarbonate copolymer formulation to obtain a theoretical stoichiometry of 0.5 allyl equivalents per BMI. All sample copolymer formulations were prepared by evaporatively casting films of filtered (Whatman Uniprep™ syringeless filters, 0.45 micrometer polytetrafluoroethylene membrane) CH 2 Cl 2 solutions containing dissolved copolymer and BMI. All DSC sample measurements were referenced to an indium standard (melting point (mp) 156.60° C., ΔH r =28.45 J/g) using a dual pan configuration under a nitrogen (N 2 ) purge gas. Typical sample masses ranged from 10 to 15 milligrams (mg), and all samples were compressed into pellets sized to fit an aluminum sample pan to maximize heat flow while minimizing thermal lag in the sample. Typical cycles for the first heat and second heat are listed in Table 2 below. DSC scanning kinetics data collection and manipulation was made using the Pyris V5.00.02 software package. No attempt was made to correct the data generated by normalizing it relative to M w , M n , composition, or mass variations between sets of replicate runs.
TABLE 2 Typical DSC experimental heat flow cycles (endothermic event up) Heat Cycle Step Step Description 1 1 Hold for 2.0 min at 25.00° C. 1 2 Heat from 25.00° C. to 425.00° C. at 10.00° C./min 1 3 Cool from 425.00° C. to 25.00° C. at 10.00° C./min 2 4 Hold for 5.0 min at 25.00° C. 2 5 Heat from 25.00° C. to 425.00° C. at 10.00° C./min 2 6 Cool from 425.00° C. to 25.00° C. at 10.00° C./min
[0039] In this screening model study, the thermal cross-linking of DABPA-co-BHPM polycarbonates with BMI was probed in situ using DSC thermal analysis. As indicated in FIG. 1 a, DABPA-co-BHPM polycarbonates are thermoset at temperatures from 130-200° C. as electron deficient BMIs react via an Ene addition to the electron rich diene in the form of an ortho-allylphenyl function. The first and second that for each of the DABPA-co-BHPM/BMI formulations Examples 1-4 is shown in FIGS. 2 and 3 , respectively. The T g for the undoped and uncured polycarbonate copolymers is summarized in Table 3.
TABLE 3 Example Polymer Tg (° C.) Control BHPM 250 Example 1 DABPA-co-BHPM (n = 0.1 215 DABPA) Example 2 DABPA-co-BHPM (n = 0.2 185 DABPA) Example 3 DABPA-co-BHPM (n = 0.3 172 DABPA) Example 4 DABPA-co-BHPM (n = 0.4 159 DABPA)
[0040] An interpretation of the results for the 1 st and 2 nd heat of the DABPA-co-BHPM PC copolymer formulations is as follows. In FIG. 2 , heat flow is seen to increase as the temperature is ramped, consistent with an upward slope of the heating curve. At T=156° C., the unreacted BMI dispersed within cast films of the DABPA-co-BHPM PC copolymer formulations is undergoing an endothermic phase transition as the solid BMI melts. The integrated area under each curve increases roughly in proportion to the concentration of the solid BMI dispersed within the polycarbonate copolymer formulation, that is, the concentration of dispersed BMI increases from heating curve 1 to 4 (n=0.1-0.4 DABPA, respectively). This transition is reproducible between the different polycarbonate compositions, occurring at the reported melting point for 1,1′-(methylenedi-4,1-phenylene)bismaleimide (mp=156-158° C.), and this in turn is consistent with a discrete, low molecular weight component dispersed within the copolymer matrix.
[0041] After the BMI has melted, heating continues until the onset of curing at approximately 185° C., as suggested by a broad, shallow exothermic event evident in all of the heating curves. This interpretation is consistent with several additional observations. First, the T g associated with any of the unreacted polycarbonate copolymers (Table 3) were not observed. Secondly, there is no hysteresis observed in the heating curve for the 2 nd heat ( FIG. 3 ), that is, neither an endothermic event associated with the melting of BMI or an exothermic event associated with thermal curing are observed in the 2 nd heat. Indeed, it should also be readily apparent that there are no observable transitions associated with unreacted DABPA-co-BHPM PC copolymers, e.g., T g (Table 3). This result implies that a thermal cross-linking event has occurred, resulting in a cross-linked network. The results further suggest BMI acts as a cross-linking agent to form a polymer network that is distinct from the original starting materials used to form the network. The resultant polymer network does not exhibit any detectable T g under the thermal treatment describe using DSC methods.
Example 5
T g of Doped DABPA-co-BHPM PC
[0042] Samples of DABPA-co-BHPM PC containing varying amounts of DABPA were doped with chromophore LM 46M at 25 weight percent loadings and measured for Tg. A distinct trend in the reduction of the glass transition temperature was observed with the incorporation of the chromophore.
TABLE 4 Example 5 Tg (° C.) of copolymer doped with (Mole fraction of DABPA) 25 wt. % chromophore 0.1 133 0.2 122 0.3 110 0.4 100
[0043] While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled 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, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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Crosslinkable polymeric materials are disclosed useful for the temporal stabilization of a poling-induced noncentrosymmetric host lattice containing guest nonlinear optical chromophores. The materials are also suitable as crosslinkable coatings in the absence of chromophores. Also disclosed is a method of crosslinking such polymeric material.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 11/622,574, filed Jan. 12, 2007, which is a division of U.S. Pat. No. 7,179,691, issued Feb. 20, 2007, and entitled “A NOVEL METHOD FOR FOUR DIRECTION LOW CAPACITANCE ESD PROTECTION”.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the structure and manufacturing process of a FET semiconductor device for ESD protection of electronic circuit devices and more particularly to a structure with a guard ring for low capacitance input ESD protection.
2. Description of Prior Art
Because of high input impedance and thin oxide gate structures, the problem of electrostatic discharge damage (ESD) with field effect transistor (FET) devices can be severe. Therefore the input/output (I/O) circuit locations or pads usually have a protective device connected between the I/O pad and the internal circuits which allows the ESD current to be shunted to an alternative voltage source, typically ground, protecting the active internal circuits from damage.
There can be several different types of device structures used for these protective devices, such as single diodes, stacked diodes, field effect transistor (FET) devices, and silicon controlled rectifiers (SCR).
With prior art devices, the capacitance associated with the ESD protection device on the active circuit input pad could be a concern as circuit speeds increase. A typical prior art protection circuit scheme is represented in FIG. 1A . The active circuit input-output (I/O) terminal or pad 10 is connected to the ESD protection circuit devices ESD- 1 element 12 with associated parasitic capacitance C 12 and parasitic diode D 12 , and protection device ESD- 2 element 14 with associated parasitic capacitance C 14 and parasitic diode D 14 . The I/O pad 10 is also connected to the input or output stage of the active logic circuits A. Also shown in FIG. 1 is the protection devices ESD-Vcc element 16 with associated parasitic capacitance 16 and parasitic diode D 16 that protects against high ESD voltages occurring on the circuit power lines Vcc and Vss.
A positive ESD voltage at the input pad 10 would turn on diode D 14 and ESD- 1 12 providing a suitable discharge path for the ESD energy. For a negative ESD event on the I/O pad 10 , diode D 12 is placed into a conducting mode, as is ESD-Vcc 16 , again providing a suitable discharge path for the ESD energy.
Typical prior art protection devices are shown in schematic form in FIG. 1B . Protection device ESD- 1 is shown as a N channel metal oxide semiconductor (NMOS) 12 , and ESD protection device ESD- 2 is shown as a P channel MOS (PMOS) 14 . The ESD-Vcc protection device is shown as a NMOS device 16 . FIG. 1C shows a representative cross-section of the ESD protection circuit devices. NFET 12 has its source 12 S connected to its gate 12 G and to the Substrate 20 P+ contact 22 and to a second voltage source Vss, typically ground. The NMOS 12 drain D 12 is connected to the ESD- 2 PMOS protection device 14 drain 14 D. The gate 14 G of ESD- 2 PMOS protection device 14 is connected to its source element 14 S and to the source 16 S of ESD-VCC NMOS protection device 16 and subsequently to a first voltage source Vcc.
Although the prior art circuit shown in FIG. 1B provides ESD protection for the active devices, the stray or parasitic capacitance C 12 and C 13 impose undesired capacitive loading to the I/O pad and logic circuit input stage A.
The invention provides a unique structure and method to eliminate some of this capacitance on the I/O pad while still providing appropriate ESD protection.
The following patents and reports pertain to ESD protection.
U.S. Pat. No. 6,097,066 (Lee et al.) shows an ESD structure with a third ring shape serving as a guard ring.
U.S. Pat. No. 5,714,784 (Ker et al.) reveals an ESD structure with guard rings.
U.S. Pat. No. 5,637,900 (Ker et al.) shows an ESD structure with P+ guard rings.
U.S. Pat. No. 6,249,413 (Duvvury) and U.S. Pat. No. 5,905,287 (Hirata) show related ESD structures and guard rings.
SUMMARY OF THE INVENTION
Accordingly, it is the primary objective of the invention to provide an effective and manufacturable method and structure for reducing the capacitance of the protective device providing resistance to the potential damage caused by the phenomenon known as electrostatic discharge (ESD) by utilizing a low capacitance ESD protection device connected to an input pad of an integrated circuit device.
It is a further objective of the invention to improve ESD protection for high frequency applications by providing a low input capacitance structure that will have minimum impact on device performance while maintaining reasonable ESD protection levels.
A still additional objective of the invention is to provide the ESD protection with reduced capacitance without changing the characteristics of the internal circuits being protected and by using a process compatible with the process of integrated MOS device manufacturing.
The above objectives are achieved in accordance with the methods of the invention that describes a structure and a manufacturing process for semiconductor ESD protection devices with reduced input capacitance. One embodiment of the invention utilizes a NMOS FET structure with associated junction diode and parasitic NPN bipolar transistor for ESD protection for both positive and negative ESD voltages occurring on the active circuit input pad. There is a heavily doped P+ guard ring that protects the NMOS device from exhibiting latchup characteristics. The guard ring also enhances the junction diode characteristics improving ESD protection for negative ESD voltages on the input pad. A heavily doped N+ guard ring surrounding the NMOS device including the P+ guard ring enhances the Vcc to Vss ESD protection diode characteristics, and eliminates the need for an additional device, often referred to as ESD 2 , to protect against this mode of ESD occurrence, which would normally be attached from the input pad to Vcc. This design structure eliminates the capacitance associated with the prior art devices that have a second ESD protection device from the input pad to Vcc.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a simplified schematic of prior art ESD protection scheme.
FIG. 1B shows a detailed schematic for typical prior art device configuration for ESD protection.
FIG. 1C shows a typical vertical cross section for prior art ESD protection scheme.
FIG. 2A is a simplified schematic representation of the principle elements of the invention ESD protection device.
FIG. 2B is a schematic for one embodiment of the invention ESD protection scheme.
FIG. 3 is a top view representation of the horizontal topography of one embodiment of the invention.
FIG. 4 is a vertical cross section of one embodiment of the invention.
FIG. 5 is a vertical cross section of a second embodiment of the invention.
FIG. 6 is a flow chart of the process for the device protection circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2A shows a simplified representation of the principle advantage of the invention. As shown in FIG. 2A , the input pad 10 is protected from ESD incidents by the protection devices ESD- 1 element 12 . The invention embodiment details are sufficient to protect the input circuit from both positive and negative ESD voltage events. In addition, the embodiment of the invention also protects against positive and negative ESD voltages that may occur on the Vcc and or on the Vss power bus.
FIG. 2B shows typical device schematic devices for a NMOS device 12 used for the protective devices ESD- 1 . The NMOS 12 drain 12 D is connected to the input pad 10 , and the source 12 S and gate 12 G are connected to a second voltage source Vss, typically ground. Shown electrically in parallel with ESD- 1 NMOS device 12 are the parasitic elements diode D 12 and capacitor C 12 connected between the input pad 10 and the second voltage source, Vss. Also shown in FIG. 2B is the bipolar NPN parasitic transistor TX 12 with emitter connected to the second voltage source, Vss, the base connected to the second voltage source Vss through a parasitic resistor R 12 , and the collector connected to the input pad 10 . As noted, the active logic circuit input stage entry point is designated by the element A.
Protection device ESD-Vcc 16 is shown as NMOS 16 with drain 16 D connected to a first voltage source, Vcc, and source 16 S and gate 16 G connected to a second voltage source Vss, typically ground. ESD-Vcc device 16 also has parasitic capacitance C 16 and diode D 16 with cathode connected to the first voltage source Vcc and anode connected to the second voltage source Vss. The capacitance C 16 is normally not a degrading factor to circuit performance as it is connected between the power buses. Also shown I the parasitic NPN bipolar transistor TX 16 electrically in parallel with NMOS 16 . As shown, the TX 16 collector is connected to the first voltage source Vcc, the emitter connected to the second voltage source Vss, and the base connected to the second voltage source Vss through the parasitic resistor R 16 .
During a positive ESD event at the input pad 10 , TX 12 collector base junction goes into breakdown turning on TX 12 providing a discharge path to Vss. A negative ED event on the input pad 10 is conducted through diode D 12 to Vss. If sufficient energy is presented to pull down Vss below normal ground level, TX 16 will turn on providing an additional energy discharge path.
FIG. 3 shows the horizontal topography for the embodiment of the invention. Surrounding the ESD protection device ESD- 1 12 is a P+ guard ring 30 , which is connected to the second voltage source, Vss, typically ground. This forms the anode of the diode D 12 , the cathode of which I s connected to the input pad 10 and is a key element for the discharging of negative ESD events with respect to Vss. Another P+ guard ring 34 surrounds the ESD protection device ESD- 1 16 , which is also connected to the second voltage source, Vss, typically ground. A unique concept of the invention is an N+ doped guard ring 32 that surrounds the P+ guard ring 30 . This N+ guard ring 32 forms the anode of diode D 16 that is instrumental in providing a discharge path for positive ESD events with respect to Vcc.
FIG. 4 shows a typical cross section of the embodiment of the invention. ESD- 1 which consists of the NFET element 12 with associated parasitic elements, is created upon a P doped substrate 20 with a crystal orientation of <100> and typically doped with an acceptor element such as Boron to a density of between 5E14 and 1E15 atoms per cubic centimeter (a/cm 3 ). After suitable patterning with photoresist (PR), a plurality of N+ and P+regions are created within the substrate. As shown in FIG. 4 , two of the N+regions straddle the gate element 12 G of the NMOS FET device 12 and form the source 12 S and drain 12 D which together with the gate element 12 G form the NMOS device 12 . The N+diffusion regions have a typical donor dopant density of between 1E20 and 1E21 a/cm 3 . The P+guard ring 30 surrounds NMOS device 12 and is doped with an acceptor dopant to between 1E20 and 1E21 a/cm 3 . Completing the device structure is the N+ guard ring 32 doped with a donor element to between 1E20 and 1E21a/cm 3 . As shown in FIG. 4 , the P+ guard ring 30 , NMOS source 12 S, and NMOS 23 gate 12 G are connected to the second voltage source Vss, typically ground. The NMOS drain 12 D is connected to the input logic line 10 . The P+ guard ring 32 is connected to the first voltage source, Vcc. Field oxide (FOX) 18 is used to provide isolation between ESD- 1 device 12 and ESD-Vcc device 16 .
Another embodiment of the invention is shown in FIG. 5 . In this embodiment, a SCR device 38 implements the ESD- 1 protection element. An N-well 36 is implanted within the P substrate 20 with a donor element, typically phosphorus, to produce a doping density of between 1E16 and 1E 18a/cm 3 . Within the N-well 36 are doped regions N+ 40 and P+ 42 that through their electrical contact systems are connected to the logic circuit input line 10 . The P+ region 42 forms the anode of a PNPN SCR device which operating method is derived from a vertical PNP bipolar parasitic transistor TX 38 - 1 and a lateral parasitic NPN bipolar transistor TX 38 - 2 as is understood in the art.
As indicated in FIG. 5 , the P+ region 42 forms the emitter of TX 38 - 1 , the base is formed by the N-well 36 and connected back to the input pad through the N-well 36 and the N+ diffused region 40 . The resistor R 38 - 1 is the inherent sheet resistance in the N-well 36 . The collector of TX 38 - 1 is formed by the substrate 20 and connected through the inherent sheet resistor R 38 - 2 to the P+ guard ring 30 and consequently to a second voltage source typically ground. The N-well 36 forms the collector of the lateral parasitic transistor TX 38 - 2 to the P+ guard ring and subsequently to the second voltage source Vss typically ground. The emitter of TX 38 - 2 is formed by the N+ region 44 , which is electrically connected to the second voltage source Vss, or ground.
The P+ guard ring 30 surrounding the device also serves as substrate contact region, and as previously mentioned, is connected tot he second voltage source, typically ground. The invention embodiment of the N+ guard ring 32 shown in FIG. 5 is connected tot he first voltage source, Vcc. The diode D 16 is formed as before between the P+ guard ring 30 and N+ guard ring 32 as well as the ESD-Vcc device P+ guard ring 34 and N+ drain 16 S. Diode D 12 is formed by the P+ guard ring 30 and the N-well 36 and its associated N+ contact region 40 .
As indicated in FIG. 5 , the ESD protection device ESD-Vcc 16 , is again embodied as an NMOS Fet 16 . The drain 16 D, gate 16 G and P+ guard ring 34 associated with e NMOS device 16 are connected to the second voltage source, Vss, typically ground. The NMOS FET 16 source 16 S is connected to the first voltage source, Vcc.
Isolation for the devices is provided by shallow trench isolation elements 28 . Diode D 12 is formed between the P+ guard ring 30 and ESD- 1 device N-well 36 N+ contact 40 . The diode D 12 provides a discharge path for negative ESD events on the input pad 10 relative to Vss. A positive ESD event relatives to Vss will be discharges through ESD- 1 SCR 38 as before. A positive ESD event occurring on the input pad will cause the collector base junction of TX- 38 - 2 to conduct providing positive feedback to turn on TX 38 - 1 until the ESD event expires.
Diode D 16 is formed between the SCR device 38 N+ guard ring 32 and the P+ guard ring 30 as well as the ESD-Vcc P+ guard ring 34 and NFET 16 source 16 S and drain 16 D. A positive ESD event relative to Vcc will turn on ESD- 1 SCR 38 as described above, and consequently by discharged through diode D 16 to Vcc. A negative ESD event with respect to Vcc will be discharged through diode D 12 and the ESD-Vcc NMOS device 16 to Vcc.
FIG. 6 outlines a process for constructing the devices of the invention for the embodiment whereby ESD- 1 is a NMOS FET associated parasitic elements and ESD-Vcc is also a NMOS FET device with its associated parasitic elements. As indicated by element 60 in FIG. 6 , isolation structures are created within a P doped substrate. The isolation elements can be either thick field oxide, or shallow trench isolation (STI) structures filled with a dielectric such as SiO 2 . The isolation elements are utilized to define the active device logic area.
First and second gate elements are created from patterning gate oxide and polysilicon layers on the substrate surface as indicated in element 62 . FIG. 6 element 64 shows that N+ regions are created after appropriate patterning with well-known methods such as optical masks and photoresist to create source and drain regions that together the gate elements form first and second NMOS ESD protection devices corresponding to ESD- 1 and ESD_Vcc. Concurrently with the creation of the N+ source/drain regions, a N+ guard ring is created surrounding the first NFET as indicated in element 66 , allowing sufficient room for a P+ guard ring to be inserted between the N+ guard ring and the device itself.
The P+ guard rings are created immediately surrounding the first and second NMOS devices, respectively, as indicated in element 68 . These P+ guard rings provide the anode side of the diodes associated with ESD- 1 and ESD-Vcc. The N+ guard ring forms the cathode of the diode that shunts negative ESD voltages appearing on Vcc to ground.
Creating a metallurgical electrical conduction system allows the elements to be appropriately connected to the respective circuit nodes. Connecting the drain of the first NMOS ESD-! Protection device to the input-output pad while connecting the source and gate elements as well as the P+ guard rings to a second voltage source Vss, typically ground, initiates the I/O ESD protection circuit. Connecting the drain of the second NMOS ESD-Vcc protection device as well as the N+ guard ring to the first voltage source Vcc, completes the ESD protection circuit. Device processing is continued using conventional techniques such as utilizing a surface passivation layer to provide protection. The surface passivation layer is comprised of borosilicate glass or boron phosphosilicate glass. Processing is continued to completion.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention.
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The invention describes a structure and a process for providing ESD semiconductor protection with reduced input capacitance. The structure consists of heavily doped P+ guard rings surrounding the I/O ESD protection device and the Vcc to Bss protection device. In addition, there is a heavily doped N+ guard ring surrounding the I/O protection device its P+ guard ring. The guard rings enhance structure diode elements providing enhanced ESD energy discharge path capability enabling the elimination of a specific conventional Vss to I/O pad ESD protection device. This reduces the capacitance seen by the I/O circuit while still providing adequate ESD protection for the active circuit devices.
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This application is the National Stage of International Application No. PCT/FI2006/050083, International Filing Date, 28 Feb. 2006, which designated the United States of America.
FIELD OF THE INVENTION
This invention relates to a field of assisted navigation systems and more specifically to a format, in which information relating to the health of the satellites is distributed from a communications network to terminals. The invention also relates to a device comprising a positioning receiver for performing positioning on the basis of one or more signals of a satellite navigation system. The invention also relates to a network element comprising a transmitter for transmitting assistance data of a satellite navigation system to a receiver. The invention further relates to methods for delivering assistance data of a satellite navigation system to a device and method for using the assistance data in the positioning of the device. The invention still relates to a module, computer program product, a signal, a carrier having a signal recorded thereon and an assistance data server.
BACKGROUND OF THE INVENTION
One known navigation system is the GPS system (Global Positioning System) which presently comprises more than 20 satellites, of which, usually, a half of them are simultaneously within the sight of a receiver. These satellites transmit e.g. Ephemeris data of the satellite, as well as data on the time of the satellite. A receiver used in positioning normally deduces its position by calculating the propagation time of a signal received simultaneously from several satellites belonging to the positioning system to the receiver and calculates the time of transmission (ToT) of the signals. For the positioning, the receiver must typically receive the signal of at least four satellites within sight to compute the position. The other already launched navigation system is the Russian-based GLONASS.
In the future, there will also exist other satellite based navigation systems than GPS and GLONASS. In the Europe the Galileo system is under construction and will be launched within a few years. Space Based Augmentation Systems SBAS (WAAS, EGNOS, GAGAN) are also being ramped up. Local Area Augmentation Systems LAAS, which uses fixed navigation stations on the ground, are becoming more common. Strictly speaking, the Local Area Augmentation Systems are not actually satellite based navigation systems although the navigation stations are called as “pseudo satellites” or “pseudolites”. The navigation principles applicable with the satellite based systems are also applicable with the Local Area Augmentation Systems. Pseudolite signals can be received with a standard GNSS receiver. Moreover, Japanese are developing their own GPS complementing system called Quasi-Zenith Satellite System QZSS.
The satellite based navigation systems, including systems using pseudo satellites, can collectively be called as Global Navigation Satellite Systems (GNSS). In the future there will probably be positioning receivers which can perform positioning operations using, either simultaneously or alternatively, more than one navigation system. Such hybrid receivers can switch from a first system to a second system if e.g. signal strengths of the first system fall below a certain limit, or if there are not enough visible satellites of the first system, or if the constellation of the visible satellites of the first system is not appropriate for positioning. Simultaneous use of different system comes into question in challenging conditions, such as urban areas, where there is limited number of satellites in view. In such cases, navigation based on only one system is practically impossible due to the low availability of signals. However, hybrid use of different navigation systems enables navigation in these difficult signal conditions.
Each satellite of the GPS system transmits a ranging signal at a carrier frequency of 1575.42 MHz called L1. This frequency is also indicated with 154f 0 , where f 0 32 10.23 MHz. Furthermore, the satellites transmit another ranging signal at a carrier frequency of 1227.6 MHz called L2, i.e. 120f 0 . In the satellite, the modulation of these signals is performed with at least one pseudo random sequence. This pseudo random sequence is different for each satellite. As a result of the modulation, a code-modulated wideband signal is generated. The modulation technique used makes it possible in the receiver to distinguish between the signals transmitted from different satellites, although the carrier frequencies used in the transmission are substantially the same. Doppler effect results in a small (±5 kHz) change in the carrier frequency depending upon the constellation geometry. This modulation technique is called code division multiple access (CDMA). In each satellite, for modulating the L1 signal, the pseudo sequence used is e.g. a so-called C/A code (Coarse/Acquisition code), which is a code from the family of the Gold codes. Each GPS satellite transmits a signal by using an individual C/A code. The codes are formed as a modulo-2 sum of two 1023-bit binary sequences. The first binary sequence G 1 is formed with a polynomial X 10 +X 3 +1, and the second binary sequence G 2 is formed by delaying the polynomial X 10 +X 9 +X 8 +X 6 +X 3 +X 2 +1 in such a way that the delay is different for each satellite. This arrangement makes it possible to produce different C/A codes with an identical code generator. The C/A codes are thus binary codes whose chipping rate in the GPS system is 1.023 MHz. The C/A code comprises 1023 chips, wherein the code epoch is 1 ms. The L1 carrier signal is further modulated with navigation information at a bit rate of 50 bit/s. The navigation information comprises information about the health of the satellite, its orbit, clock behaviour, etc.
In the GPS system, satellites transmit navigation messages including Ephemeris data and time data, which are used in the positioning receiver to determine the position of the satellite at a given instant. These Ephemeris data and time data are transmitted in frames which are further divided into subframes. FIG. 6 shows an example of such a frame structure FR. In the GPS system, each frame comprises 1500 bits which are divided into five subframes of 300 bits each. Since the transmission of one bit takes 20 ms, the transmission of each subframe thus takes 6 s, and the whole frame is transmitted in 30 seconds. The subframes are numbered from 1 to 5. In each subframe 1 , e.g. time data is transmitted, indicating the moment of transmission of the subframe as well as information about the deviation of the satellite clock with respect to the time in the GPS system.
The subframes 2 and 3 are used for the transmission of Ephemeris data. The subframe 4 contains other system information, such as universal time, coordinated (UTC). The subframe 5 is intended for the transmission of almanac data on all the satellites. The entity of these subframes and frames is called a GPS navigation message which comprises 25 frames, or 125 subframes. The length of the navigation message is thus 12 min 30 s.
In the GPS system, time is measured in seconds from the beginning of a week. In the GPS system, the moment of beginning of a week is midnight between a Saturday and a Sunday. Each subframe to be transmitted contains information on the moment of the GPS week when the subframe was transmitted. Thus, the time data indicates the moment of transmission of a certain bit, i.e. in the GPS system, the moment of transmission of the last bit in the subframe. In the satellites, time is measured with high-precision atomic chronometers. In spite of this, the operation of each satellite is controlled in a control centre for the GPS system (not shown), and e.g. a time comparison is performed to detect chronometric errors in the satellites and to transmit this information to the satellite.
During their operation, the satellites monitor the condition of their equipment. The satellites may use for example so-called watch-dog operations to detect and report possible faults in the equipment. The errors and malfunctions can be instantaneous or longer lasting. On the basis of the health data, some of the faults can possibly be compensated for, or the information transmitted by a malfunctioning satellite can be totally disregarded. The malfunctioning satellite sets a flag in a satellite health field of a navigation message indicative of a failure of the satellite. It is also possible that a Control Segment of a Satellite Navigation System detects abnormalities in the operation of a satellite or in signals of a satellite. Hence, the Control Segment can also set a non-healthy indication for such a satellite. This indication can also be set when a satellite is tested or during a possible correction operation of the orbit of the satellite.
It is also possible to detect abnormalities in the operation of a satellite by examining signals transmitted by a satellite. For example, an observing station may perform measurements of residuals of a pseudorange and if the residual deviates from a computational residual more than a predetermined threshold, the observing station determines that the satellite is not operating properly. Another option is to compare the accuracy of the ephemeris data transmitted by a satellite to a reference data.
The number of satellites, the orbital parameters of the satellites, the structure of the navigation messages, etc. may be different in different navigation systems. Therefore, the operating parameters of a GPS based positioning receiver may not be applicable in a positioning receiver of another satellite system. On the other hand, at least the design principles of the Galileo has indicated that there will be some similarities between GPS and Galileo in such a way that at least Galileo receiver should be able to utilize GPS satellite signals in positioning.
Positioning devices (or positioning receivers) i.e. devices which have the ability to perform positioning on the basis of signals transmitted in a navigation system can not always receive strong enough signals from the required number of satellites. For example, it may occur that when a three-dimensional positioning should be performed by the device, it can not receive signals from four satellites. This may happen indoors, in urban environments, etc. Methods and systems have been developed for communications networks to enable position in adverse signal conditions. If the communications network only provides navigation model assistance to the receiver, the requirement for a minimum of three signals in two-dimensional positioning or four signals in three-dimensional positioning does not diminish. However, if the network provides, for instance, barometric assistance, which can be used for altitude determination, then three satellites is enough for three-dimensional positioning assuming the positioning receiver has access to barometric measurements (e.g. from an integrated barometer). These so called assisted navigation systems utilise other communication systems to transmit information relating to satellites to the positioning devices. Respectively, such positioning devices which have the ability to receive and utilize the assistance data can be called as assisted GNSS receivers, or more generally, assisted positioning devices.
Currently, only assistance data relating to GPS satellites can be provided to assisted GNSS receivers in CDMA (Code Division Multiple Access), GSM (Global System for Mobile communications) and W-CDMA (Wideband Code Division Multiple Access) networks. This assistance data format closely follows the GPS navigation model specified in the GPS-ICD-200 SIS (SIS, Signal-In-Space) specification. This navigation model includes a clock model and an orbit model. To be more precise, the clock model is used to relate the satellite time to the system time, in this case the GPS time. The orbit model is used to calculate the satellite position at a given instant. Both data are essential in satellite navigation.
The availability of the assistance data can greatly affect the positioning receiver performance. In the GPS system, it takes at least 18 seconds (the length of the first three subframes) in good signal conditions for a GPS receiver to extract a copy of the navigation message from the signal broadcasted by a GPS satellite. Therefore, if no valid copy (e.g. from a previous session) of a navigation model is available, it takes at least 18 second before the GPS satellite can be used in position calculation. Now, in AGPS receivers (Assisted GPS) a cellular network such as GSM or UMTS (Universal Mobile Telecommunications System) sends to the receiver a copy of the navigation message and, hence, the receiver does not need to extract the data from the satellite broadcast, but can obtain it directly from the cellular network. The time to first fix (TTFF) can be reduced to less than 18 seconds. This reduction in the time to first fix may be crucial in, for instance, when positioning an emergency call. This also improves user experience in various use cases, for example when the user is requesting information of services available nearby the user's current location. These kind of Location Based Services (LBS) utilize in the request the determined location of the user. Therefore, delays in the determination of the location can delay the response(s) from the LBS to the user.
Moreover, in adverse signal conditions the utilization of the assisted data may be the only option for navigation. This is because a drop in the signal power level may make it impossible for the GNSS receiver to obtain a copy of the navigation message. However, when the navigation data is provided to the receiver from an external source (such as a cellular network), navigation is enabled again. This feature can be important in indoor conditions as well as in urban areas, where signal levels may significantly vary due to buildings and other obstacles, which attenuate satellite signals.
When a mobile terminal having an assisted positioning receiver requests for assistance data, the network sends the mobile terminal one navigation model for each satellite in the view of the assisted positioning receiver. The format in which the assistance data is sent is specified in various standards. Control Plane solutions include RRLP (Radio Resource Location Services Protocol) in GSM, RRC (Radio Resource Control) in W-CDMA and IS-801.1/IS-801.A in CDMA. Broadcast assistance data information elements are defined in the standard TS 44.035 for GSM. Finally, there are User Plane solutions OMA SUPL 1.0 and various proprietary solutions for CDMA networks. The common factor for all these solutions is that they only support GPS. However, due to the ramp up of Galileo, all the standards shall be modified in the near future in order to achieve Galileo compatibility.
The international patent application publication WO 02/67462 discloses GPS assistance data messages in cellular communications networks and methods for transmitting GPS assistance data in cellular networks.
The navigation systems index the satellites to express the satellite the information relates to. This is called as satellite indexing. The satellite index is used to identify the navigation model with a specific satellite. Every navigation system has its own indexing method.
GPS indexes satellites (SV, Space Vehicle) based on PRN (PseudoRandom Noise) numbers. The PRN number can be identified with the CDMA spread code used by the satellites.
Galileo uses a 7-bit field (1-128) to identify the satellite. The number can be identified with the PRN code used by the satellite.
GLONASS uses a 5-bit field to characterize satellites. The number can be identified with the satellite position in the orbital planes (this position is called a “slot”). Moreover, in contrast to other systems, GLONASS uses FDMA (Frequency Division Multiple Access) to spread satellite broadcasts in spectrum. It is noted here that there is also a CDMA spread code in use in the GLONASS. There is, therefore, a table that maps the satellite slot number to the broadcast frequency. This map must be included in any assistance data format.
SBAS systems use PRN numbers similar to GPS, but they have an offset of 120. Therefore, the first satellite of the SBAS system has a satellite number of 120.
Since QZSS SIS ICD is not public yet, there is no detailed information on the satellite indexing in the system. However, since the system is a GPS augmentation, the GPS compatible format should at high probability be compatible with QZSS as well.
Pseudolites (LAAS) are the most problematic in the indexing sense. There is no standard defined for indexing pseudolites currently. However, the indexing should at least loosely follow the GPS-type indexing, since they use GPS-type PRNs. Therefore, by ensuring that the range of satellite indices is sufficient, it should be possible to describe LAAS transmitters with GPS-type satellite indexing.
In addition to these requirements (indexing, clock model and orbit model), the navigation model must include information on model reference time (t REFERENCE in the clock model, similar time stamp is required for the orbit model), model validity period, issue of data (in order to be able differentiate between model data sets), SV health (indicates whether navigation data from the SV is usable or not).
The current satellite health field requires modification, since in the future GPS (and other systems) do not transmit only one signal, but various signals at different frequencies. Then, it is possible that one of these signals is unusable, but others are fine. Then, the satellite health must be able to indicate this mode of malfunction. Current solution in GPS is only able to express malfunction is some signal (without specifying which one). The problem was previously solved only by saying that the whole satellite is broken and not just some specific signal.
SUMMARY OF THE INVENTION
The current invention is that instead of specifying that some particular satellite is broken, a list of specific broken signals that the particular satellite transmits is provided. If the whole satellite is broken, then there is a special value for marking any signal broken for that particular satellite. The approach can be used at least with GPS, Galileo, GLONASS, SBAS, LAAS and QZSS. There are also reservations for yet unknown future systems.
According to a first aspect of the present invention there is provided a device comprising
a positioning receiver for performing positioning on the basis of one or more signals transmitted by reference stations of at least one satellite navigation system; a receiver for receiving assistance data relating to at least one navigation system; and an examining element adapted to examine the received assistance data;
characterised in that said examining element adapted to examine the assistance data to find out information relating to the status of said one or more signals of the reference stations of the navigation system, said information relating to the status of said one or more signals of the reference stations comprising indication on the reference station the signal relates to, and said status indicating the usability of the signal, wherein the device is adapted not to use in the positioning such a signal which is indicated not to be usable.
According to a second aspect of the present invention there is provided a network element comprising
a controlling element for forming assistance data relating to one or more reference stations of at least one navigation system; and a transmitting element for transmitting assistance data to a communications network;
characterised in that the network element further comprises
an examining element adapted to examine the status of said one or more signals of the reference stations of the navigation system to determine the usability of the signal in a positioning of a device;
wherein the controlling element is adapted to
insert, for each signal the examining element determined not to be usable in a positioning of the device, an indication on the non-usability of the signal, said indication comprising information on the signal and on the reference station the signal relates to into the assistance data.
According to a third aspect of the present invention there is provided a system comprising:
network element which comprises
a controlling element for forming assistance data relating to one or more reference stations of at least one navigation system; and a transmitting element for transmitting assistance data to a communications network;
a device which comprises
a positioning receiver for performing positioning on the basis of one or more signals transmitted by reference stations of said at least one satellite navigation system; a receiver for receiving said assistance data from the communications network; and an examining element adapted to examine the received assistance data;
characterised in that the network element of the system further comprises
an examining element adapted to examine the received navigation data to find out information relating to the status of said one or more signals of the reference stations of the navigation system, said information relating to the status of said one or more signals of the reference stations comprising indication on the reference station the signal relates to, and said status indicating the usability of the signal;
wherein the controlling element is adapted to
insert, for each signal the examining element determined not to be usable in a positioning of a device, an indication on the non-usability of the signal, said indication comprising information on the signal and on the reference station the signal relates to into the assistance data;
and that said examining element of the device is adapted to examine the assistance data to find out information relating to the status of said one or more signals of the reference stations of the navigation system, said information relating to the status of said one or more signals of the reference stations comprising indication on the reference station the signal relates to, and said status indicating the usability of the signal, wherein the device is adapted not to use in the positioning such a signal which is indicated not to be usable.
According to a fourth aspect of the present invention there is provided a module for a device, the device comprising
a positioning receiver for performing positioning on the basis of one or more signals transmitted by reference stations of at least one satellite navigation system; and a receiver for receiving assistance data from a communications network;
wherein the module comprises an examining element adapted to examine the received assistance data;
characterised in that said examining element is adapted to examine the assistance data to find out information relating to the status of said one or more signals of the reference stations of the navigation system, said information relating to the status of said one or more signals of the reference stations comprising indication on the reference station the signal relates to, and said status indicating the usability of the signal, wherein the module further comprises an output to transfer to the positioning receiver an indication on such a signal which is indicated not to be usable.
According to a fifth aspect of the present invention there is provided a method for transmitting assistance data to a device, the method comprising:
forming assistance data relating to one or more reference stations of at least one navigation system; and transferring the assistance data to the device;
characterised in that the method further comprises
examining the status of said one or more signals of the reference stations of the navigation system to determine the usability of the signal in a positioning of a device; and inserting, for each signal the examining indicated not to be usable in a positioning of the device, an indication on the non-usability of the signal, said indication comprising information on the signal and on the reference station the signal relates to into the assistance data.
According to a sixth aspect of the present invention there is provided a method for using assistance data in a positioning of a device, the method comprising:
receiving assistance data relating to one or more reference stations of at least one navigation system;
characterised in that the method further comprises
examining the received assistance data to find out information relating to the status of said one or more signals of the reference stations of the navigation system, said information relating to the status of said one or more signals of the reference stations comprising indication on the reference station the signal relates to, and said status indicating the usability of the signal; and
leaving out such a signal, which is indicated not to be usable, from signals to be used in a positioning of the device.
According to a seventh aspect of the present invention there is provided a computer program product for storing computer program having computer executable instructions for
forming assistance data relating to one or more reference stations of at least one navigation system; and transferring the assistance data to a device;
characterised in that the computer program further comprises computer executable instructions for
examining the status of said one or more signals of the reference stations of the navigation system to determine the usability of the signal in a positioning of a device;
inserting, for each signal the examining indicated not to be usable in a positioning of the device, an indication on the non-usability of the signal, said indication comprising information on the signal and on the reference station the signal relates to into the assistance data.
According to a eighth aspect of the present invention there is provided a computer program product for storing computer program having computer executable instructions for
receiving assistance data relating to one or more reference stations of at least one navigation system;
characterised in that the computer program further comprises computer executable instructions for
examining the received assistance data to find out information relating to the status of said one or more signals of the reference stations of the navigation system, said information relating to the status of said one or more signals of the reference stations comprising indication on the reference station the signal relates to, and said status indicating the usability of the signal; and
leaving out such a signal, which is indicated not to be usable, from signals to be used in a positioning of the device.
According to a ninth aspect of the present invention there is provided a signal for delivering assistance data to a device, the signal comprising
assistance data relating to one or more reference stations of at least one navigation system;
characterised in that the signal further comprises, for each signal of a reference station not usable in positioning, an indication on the non-usability of the signal, said indication comprising information on the signal and on the reference station the signal relates to.
According to a tenth aspect of the present invention there is provided a a carrier having a signal recorded thereon for delivering assistance data to a device, the signal comprising
assistance data relating to one or more reference stations of at least one navigation system;
characterised in that the signal further comprises, for each signal of a reference station not usable in positioning, an indication on the non-usability of the signal, said indication comprising information on the signal and on the reference station the signal relates to.
According to a eleventh aspect of the present invention there is provided an assistance data server comprising
a controlling element for forming assistance data elating to one or more reference stations of at least one navigation system; and a transmitting element for transmitting the assistance data to a communications network;
characterised in that the assistance data server further comprises
an examining element adapted to examine the status of said one or more signals of the reference stations of the navigation system to determine the usability of the signal in a positioning of a device,
wherein the controlling element is adapted to insert, for each signal the examining element determined not to be usable in a positioning of a device, an indication on the non-usability of the signal, said indication comprising information on the signal and on the reference station the signal relates to into the assistance data.
The invention shows some advantages over prior art. In those cases where only some specific signal is broken, the other signals that the particular satellite transmits are still usable and therefore there is going to be more usable signals and therefore the availability of the A-GNSS service can be improved.
DESCRIPTION OF THE DRAWINGS
In the following, the invention will be described in more detail with reference to the appended drawings, in which
FIG. 1 depicts as a general, simplified diagram a system in which the present invention can be applied,
FIG. 2 depicts a reference receiver of a navigation system according to an example embodiment of the present invention as a simplified block diagram,
FIG. 3 depicts a network element according to an example embodiment of the present invention as a simplified block diagram,
FIG. 4 depicts a device according to an example embodiment of the present invention as a simplified block diagram,
FIG. 5 depicts according to an example embodiment of the present invention; and
FIG. 6 shows an example of a frame structure used in the GPS system.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 there is depicted an example of a system 1 which can be used for positioning a device R. The system 1 comprises reference stations S, such as satellites S 1 of a first navigation system, for example the GPS, and satellites S 2 of a second navigation system, for example the GLONASS. It should be noted here that GPS and GLONASS are only mentioned as non-limiting examples here and also other reference stations S than satellites can be used (e.g. pseudolites of the LAAS). Also the number of reference stations is greater than shown in FIG. 1 . The navigation systems comprise one or more ground stations G. The ground station G controls the operation of the satellites S 1 , S 2 of the navigation systems 2 , 3 , respectively. The ground station G can e.g. determine deviations of the orbits of the satellites and the accuracy of the clock(s) of the satellites (not shown). If the ground station G detects a need to correct the orbit or the clock of a satellite 51 , S 2 , it transmits a control signal (or control signals) to the satellite S 1 , S 2 which then performs a correction operation on the basis of the control signal(s). In other words, the ground station G refers to the Ground Segment of the navigation system.
During their operation, the satellites S 1 , S 2 monitor the condition of their equipment. The satellites S 1 , S 2 may use, for example, watch-dog operations to detect and report possible faults in the equipment. The errors and malfunctions can be instantaneous or longer lasting. On the basis of the health data, some of the faults can possibly be compensated for, or the information transmitted by a malfunctioning satellite can be totally disregarded. The malfunctioning satellite S 1 , S 2 sets a flag in a satellite health field of a navigation message indicative of a failure of the satellite. The satellite S 1 ,S 2 can also indicate in the navigation message a signal or signals which is/are not operating properly. It is also possible that the ground station G can detect that some satellite is not operating properly and set an indication of the malfunctioning signal(s) of that satellite. This indication can then be transmitted to the communications network P in a navigation message.
In this non-limiting example embodiment the communications network P is the GSM network and the network element M communicating with the reference receiver C. 2 is the Serving Mobile Location Centre (SMLC) of the GSM network. The reference receiver C. 2 can transmit assistance data to the network element M. The network element stores the assistance data to a memory M. 4 ( FIG. 3 ) for transmission to a device R when the device R needs the assistance data to perform assisted positioning operation. It is also possible to transmit the assistance data from the network element M to the device R before it is needed. For example, the device R can request the assistance data of all visible satellites and store the navigation data to the memory R. 4 of the device R for later use.
The network element M can also be the Serving Mobile Location Centre (SMLC) of the GSM network. The Serving Mobile Location Centre is either a separate network element (such as the MSC) or integrated functionality in a base station B (BSC, Base Station Controller) that contains the functionality required to support location based services. The SMLC manages the overall co-ordination and scheduling of resources required for locating a device R. It also calculates the final location estimate and estimates the achieved accuracy. The SMLC may control a number of Location Measurement Units (LMU) for the purpose of obtaining radio interface measurements to locate or help locate the mobile station subscribers in the area that it serves.
Now, the main elements of an example embodiment of the reference receiver C. 2 will be described in more detail with reference to FIG. 2 . The disclosure is applicable to both the reference receiver C of the first navigation system and the reference receiver C″ of the second navigation system, although practical implementations may be different from each other. The reference receiver C. 2 comprises a controller C. 1 for controlling the operation of the reference receiver C. 2 . The controller C. 1 comprises e.g. a processor, a microprocessor, a digital signal processor (DSP) or a combination of these. It is obvious that there can also be more than one processor, microprocessor, DSP, etc. in the controller C. 1 . There is also a receiver C. 2 . 2 for receiving signals from the satellites S 1 , S 2 of the navigation system. The reference receiver C. 2 further comprises a communication block C. 3 for communicating, either directly or indirectly, with the network element M of the communications network P. The communication block C. 3 comprises a transmitter C. 3 . 1 for transmitting signals to the network element M and, if necessary, a receiver C. 3 . 2 for receiving signals transmitted by the network element M to the reference receiver C. 2 . The reference receiver C. 2 may also comprise memory C. 4 for storing data and software (computer program code).
The structure of an example embodiment of the network element M is depicted in FIG. 3 . The network element M comprises a controller M. 1 . Also the controller M. 1 of the network element may be constructed of a processor, a microprocessor, a digital signal processor (DSP) or a combination of these. It is obvious that there can also be more than one processor, microprocessor, DSP, etc. in the controller M. 1 . The network element M can communicate with the network element C. 2 by the first communication block M. 2 . The first communication block M. 2 comprises a receiver M. 2 . 2 for receiving signals from the reference receivers C. 2 of the navigation systems. The first communication block M. 2 may also comprise a transmitter M. 2 . 1 for transmitting e.g. request messages to the reference receiver C. 2 of the navigation system. The network element M further comprises a second communication block C. 3 for communicating with the base stations B or other access points of the communications network P. The second communication block M. 3 comprises a transmitter M. 3 . 1 for transmitting signals to the base stations B and a receiver M. 3 . 2 for receiving signals transmitted by the base stations B to the network element M. The network element M also comprises memory M. 4 for storing data and software (computer program code).
The network element M obtains the assistance data either from satellite broadcasts by using a reference receiver C. 2 or some other external solution, e.g. from an assistance data server X intended to gather and transmit such information to communications networks. The assistance data server X comprises analogous elements with the network element M with respect to the operations relating to the receiving navigation data, forming and transmitting the assistance data (i.e. the receiver M. 2 . 2 , the controller M. 1 , the transmitter M. 3 . 1 , the memory M. 4 ). The assistance data server X may also comprise elements of the reference receiver C. 2 . The assistance data server X is, for example, a server of a commercial service provider from who assistance data can be requested, maybe against a fee.
The reference receiver C. 2 is not necessarily a separate device located outside the communications network P but can also be a part of the network element M.
In another example embodiment the assistance data server X can also analyse signals received by the reference receiver C. 2 (which can also be part of the assistance data server X) and determine whether a signal/satellite is operating properly or not.
FIG. 4 depicts a device R according to an example embodiment of the present invention as a simplified block diagram. The device R comprises one or more positioning receivers R. 3 for receiving signals from the reference stations S 1 , S 2 of one or more navigation systems. There can be one positioning receiver R. 3 for each navigation system the device R is intended to support, or it may be possible to use one positioning receiver R. 3 for performing positioning on the basis of signals of more than one navigation system. The device R also comprises a controller R. 1 for controlling the operation of the device R. Again, the controller R. 1 of the network element may be constructed of a processor, a microprocessor, a digital signal processor (DSP) or a combination of these. It is obvious that there can also be more than one processor, microprocessor, DSP, etc. It is also possible that the positioning receiver R. 3 can comprise a controlling element R. 3 . 1 (e.g. a processor, a microprocessor and/or a DSP), or the positioning receiver R. 3 uses the controller of the device R in positioning. It is also possible that some of the positioning operations are carried out by the controlling element R. 3 . 1 of the positioning receiver R. 3 and some other positioning operations are carried out by the controller R. 1 of the device. The device R can communicate with a base station B of the communications network P by the communication block R. 2 . The communication block R. 2 comprises a receiver R. 2 . 2 for receiving signals from the base station B of the communications network P. The communication block M. 2 also comprises a transmitter R. 2 . 1 for transmitting messages to the base station B of the communications network P. Data and software can be stored to the memory R. 4 of the device. The device R is also provided with a user interface R. 5 (UI) which comprises, for example, a display R. 5 . 1 , a keypad R. 5 . 2 (and/or a keyboard), and audio means R. 5 . 3 , such as a microphone and a loudspeaker. It is also possible that the device has more than one user interface.
The device R is, for example, a mobile communication device intended to communicate with the communications network P as is known as such. The user interface R. 5 can be common to both the mobile communication part and the positioning receiver R. 3 .
In the following, a non-limiting example of fields of the Real-Time Integrity information element will be disclosed with reference to the Table 1. In the Table 1, associated bit counts are shown. According to the present invention, The Real-Time Integrity field is intended to be used to communicate the satellite health data to the device R.
TABLE 1
Scale
Parameter
# Bits
Factor
Range
Units
Incl.
The following field occurs once per message
UTC
32
1
0-(2 32 − 1)
sec
M
The following field occurs once per signal (NBS times)
Bad_SSS_ID
14
1
—
—
C
The Real-Time Integrity field of the GNSS Assistance Data Information Element contains parameters that describe the real-time status of the GNSS constellations. Primarily intended for non-differential applications, the real-time integrity of the satellite constellation is of importance as there is no differential correction data by which the device R can determine the soundness of each satellite signal. The Real-Time Satellite Integrity data communicates possible abnormalities in the operation of the satellite(s) of the GNSS constellations to the device R in real-time or almost real-time. The network element M shall always transmit the Real Time Integrity field with the current list of unhealthy signals, for any A-GNSS positioning attempt and whenever A-GNSS assistance data is sent. If the number of bad signals (NBS) is zero, then the Real Time Integrity field shall be omitted. When the Extended Reference IE is included in the RRLP Measure Position Request message or in the RRLP Assistance Data message, then the MS shall interpret the absence of a Real Time Integrity field in the assistance data provided by the SMLC to mean that the number of bad signals is zero. If the Extended Reference IE is not present, this interpretation applies when the assistance data is provided by the network element M following a previous request of the device R for Real Time Integrity data.
The UTC field indicates the UTC time (Universal Time, Co-ordinated) when the list was generated.
The NBS value indicates the number of SSS ID's that follow that the device R should not use at this time in a position fix. This NBS value is determined from the Bad_SSS ID list.
The Bad_SSS ID field is used to indicate the system, satellite index SSS ID, SV/Slot and Signal ID of the satellite signal which is not functioning properly. Because the indication contains information on the satellite system, the Bad_SSS ID field can be generally used to indicate the different positioning signals in the different satellites and different satellite systems. The SSS ID is a 14-bit field divided to 3 subfields which are as follows:
The first three bits form the System ID field, which contains the ID number of the satellite system;
the next six bits form the SV/Slot ID field, which contains the index of the satellite in the system; and
the last five bits form the Signal ID field, which contains the ID number of the positioning signal
The bit mask for SSS ID is the following:
System ID (3 bits, range 0 . . . 7): xxx-----------
SV/Slot ID (6 bits, range 0 . . . 63): ---xxxxxx-----
Signal ID (5 bits, range 0 . . . 31): ---------xxxxx
The System ID specifies the satellite system that the satellite and signal belong to. In the current version of this interface the following systems are supported: GPS, Galileo and SBAS, GLONASS, QZSS and LAAS (pseudolite). In Table 2 the correspondence between the system and the value of the System ID field is depicted.
TABLE 2
System ID
Indication
GPS
0
SBAS (e.g. WAAS, EGNOS)
1
Galileo
2
GLONASS
3
QZSS
4
LAAS
5
Reserved for future use
6
Reserved for future use
7
The SV ID is an index number for a satellite within a satellite system. The SV_ID has a value range: 0-63. The SV ID value range starts from 0 for each satellite system. Actual PRN number for the satellite can be obtained by adding a satellite system specific offset to the SV ID value. The offsets are defined in the following table 3.
TABLE 3
System ID
Index Offset Parameter
Value
GPS
SV_BASE_GPS
1
SBAS
SV_BASE_SBAS
120
Galileo
SV_BASE_GALILEO
1
GLONASS
SV_BASE_GLONASS
1
QZSS
SV_BASE_QZSS
TBD
LAAS
SV_BASE_LAAS
TBD
In the case of GLONASS, SV ID refers to orbit Slot Number of a specific satellite.
However, it is also possible to use other implementations than the above mentioned to indicate the information relating to non-properly working signals.
The Signal ID specifies one satellite-positioning signal from the different signals output by a satellite. An ANY value is used in signal ID when a specific satellite is selected without specifying any signal. This is needed e.g. in real time integrity information element when reporting integrity failure for a satellite rather than a failure for a specific signal.
TABLE 4
Signal ID
Indication
Any
0
GPS_L1_CA
1
GPS_L2C (data)
2
GPS_L2C (pilot)
3
GPS_L5 (data)
4
GPS_L5 (pilot)
5
GALILEO_L1-B (data)
6
GALILEO_L1-C (pilot)
7
GALILEO_E5A (data)
8
GALILEO_E5A (pilot)
9
GALILEO_E5B (data)
10
GALILEO_E5B (pilot)
11
GLONASS L1
12
GLONASS L2C
13
Reserved for future use
14-31
The navigation system assistance data message contains also other fields and information elements than the real time integrity information element. However, they are not important in view of the present invention and it is not necessary to discuss them in more detail here.
When there is a necessary to transmit the navigation system assistance data message in the communications network, e.g. from the network element M to the device R, the information is mapped into one or more messages applicable in the communications network. For example, in GSM communications network there is a certain message delivery approach (Radio Resource LCS Protocol, RRLP) formed for transmission of location related information. This approach is defined in the standard 3GPP TS 44.031, which defines the format of the assisted GPS data exchanged between the network element M and the device R. In this invention, this approach can be used to send the more general health data to the device R.
In the network element M the available navigation information such as DGPS/DGNSS correction, ephemeris and clock correction and almanac data is mapped into corresponding fields of the assistance data message(s). The ephemeris, clock correction, almanac and other data relating to a particular satellite are obtained from a satellite navigation message of that satellite or from an external service X. The message is received by the reference receiver C or by a reference receiver in the external service module X. The assistance data message comprises a Cipher Control element to indicate if the information is ciphered or not, Ciphering Serial Number element, and Data Information Element. The Data Information Element (Data IE) carries the navigation information. The elements are depicted in Table 5 below.
The Assistance Data message is, for example, built so that it is fitted into a fixed length message not necessary occupying the whole message. It can contain three data sets: DGPS/DGNSS correction, ephemeris and clock correction, almanac and other data information. In case that the fixed length message has less information elements than bits available then the rest of the message is filled with fill bits. No undefined spare bits are usually not allowed between elements. In an example embodiment the channel to broadcast the Assistance Data message is e.g. CBCH over which the SMSCB DRX service is used. One SMSCB message has fixed information data length of 82 octets and the maximum length of GPS Assistance Data is 82 octets. The device R can identify the LCS SMSCB message with Message Identifiers declared in 3GPP TS 23.041.
TABLE 5
Occur-
Pres-
Parameter
Bits
Resol.
Range
Units
rences
ence
Cipher
Cipher
1
—
0-1
—
1
M
Control
On/Off
Ciphering
1
—
0-1
—
1
M
Key Flag
Ciphering Serial
16
—
0-65535
—
1
C
Number
Data
638
—
—
—
—
M
In FIG. 5 an example assistance message A according to an example embodiment of the present invention is shown. The message comprises the Real-Time Integrity field A. 1 . The Real-Time Integrity field A. 1 comprises a Time field A. 1 . 1 (UTC) and one or more Bad Signal Indication fields A. 2 according to the number of non-healthy signals which should be reported to the device R. The Bad Signal Indication field A. 2 contains information of the satellite to which the faulty signal belongs (A. 2 . 2 ), the system the satellite belongs (A. 2 . 1 ), and indication of the signal (A. 2 . 3 ), which has failed. In this example embodiment the assistance message A does not contain an explicit indication of the number of failed signals but it can directly be derived from the number of Bad Signal Indication fields A. 2 included in the message.
Now, an example situation on the usage of the assistance message format according to the present invention will be described in the following. The network element has storage area M. 4 . 1 in the memory M. 4 for storing navigation data received from the reference receiver C. 2 . If there is no navigation data stored e.g. of the satellites of the first navigation system, the controller M. 1 of the network element forms a query message (not shown) and transfers it to the first communication block M. 2 of the network element. The transmitter M. 2 . 1 makes protocol conversations, if necessary, to the message and transmits the message to the reference receiver C of the first navigation system. The receiver C. 3 . 2 of the communication block of the first reference receiver C receives the message, makes protocol conversions, if necessary, and transfers the message to the controller C. 1 of the reference receiver C. The controller C. 1 examines the message and determines that it is a request to transmit navigation data to the network element M. If the memory C. 4 contains the requested navigation data, it can be transmitted to the network element M, unless there is a need to update the navigation data before the transmission.
After the navigation data is updated, the controller C. 1 of the reference receiver forms a message containing the navigation data and transfers it to the transmitter C. 3 . 1 of the second communication block of the first reference receiver C. The controller C. 1 also determines if there are satellites which are not operating properly. The controller C. 1 examines signals from such non-healthy satellites to determine if there are any healthy signals which can be received from that satellite. For example, the controller C. 1 may perform measurements of residuals of a pseudorange and if the residual deviates from a computational residual more than a predetermined threshold, the controller C. 1 determines that the satellite is not operating properly. Another option is to compare the accuracy of the ephemeris data transmitted by a satellite to a reference data. If the examination indicates that there is at least one healthy signal available from that satellite, the controller C. 1 forms an indication of each of the non-healthy (i.e. failed) signals of that satellite to the assistance data message. However, if the examination indicates that all the signals from the non-healthy satellite are failed, the special indication value (=any) can be formed for that satellite. In that case there is only one Bad Signal Indication field A. 2 relating to that satellite in the assistance data message.
The transmitter C. 3 . 1 transmits, after protocol conversions if necessary, the navigation data to the network element M. The receiver M. 2 . 2 of the network element receives the message, makes protocol conversions, if necessary, and transfers the message to the controller M. 1 of the network element, or stores the navigation data received in the message directly to the memory M. 4 of the network element. The memory may comprise certain areas (M. 4 . 1 , M. 4 . 2 in FIG. 3 ) for storing navigation data of satellites of different navigation systems. Hence, the data is stored to the area which is reserved for the navigation system from which the navigation data was received.
The assistance data can be transmitted to the device R either by request or by a broadcast transmission, e.g. on a control channel of the communications network P. In the GSM system a GPS Assistance Data Broadcast Message format is defined which can be used in such broadcast transmissions for GPS. The assistance data is included in the message utilising the format defined in this invention. For example, the controller M. 1 of the network element M examines whether there are any bad signal indications and if the examination indicates that there is at least one failed signal, the controller M. 1 forms the Real-Time Integrity field A. 1 and inserts into it the Bad Signal Indication field A. 2 for the faulty signals/satellites. Then, the controller M. 1 constructs an assistance data message comprising the Real-Time Integrity field A. 1 to be transmitted to the device R.
It should be noted here that the definition of time in this assistance data format is different from the present GPS time. As mentioned earlier, for instance, GPS time rolls over every week. The new time definition does not do this. Moreover, the manner in which time is defined is not relevant from the point of view of the invention.
The controller can browse the navigation data of the first navigation system stored in the first storage area M. 4 . 1 to form other assistance data messages to transmit other navigation data, when necessary.
When assistance data message A is formed, the assistance data message can be transmitted to the communications network. The controller M. 1 . transfers the data in the assistance data message storage area M. 4 . 3 to the second communication block M. 3 of the network element. The transmitter M. 3 . 1 of the second communication block of the network element M performs the necessary operations for forming the signals for transmission carrying the assistance data, and transmits the signals to the communications network P.
The signals are received by the receiver R. 2 . 2 of the communication block of the device R. The receiver R. 2 . 2 demodulates the data from the received signals and e.g. transfers the data to the controller R. 1 of the device R. The controller R. 1 stores the data into the memory R. 4 of the device R and examines (R. 1 . 1 ) the assistance data. The examination comprises determining (R. 1 . 2 ) the Bad Signal Indication fields A. 2 (if any). As mentioned above, the device R can deduce the number of failed signals from the number of Bad Signal Indication fields A. 2 included in the message. Indication on the failed signals can be transferred to the positioning receiver R. 3 e.g. through the output line R. 1 . 3 of the controller R. 1 . However, it is also possible that the controller R. 1 is also used in the positioning operations wherein it may not be necessary to transfer the data (indication on the failed signals and/or the number of failed signals) to the positioning receiver R. 3 but the controller R. 1 can use the data stored in the memory R. 4 .
The memory R. 4 can comprise a storage area R. 4 . 1 for storing the navigation data received in the assistance data messages as well as indication of the faulty signals. Navigation data can also be received, in some circumstances, from satellites by demodulating received satellite signals.
When the assistance data is retrieved from the assistance data record(s), they can be kept in the memory and used in the positioning. For example, when the positioning receiver R. 3 can only demodulate signals from one or two satellites, the positioning receiver R. 3 can use the assistance data for performing the positioning as is known as such.
When the positioning receiver R. 3 needs to use assistance navigation data of one or more satellites, it also examines the information relating to the real-time integrity field to determine whether there are any signals from satellites which are not working properly, and tries to use other signals/satellites instead.
The device R can perform the positioning at certain intervals, or when a predetermined condition is fulfilled. The predetermined condition can include, for example, one or more of the following situations: the user initiates to a call e.g. to an emergency centre; the user selects a positioning operation from a menu of the device R; the device R and the communications network P perform a handover to another cell of the communications network P; the communications network P sends a positioning request to the device R; etc.
It is also possible that the communications network, e.g. the network element M requests the device R to perform positioning. The request can be send using the RRLP message delivery mechanism. Also the reply can be sent using the RRLP message delivery mechanism.
When the positioning is to be performed, the positioning receiver R. 3 or the controller R. 1 of the device can examine whether there is enough up-to-date navigation data stored in the memory R. 4 . If some navigation data is not up-to-date (i.e. the navigation data has become older than a preset time), or some necessary navigation data is missing, the device can form and send a request message to the communications network P, for example to the base station B, which forwards the request message to the network element M. The network element M gathers the requested navigation data and forms a reply message. The reply message is then transmitted via the serving base station B to the device R. The receiver R. 2 . 1 of the communication block R. 2 of the device receives and demodulates the reply message to retrieve the navigation data. The navigation data is stored e.g. into the navigation data storage area R. 4 . 1 of the memory R. 4 .
It should be noted that the navigation assistance message specified contains various items (specifically, t oe — MSB, fit interval, IOD, t oc , T GD , t oe , r 0 , r 1 ) that are, of course, important for the navigation model to function properly, but are not important from the point-of-view of this invention. For instance, the reference time for the model can be given in various ways (now, t oe — MSB, t oc and t oe ), but changing it does not affect the functionality of the transmission of the SV health indication. The parameters, which are not important from the point-of-view of the current invention, are only given for the sake of completeness.
Also, it should be emphasized that the actual bit counts and scale factors are subject to change, if new specifications or clarifications should appear. Changing the bit counts and/or scale factors does not change the spirit of the invention. For instance, adding resolution to velocity components would not be a different invention. As a yet another example, consider the SS ID. The indexing method currently used in standards is able to differentiate only between GPS satellites. The now proposed SS ID contains information on the system and the satellite. These two can be expressed in the same field, but it is not necessary to do so (given that the system is defined in some other field). Hence, a simple modification of the fields would not, again, change the spirit of the invention.
The communications network P can be a wireless network, a wired network, or a combination of these. Some non-limiting examples of the communications networks have already been mentioned above but WLAN and WiMax networks can also be mentioned here.
The operations of the different elements of the system can mostly be carried out by software, i.e. the controllers of the elements operate on the basis of computer instructions. It is, of course, possible that some operations or parts of them can be “hard coded” i.e. implemented by hardware.
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The invention relates to navigation systems and elements. A network element (M) includes a controlling element (M.1) for forming assistance data relating to one or more reference stations (S1, S2) of at least one navigation system; and a transmitter (M.3.1) for transmitting the assistance data via a communications network (P) to a device (R). The device (R) includes a positioning receiver (R.3) for performing positioning on the basis of one or more signals transmitted by reference stations (S1, S2) of the at least one satellite navigation system; a receiver (R.2.2) for receiving the assistance data relating to at least one navigation system from the network element (M); and an examining element (R.1.1) adapted to examine the received assistance data to find out information relating to the status of the one or more signals of the reference stations (S1, S2) including indication on the reference station (S1, S2) the signal relates to, and the status indicating the usability of the signal. Therefore, the device (R) is adapted not to use in the positioning such a signal which is indicated not to be usable.
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[0001] This application claims the benefit of the filing date of U.S. Provisional Application No. 62/001,773 filed on May 22, 2014, the teachings of which are incorporated herein by reference in their entirety.
BACKGROUND
[0002] The current disclosure relates to electronics, and more specifically but not exclusively, to heat dissipation for active semiconductor devices.
[0003] Wireless communication systems may include base stations that transmit electromagnetic (EM) signals. The base station transmitters employ radio-frequency (RF) power amplifiers to amplify RF EM signals for transmission. RF power amplifiers are active semiconductor-based devices that may employ any of various different technologies to achieve amplification, e.g., LDMOS (laterally diffused metal oxide semiconductor), GaN, or GaAs. Typically, a base-station transmitter comprises a series of amplification stages—which may be referred to as a lineup—that increases in power level from lower-level amplification to higher-level amplification. A final-stage RF power amplifier typically generates more heat than an earlier-stage RF power amplifier. A lineup of RF power amplifiers comprising final-stage and/or pre-final-stage power amplifiers may be mounted onto a printed circuit board (PCB) that comprises additional electronic components.
[0004] FIGS. 1A-1D show various views of exemplary conventional packaged RF power amplifier device 100 . FIG. 1A is a first orthogonal view of amplifier device 100 . FIG. 1B is a second orthogonal view of amplifier device 100 of FIG. 1A . FIG. 1C is a third orthogonal view of amplifier device 100 of FIG. 1A . FIG. 1D is a perspective view of amplifier device 100 of FIG. 1A . Amplifier device 100 is packaged in an earless flanged LDMOS package.
[0005] Specifically, amplifier device 100 comprises drain lead 101 , gate lead 102 , source lead 103 , and encapsulant 104 . Drain lead 101 and gate lead 102 are in the form of fins. Source lead 103 forms the earless flange of amplifier device 100 and may be referred to as flange 103 . Note that LDMOS packages with eared flanges (not shown) have flanges that extend further out to the sides, where the extensions may have slots or holes for screws or similar attachment means. Also note that LDMOS packages with earless flanges are sometimes referred to elsewhere as flangeless packages. Encapsulant 104 may comprise, for example, ceramic and/or epoxy. Amplifier device 100 also comprises a semiconductor die that is encapsulated by encapsulant 104 and not visible in FIGS. 1A-1D .
[0006] The semiconductor die comprises a power transistor whose terminals are conductively connected to the corresponding external leads. In other words, the power transistor's drain, source, and gate terminals are conductively connected to drain lead 101 , source lead 103 , and gate lead 102 , respectively. The transistor may also have a bulk-semiconductor terminal that is conductively connected to source lead 103 . Note that the transistor may be a compound transistor where a plurality of smaller individual transistors are connected together so as to function like a single larger transistor. The leads 101 , 102 , and 103 are metallic—e.g., copper. Most of the heat generated by amplifier device 100 is dissipated through flange 103 , which has relatively large surface area.
[0007] RF power amplifiers tend to generate a considerable amount of heat, where a higher power level generally correlates with more heat generated. Heat generated by RF power amplifiers needs to be dissipated to prevent device failure and in order to extend the operational life of the RF power amplifiers and/or nearby components. Conventional means of heat dissipation include the attachment of a finned heat sink to the RF power amplifier.
[0008] FIG. 2 is a simplified exploded perspective view of exemplary conventional RF power amplifier system 200 . System 200 includes PCB 201 , metal pallet 202 , and two RF power amplifier devices 203 , which each may be substantially similar to amplifier device 100 of FIGS. 1A-1D . PCB 201 has two apertures 204 for the two corresponding amplifier devices 203 and holes 205 for corresponding screws (not shown). Metal pallet 202 is a bulk metal plate comprising, for example, copper or aluminum. Pallet 202 has two depressions 206 for the bottom surfaces of the flanges of the two amplifier devices 203 and holes 207 for the above-mentioned corresponding screws.
[0009] Amplifier devices 203 are mounted onto PCB 201 , where the drain, gate, and source leads of the amplifier devices 203 are electrically connected to corresponding contacts (not shown) on PCB 201 . The flanges of the amplifier devices 203 , which correspond to the source leads, are inserted through corresponding apertures 204 in the PCB 201 and into corresponding depressions 206 on pallet 202 . PCB 201 also has mounted thereon additional components 208 . Components 208 and amplifier devices 203 are electrically interconnected via traces (not shown) on PCB 201 .
[0010] System 200 may further include a heat sink (not shown) whose top attaches to the bottom of pallet 202 . The heat sink comprises, on the top, a bulk metal plate and, on the bottom, an array of metallic fins extending out from the bulk metal plate. The top of the heat sink may include screw holes for the above-mentioned corresponding screws for attachment to pallet 202 and PCB 201 . A solid thermal medium or thermal grease (not shown) may also be applied between the pallet 202 and the heat sink to help facilitate proper thermal transfer between the mating surfaces.
[0011] Metals are relatively efficient heat conductors and a conventional heat sink conducts heat from the heat-generating device to the medium surrounding the fins—which is typically air—thereby effectively increasing the heat-dissipating surface area of the heat-generating device. However, the heat-dissipating capabilities of the pallet and heat sink combination are limited and, as result, the amplifier devices 100 may need to be spaced relatively far apart from each other so that they are not damaged by excessive heat from neighboring amplifier devices 100 . More-efficient means of dissipating heat from an active device would lower the device's temperature, help extend its life, and provide additional benefits.
SUMMARY
[0012] One embodiment of the disclosure can be an apparatus comprising a vapor chamber having a top and a bottom and enclosing a sealed cavity that is partially filled with a coolant. The vapor chamber comprises a thermo-conductive material. The top of the vapor chamber has at least one depression formed therein. The depression is adapted to receive and thermo-conductively connect to at least part of a bottom of a corresponding packaged semiconductor device mounted through a corresponding aperture in a corresponding printed circuit board (PCB).
[0013] Another embodiment of the disclosure can be a method for assembling an apparatus. The method comprises mounting a set of one or more packaged semiconductor devices onto a printed circuit board (PCB) and attaching the PCB to a vapor chamber. Each packaged semiconductor device of the set of one or more packaged semiconductor devices has a bottom and is mounted through a corresponding aperture in the PCB. The vapor chamber has a top and a bottom and encloses a sealed cavity that is partially filled with a coolant. The vapor chamber comprises a thermo-conductive material. The top has a set of one or more depressions formed therein corresponding to the set of one or more packaged semiconductor devices. Each depression is adapted to receive and thermo-conductively connect to at least part of the bottom of a corresponding packaged semiconductor device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Other embodiments of the invention will become apparent. In the accompanying drawings, like reference numerals identify similar or identical elements.
[0015] FIG. 1A is a first orthogonal view of an amplifier device.
[0016] FIG. 1B is a second orthogonal view of the amplifier device of FIG. 1A .
[0017] FIG. 1C is a third orthogonal view of the amplifier device of FIG. 1A .
[0018] FIG. 1D is a perspective view of the amplifier device of FIG. 1A .
[0019] FIG. 2 is a simplified exploded perspective view of an exemplary conventional RF power amplifier system.
[0020] FIG. 3 is a simplified exploded perspective view of an exemplary vapor-chamber amplifier (VCA) system in accordance with one embodiment of the present invention.
[0021] FIG. 4 is a simplified exploded perspective view of an exemplary vapor-chamber amplifier (VCA) system in accordance with another embodiment of the invention.
DETAILED DESCRIPTION
[0022] A vapor chamber is a sealed metal container that is partially filled with a coolant—which may also be referred to as a working fluid—and from which most air is removed. As a result, the pressure inside the vapor chamber may be significantly lower than atmospheric pressure. A vapor chamber functions like a heat pipe and may be considered to be a planar heat pipe. A vapor chamber is typically shaped substantially like a flat box on the outside. The interior surface of a vapor chamber includes a liquid-wicking structure such as, for example, sintered metal. A vapor chamber may additionally include internal support structures—e.g., columns—to prevent collapse of the vapor chamber.
[0023] In operation, a heat source on one side of a vapor chamber heats the coolant, which is initially liquid, so that the liquid evaporates. The coolant gas then travels to another side of the vapor chamber where it cools and condenses back to the liquid phase and, in the process, releases heat to that side. The liquid coolant then returns to the hot side via the wicking action of the wicking inner surface of the vapor chamber and the cycle repeats. Vapor chambers generally provide superior heat dissipation—and lighter weight—compared to bulk metal—or other solid—slugs of similar dimensions since vapor chambers dissipate more heat more uniformly than comparable slugs. Additional product weight, size, and cost reduction may be realized by using smaller and/or simpler heat sinks in conjunction with the more-efficient vapor chambers.
[0024] A vapor chamber is typically assembled from a top piece and a bottom piece that are brought together, whereupon the resulting chamber is both (i) filled with the coolant liquid and (ii) evacuated. The particular order and details of the steps may vary. For example, the top and bottom pieces may be brought together and mostly sealed, then—through the unsealed segment—filled with the coolant, then evacuated, and then fully sealed. Or the chamber may be evacuated before filling with the coolant. Or one or more of the steps—e.g., filling with coolant and/or attachment of top and bottom pieces—may be performed under vacuum, or near-vacuum, conditions. The top and bottom may be attached together by, for example, welding, pressing, and/or soldering.
[0025] FIG. 3 is a simplified exploded perspective view of exemplary vapor-chamber amplifier (VCA) system 300 in accordance with one embodiment of the present invention. VCA system 300 comprises two final-stage RF power amplifier devices 301 , pre-final-stage RF power amplifier device 302 , PCB 303 , vapor chamber 304 , heat sink 305 , and screws 306 . PCB 303 has two apertures 307 for the two corresponding final-stage RF power amplifier devices 301 and holes 308 for corresponding screws 306 .
[0026] In VCA system 300 , vapor chamber 304 is used instead of a conventional metal pallet. Vapor chamber 304 includes top piece 309 and bottom piece 310 . Top piece 309 of vapor chamber 304 includes two depressions 311 for the two corresponding final-stage RF power amplifier devices 301 and holes 312 for corresponding screws 306 . It should be noted that holes 312 do not provide an opening in or out of the coolant-holding cavity (not shown) of vapor chamber 304 . In other words, holes 312 are walled cylinders akin to tunnels running the height of vapor chamber 304 . Depressions 311 are shaped to receive the bottoms of flanges 313 of the corresponding amplifier devices 301 . Note that depressions 311 may also be referred to as recesses. Heat sink 305 includes tapped screw holes 314 for corresponding screws 306 .
[0027] Pre-final-stage RF power amplifier device 302 may be in any suitable package—such as, for example, a dual in-line package (DIP)—and is mounted on the top side of PCB 303 using any suitable mounting means, such as, for example, soldering or solder reflow. The two final-stage RF power amplifier devices 301 are packaged in LDMOS packages similar to amplifier device 100 of FIGS. 1A-1D and are mounted on the top side of PCB 303 using any suitable mounting means, such as, for example, soldering or solder reflow. The three RF power amplifier devices 302 and 301 , as well as additional electrical components (not shown) mounted on PCB 303 , may be electrically interconnected via conductive traces on or in PCB 303 .
[0028] The gate and drain leads of power amplifier devices 301 are electrically connected to corresponding contacts (not shown) on the top surface of PCB 303 . The apertures 307 of PCB 303 are shaped to admit the flanges 313 of the corresponding power amplifier devices 301 . The flange 313 of each power amplifier device 301 is inserted through the corresponding aperture 307 in the PCB 303 and into the corresponding depression 311 of the vapor chamber 304 so that the bottom of the flange 313 is in thermo-conductive and electro-conductive contact with at least the bottom of the depression 311 . A thermo-conductive contact is a contact adapted to conduct heat and may be direct or through a conductive material.
[0029] Preferably, in addition, a portion of the sides of the flange 313 is in conductive contact with a portion of the side walls of the recess 311 for increased contact area—and, consequently, increased thermal and electrical conductance—between the flange 313 and the corresponding recess 311 . The flange 313 may be directly connected to a common—e.g., ground—terminal on the PCB 303 or may be conductively connected to a common terminal on the PCB 303 via the vapor chamber 304 . Notably, the vapor chamber 304 may serve as a common—e.g., ground—path for all of the RF power amplifier devices 301 and the PCB 303 . In other words, the vapor chamber 304 may provide a uniform path for ground currents to flow among the flanges 313 and the PCB 303 .
[0030] PCB 303 , vapor chamber 304 , and heat sink 305 may be attached together using screws 306 . Note that, in order to improve thermal conductance and/or improve cohesion, solder and/or thermal paste may be used between various components of system 300 . For example, solder and/or thermal paste (not shown) may be used between flanges 313 and corresponding recesses 311 . Solder and/or thermal paste (not shown) may be used between the bottom surface (as shown in FIG. 3 ) of PCB 303 and the top surface of top piece 309 of vapor chamber 304 . Similarly, solder and/or thermal paste (not shown) may be used between the bottom surface of bottom piece 310 of vapor chamber 304 and the top surface of heat sink 305 .
[0031] In one implementation, the three amplifier devices 302 and 301 are soldered (e.g., directly or reflowed) to the PCB 303 , then the resulting assemblage is soldered to already assembled vapor chamber 304 , and then that assemblage is screwed onto heat sink 305 . If the already assembled vapor chamber 304 is attached to the first assemblage—i.e., PCB 303 and amplifier devices 302 and 301 —using a solder reflow process, then special fixtures may be used in the reflow oven to ensure that the top piece 309 does not separate from the bottom piece 310 during the reflow process.
[0032] In another implementation, the vapor chamber 304 is attached to the PCB 303 with a first solder—e.g., in a first solder reflow process. Note that vapor chamber 304 may be assembled during this first solder reflow process or may be assembled beforehand. After the first solder reflow process, amplifier devices 301 , amplifier device 302 , and/or other components (not shown) are mounted onto PCB 303 of that assemblage using a second, low-temperature solder reflow process with a second, different, low-temperature—e.g., bismuth-based—solder. Note that the second solder reflow process includes soldering flanges 313 of amplifier devices 301 to the corresponding depressions 311 of vapor chamber 304 . The use of the low-temperature solder helps protect the assembled vapor chamber 304 as it flows through the reflow process by reducing thermal stress on the vapor chamber 304 and helping prevent separation and/or leaks. This lower reflow processing temperature also helps protect the integrity of the solder and/or thermal paste connection that may be used between the bottom surface of PCB 303 and top piece 309 , which may be at higher risk of damage due to increased thermal conductivity of vapor chamber 304 .
[0033] In another implementation, the amplifier devices 302 and 301 are soldered to the PCB 303 , then the resulting assemblage is soldered to unattached top piece 309 , and then that assemblage is soldered to unattached bottom piece 310 to form an assemblage including assembled vapor chamber 304 .
[0034] In yet another implementation, amplifier devices 301 , amplifier device 302 , PCB 303 , and vapor chamber 304 are all substantially simultaneously attached together—possibly together with additional components (not shown)—in one solder reflow step using only one type of solder. Any of the above implementations may be combined with any suitable process—such as, for example, those described above—for evacuating the vapor chamber 304 of air and providing the vapor chamber 304 with its coolant. After the attachment of vapor chamber 304 to PCB 303 , amplifier devices 301 and 302 , and any other PCB-mounted components—as, for example, in any of the above-described implementations—that assemblage is attached to heat sink 305 using screws 306 .
[0035] The localized heat generated inside RF power amplifier devices 301 gets quickly distributed over the volume of the vapor chamber 304 and spread over a larger surface. This rapid heat distribution reduces the overall flange temperature of the RF power amplifier devices 301 while improving the mean time before failure (MTBF) of the amplifier devices 301 and, consequently, the MTBF of the corresponding system 300 that includes the amplifiers 301 . In general, improved heat dissipation also allows placement of multiple RF power amplifier devices closer to each other, thereby reducing the overall size, weight, and cost of the corresponding product.
[0036] FIG. 4 is a simplified exploded perspective view of exemplary vapor-chamber amplifier (VCA) system 400 in accordance with another embodiment of the invention. Elements of VCA system 400 that are substantially similar to corresponding elements of VCA system 300 of FIG. 3 are similarly labeled, but with a different prefix.
[0037] VCA system 400 comprises four pre-final-stage RF power amplifier devices 402 and four final-stage RF power amplifier devices 401 . Each final-stage RF power amplifier device 401 comprises one flange 413 , two gate leads 420 , and two drain leads 421 and functions substantially the same as RF power amplifier device 100 of FIGS. 1A-1D . PCB 403 has four corresponding apertures 407 for the four amplifier devices 401 . Vapor chamber 404 has four corresponding depressions 411 for the four amplifier devices 401 . The various elements of VCA system 400 may be attached together in any suitable manner, such as, for example, described above for the corresponding elements of VCA system 300 . The power amplifier devices 401 are spaced relatively close together, where the distance separating adjacent amplifier devices 401 is less than the length of an amplifier device 401 . This relatively close spacing is possible thanks to the improved heat dissipation from the use of vapor chamber 404 .
[0038] Embodiments of the invention have been described where the fins of the power amplifier devices correspond to the gate and drain nodes of the contained transistor and the flange corresponds to the source of the transistor. The invention is not, however, so limited. In alternative embodiments, the external leads of the device may be organized in different ways. In other words, the nodes of the transistor within an amplifier device may be connected in a different manner to the external leads of the device.
[0039] Embodiments of the invention have been described where the final-stage RF power amplifier devices are packaged in LDMOS packages. The invention is not, however, so limited. In alternative embodiments different package types are used for the final-stage RF power amplifier devices. It should be noted that, in general, embodiments of the invention may have one or more power amplifiers devices—final-stage or not—where at least one power amplifier device is configured through an aperture in a PCB and into a recess in a vapor chamber.
[0040] Embodiments of the invention have been shown where VCA systems use screws to attach and hold together various components. The invention is not, however, so limited. Alternative embodiments attach and hold together a PCB, a vapor chamber, and a heat sink without the use of any screws for the attachment. Any suitable alternative attachment means may be used to hold together the various elements of a VCA system. For example, in one alternative embodiments, the various elements, including the heat sink, are held together with solder but without screws.
[0041] Embodiments of the invention have been described where a VCA system includes a conventional heat sink attached to the vapor chamber. The invention is not, however, so limited. In some alternative embodiments, the vapor chamber is attached to an element other than a conventional heat sink. In some other alternative embodiments, the bottom piece of the vapor chamber is not attached to anything but instead itself functions as a heat sink, radiating heat to its environment.
[0042] Embodiments of the invention have been described where the vapor chamber is formed by attaching together a top piece and a bottom piece. The invention is not, however, so limited. In alternative embodiments, the vapor chamber may be formed by any suitable process. For example, a vapor chamber may be assembled from more than two pieces. A vapor chamber may be assembled from pieces other than a top and bottom piece. For example, a vapor chamber may be assembled from a left and a right piece. A vapor chamber may be formed from a single piece that is molded, milled, or otherwise excavated to form the inner cavity, where the cavity is sealed after partial filling with the coolant and/or de-pressurization. In these alternative embodiments, the vapor chamber's top and bottom correspond, respectively, to the above-described top piece and bottom piece.
[0043] It should be noted that not every instance of plural elements—such as, for example, RF power amplifier devices, screws, and screw holes—is necessarily labeled in the figures; rather, in some cases, only exemplary instances are labeled. It should also be noted that, as used herein, the term apparatus may refer to a particular element—such as, for example, a vapor chamber—as well as a larger system incorporating that element—such as, for example, a VCA system.
[0044] Exemplary embodiments have been described wherein particular entities (a.k.a. modules) perform particular functions. However, the particular functions may be performed by any suitable entity and are not restricted to being performed by the particular entities named in the exemplary embodiments.
[0045] It will be further understood that various changes in the details, materials, and arrangements of the parts which have been described and illustrated in order to explain the nature of this invention may be made by those skilled in the art without departing from the scope of the invention as expressed in the following claims.
[0046] Reference herein to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments necessarily mutually exclusive of other embodiments. The same applies to the term “implementation.”
[0047] Unless explicitly stated otherwise, each numerical value and range should be interpreted as being approximate as if the word “about” or “approximately” preceded the value of the value or range. As used in this application, unless otherwise explicitly indicated, the term “connected” is intended to cover both direct and indirect connections between elements.
[0048] For purposes of this description, the terms “couple,” “coupling,” “coupled,” “connect,” “connecting,” or “connected” refer to any manner known in the art or later developed in which energy is allowed to be transferred between two or more elements, and the interposition of one or more additional elements is contemplated, although not required. The terms “directly coupled,” “directly connected,” etc., imply that the connected elements are either contiguous or connected via a conductor for the transferred energy.
[0049] The use of figure numbers and/or figure reference labels in the claims is intended to identify one or more possible embodiments of the claimed subject matter in order to facilitate the interpretation of the claims. Such use is not to be construed as limiting the scope of those claims to the embodiments shown in the corresponding figures.
[0050] The embodiments covered by the claims in this application are limited to embodiments that (1) are enabled by this specification and (2) correspond to statutory subject matter. Non-enabled embodiments and embodiments that correspond to non-statutory subject matter are explicitly disclaimed even if they fall within the scope of the claims.
[0051] Although the steps in the following method claims are recited in a particular sequence with corresponding labeling, unless the claim recitations otherwise imply a particular sequence for implementing some or all of those steps, those steps are not necessarily intended to be limited to being implemented in that particular sequence.
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In one embodiment, an electronic system includes a printed circuit board, one or more packaged semiconductor devices, and a vapor chamber having a top and a bottom and enclosing a sealed cavity that is partially filled with a coolant. The vapor chamber comprises a thermo-conductive and electro-conductive material. The top of the vapor chamber has one or more depressions formed therein, each depression receiving and thermo-conductively connected to at least part of a bottom of a corresponding packaged semiconductor device, which is mounted through a corresponding aperture in the PCB. A heat sink may be thermo-conductively attached to the bottom of the vapor chamber.
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FIELD OF THE INVENTION
This invention relates to apparatus for raising and lowering a segmented pipe string from a surface vessel to the ocean floor, and more particularly is concerned with a parking brake assembly for locking the pipe string against movement relative to the ship.
BACKGROUND OF THE INVENTION
In copending application Ser. No. 479,094, filed June 13, 1974, entitled "Hydraulically Operated Heavy Lift System for Vertically Moving a String of Pipe" and assigned to the same assignee as the present invention, there is described a lift system for raising and lowering a segmented string of pipe from the deck of a surface vessel. In the heavy lift system therein described, two linear lift units are spaced along the axis of the pipe string and are arranged to alternately engage spaced collars on the pipe and move the pipe string vertically in incremental steps. Each lift unit has a stroke equal to approximately half the distance between collars. One or the other of the lift units supports the entire load of the pipe string and associated subsea mining equipment attached to the end of the pipe string. Either lift unit therefore may be subject to loads of 9,000 or 10,000 tons. It is desirable therefore to provide some means to "park" the system so as to remove the load from the lift units during static hold conditions, as a safety backup in the event of operating failure of either the heavy lift units, and to make emergency repairs on the lift system. The parking brake must be integrated with the heavy lift units so that it can function to transfer the load from the heavy lift units to the parking brake in the event of any one of a number of failure conditions which might occur in the heavy lift system, such as when either one of the drive units won't move, or a load supporting element of either drive unit won't engage or won't release. It is also necessary in controlling the load supported by the pipe to be able to rotate the pipe to align the load in particular angular direction.
SUMMARY OF THE INVENTION
The present invention is directed to a parking brake assembly for use in combination with a heavy lift system of the type described in the above-identified copending application which is capable of supporting and rotating a load-supporting string of pipe extending between a surface vessel and deep ocean mining equipment. The parking brake is positioned along the pipe string such that either lift unit can move the pipe string sufficiently to bring one of a series of spaced collars on the pipe into engagement with the parking brake mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the invention, reference should be made to the accompanying drawings, wherein:
FIG. 1 is a cross-sectional view of the heavy lift system and associated parking brake assembly;
FIG. 2 is a schematic showing of the positioning of the pipe string by the heavy lift system in transferring the load to the parking brake;
FIG. 3 is a top view of the parking brake assembly; and
FIG. 4 is a sectional view taken substantially on the line 4--4 of FIG. 3.
DETAILED DESCRIPTION
Referring to FIG. 1 in detail, there is shown a portion of the gimbal-mounted heavy lift system described in detail in the above-identified copending application. The heavy lift system is supported over the docking well from the deck 22 and A-frame assembly 24 by means of a heave compensated supporting structure including hydraulic rams 50 and 52. On top of the rams 50 and 52 are supported the bearing structure, including guide frames 46 and 48, stub shafts 54 and 56, and bearings 61 and 63, for an outer gimbal frame 58 which pivots about an axis 59. An inner gimbal frame, indicated generally at 60, is in turn pivotally supported about an axis perpendicular to the axis 59 within the outer gimbal frame 58. The inner gimbal frame 60 includes a cage structure indicated generally at 80 which extends downwardly and terminates in a lower platform 82.
A pair of upper hydralic cylinders, one of which is indicated at 74, are mounted at the top of the inner gimbal frame 60 one behind the other, as viewed in FIG. 1. The cylinders 74 operate lift rods 76. The lower ends of the rods 76 are joined by an upper yoke assembly 78 which bridges the space between the cylinders. The yoke assembly includes means for releasably supporting a string of pipe extending vertically between the cylinders 74 along the axis 79.
A lower pair of cylinders 84 and 85 are mounted on top of the lower platform 82 and actuate respectively lift rods 86 and 87. The rods are joined at their lower end by a pipe supporting lower yoke 88. The parking brake assembly, indicated generally at 90, is also mounted on the platform 82 along the vertical lift axis 79 of the heavy lift system. The parking brake, as hereinafter described in detail, engages the pipe string to transfer the full load of the mining equipment directly to the gimbal structure and off the heavy lift cylinders. The parking brake also operates to rotate the pipe string and associated mining equipment.
As described in detail in the above-identified copending application, the upper cylinders 74 and lower cylinders 84 and 85 are hydraulically controlled so as to move reciprocally up and down along the vertical axis of the pipe string, the upper and lower cylinders operating substantially out of phase so that one set of cylinders is raising the associated yoke, while the other set of cylinders is lowering the other yoke. By controlling the upper yoke 78 and lower yoke 88 to alternately engage and disengage the pipe string, the hydraulic cylinders operate to continuously move the pipe string vertically in incremental steps, so as to either raise or lower the associated mining equipment.
Referring to the schematic drawing of FIG. 2, the operation of the heavy lift system in combination with the parking brake can be better understood. Position 1 shows the upper yoke 78 at the top of its normal stroke, while the lower yoke 88 is at the bottom of its normal stroke. In this position the upper yoke and lower yoke are separated by a distance corresponding to two pipe sections, indicated generally at 92 and 94. Each pipe section is terminated at its upper end in a collar 95 which can be engaged or released by the upper and lower yokes, so as to transfer the load alternately between the upper and lower cylinders.
Position 2 of FIG. 2 shows the upper yoke 78 at the bottom of its normal stroke with the lower yoke 88 at the top of its normal stroke. The pipe string, in this position, is shifted half the distance between adjacent collars from position 1, the upper and lower yokes being separated by the length of one pipe section. By this arrangement, the upper and lower cylinders and associated yokes are controlled to alternately move the pipe string in incremental steps corresponding to half the length of a pipe section.
The parking brake assembly 90 is positioned slightly below the mid-point between the bottom position of the upper yoke 78 and the upper position of the lower yoke 88. In this position, the intermediate collar 95 in position 1 can be lowered to engage the top of the parking brake assembly 90 by the extension of the cylinders 74. The lower cylinders 84 are provided with an extra stroke range below the bottom of the normal stroke range which permits the middle pipe collar 95, when in position 1, to be lowered by the lower cylinders 84 and 85 onto the parking brake assembly 90. With the pipe string in position 2 of FIG. 2, the collar engaged with the upper yoke 78 can be released and lowered by the lower cylinders 84 and 85 onto the parking brake, or the pipe string can be raised by the upper cylinders 74 so as to bring the collar engaged with the lower yoke 88 up to the level of the parking brake assembly 90. Thus, regardless of the relative position of the upper and lower yokes, either the upper cylinders 74 or lower cylinders 84 and 85 can be used to position a collar on the pipe string onto the parking brake assembly 90. The same is also true if either yoke at any point in time fails to function either to open or to close.
Referring to FIGS. 3 and 4, the parking brake assembly 90 is shown in detail. The parking brake assembly 90 includes a base frame indicated generally at 96, which includes a base plate 98 having a central opening 100 through which the pipe string is adapted to pass. The opening 100 is greater in diameter than the collars 95 of the pipe string. The base plate 98 is adapted to be bolted or otherwise secured on the platform 82 between the cylinders 84 and 85. Welded to the base plate 98 is a cylindrical sidewall 102. An upper flange 104 extends around the outside of the cylindrical sidewall 102 and is joined to the base plate 98 by a plurality of angularly spaced reinforcing ribs 106. The base frame 96 in addition includes an inner cylindrical flange 108 projecting upwardly around the opening 100 in the base plate 98.
Seated in the annular space between the inner flange 108 and the sidewall 102 is a heavy duty thrust bearing indicated generally at 110. The thrust bearing includes a lower race 112 seated on the base plate 98, an upper race 114, and a plurality of rollers 116 which permit the upper race 114 to rotate relative to the lower race 112.
Supported on the thrust bearing 110 is a support ring 118 having a lower annular lip 120. A bearing shield 122 extends between the inner flange 108 of the base plate 98 and the annular lip 120 of the support ring 118. A load ring assembly is mounted on top of the support ring 118, the assembly including a load ring 124 which rests on top of the support ring 118. A radial flange 126 extends around the outer periphery of the load ring 124, the radial flange projecting under a retaining ring 130 which is screwed to the top edge of the sidewall 102. The retaining ring 130 consists of at least two sections so that it can be easily removed during assembly and disassembly of a parking brake. A plurality of dowel pins 134 lock the load ring assembly to the support ring 118.
Also secured to the outer periphery of the load ring 124 is a worm wheel 136. As best seen in FIG. 3, a worm gear 138 engages the worm wheel 136. The worm gear 138 is mounted on a drive shaft 140, the shaft being journaled at either end of the worm gear 138 in a bearing block 142. The bearing block 142 is anchored on the flange 104 on the support assembly 96. The shaft 40 is driven by a suitable electric motor drive (not shown) for applying rotation to the load ring assembly.
The load ring assembly further includes a clamp support plate 144 which is bolted or otherwise secured to the top of the load ring 124. The clamp support plate 144 has a smooth finished flat top surface 146 on which is slidably supported a pair of movable clamping members 148 and 150. The clamping members have arcuate inner surfaces 152 and 154 respectively which are of smaller radius than the outside of the pipe collar 94 so that when the clamping members are in the closed position, the pipe collar 95 engages the top of the clamp members, as shown in FIG. 4.
The clamping members 148 and 150 are movable away from each other from the closed position shown in the drawings to an open position in which the pipe collar is released. The clamp members are provided with linear guide flanges 156 and 158, respectively, extending along opposite ends of the clamping members and engaging a pair of guide tracks 160 and 162 mounted on the top surface 146 of the clamp support plate 144. A stop member 164 is positioned at the center of the guides 160 and 162 to limit the inward movement of the clamp members 148 and 150 so as to center the clamp members when in the closed position. Outer stops 166 and 168 are bolted to the surface 146 to limit the outward movement of the clamp members 148 and 150 in the open position.
Movement of the clamping members 148 and 150 between the closed and open positions is effected by a pair of hydraulic linear actuators 170 and 172. The actuators are connected at one end by brackets 174 and 176 to the clamping member 148. The other end of the actuators are connected by brackets 178 and 180 to the clamping member 150. To help center the collar of the pipe string, four pipe collar centering guides 182, 184, 186, and 188 are provided. The guides are bolted or otherwise secured to the top of the clamping members 148 and 150. The centering guides 182 and 186 are divided into two parts so as to permit the respective clamping members 148 and 150 to move apart. As best seen in FIG. 4, the centering guides are provided with inwardly sloping surfaces which engage the collar and, by wedging action, force the collar into a centered position on the parking brake.
From the above description it will be recognized that an improved parking brake arrangement is provided for locking a vertically moving pipe string in position. The parking brake is capable of clamping and supporting or releasing substantial loads while at the same time permitting a load to be rotated through 360°.
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A parking brake for subsea mining equipment that is raised and lowered by a pipe string from a surface vessel. The brake assembly is mounted between a pair of linear lift units that alternately grip equally spaced collars on the pipe and move the pipe string in incremental steps. The brake includes a releasable yoke for engaging one of the collars. The yoke is rotatable to permit rotation of the pipe string by the brake assembly. The position of the brake is such that either drive unit may be used to position the pipe string so that a collar is engaged by the yoke of the brake assembly.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a sealing or locking structure for a mobile utility cart, and more particularly to such a sealing structure for a mobile utility cart commonly called a “medical emergency crash cart” or simply a “crash cart”, for medical emergency use in hospitals and other medical institutions. The sealing structure in accordance with an aspect of the present invention enables all storage sections of the crash cart to be locked and sealed, indicating that the crash cart contains a full complement of readily accessible medical equipment, instruments, and supplies. In addition, the locking structure enables an operator of the cart to unlock and unseal a single section of the cart or to unlock and unseal all sections of the cart simultaneously.
[0003] For purposes of this application the terms “locked” and “sealed” are used synonymously to mean that the various sections of the cart are held in a closed position or condition until a seal is broken in a way that can be easily confirmed to permit one or more of such sections to be moved to an open position or condition. The term “lock” is not intended to require that any section must be “unlocked” by use of a separate mechanism such as a key.
[0004] 2. Description of Related Art
[0005] A medical emergency crash cart commonly contains medical equipment, instruments, and supplies that may be required while responding to medical emergencies, particularly for medical procedures practiced in cases of cardiac emergencies. However, the crash cart may be equipped for any type of medical emergency. The crash cart generally includes a housing having a plurality of bins, drawers, shelves, sections, and/or compartments for storing medical equipment and supplies such as syringes and drugs.
[0006] After all sections of the cart have been fully stocked with equipment, the cart is locked or sealed until the equipment is needed during an emergency. An unbroken tamper-proof seal indicates that the cart is fully stocked. During an emergency, the cart is unlocked or unsealed to enable access to the medical supplies within the cart. After the emergency, the cart typically is sent to a pharmacy department where an inventory of the cart is taken and missing items are replaced. When the cart is restocked, the cart is locked or sealed again until the next emergency.
[0007] Current crash carts employ conventional cart locking structures that simultaneously lock or unlock all sections of a cart when actuated. An advantage of such cart locking structures is that the cart can be unlocked quickly. However, if only a single item is needed from one section of the cart, a complete inventory of all sections of the cart must be made after use, which is a very time consuming task. Accordingly, one drawback of current crash carts is that discrete sections cannot be selectively unlocked during an emergency.
[0008] U.S. Pat. No. 4,790,610 (Welch et al.), No. 5,673,983 (Carlson et al.), and No. 6,158,830 (Johnson et al.) disclose mechanisms for locking multiple sections of a cart. A commercial product, known as the Starsys™ Passive Lock Security System, available from InterMetro Industries Corporation, has a number of drawers. In this product, each drawer is provided with a separate breakable or frangible seal such that any one drawer may be opened while the remaining drawers remain closed and sealed. Therefore, it can be confirmed by examination of the seals which have been broken and, therefore, which drawers need to be restocked. However, while the mechanisms disclosed in these patents have many advantages, they are not well suited for selectively unlocking one section of the cart while leaving other sections locked.
[0009] For these and other reasons, the crash carts and related locking structures of the prior art are not entirely satisfactory. A need exists for an improved crash cart and related locking structures for providing selective access to multiple sections of the cart.
SUMMARY OF THE INVENTION
[0010] It is an object of the present invention to improve the accessibility of medical equipment, instruments, and supplies in a medical emergency crash cart.
[0011] It is another object of the present invention to provide a security mechanism that offers easy visual inspection of at least two sections of the crash cart and that assures that a full complement of medical equipment, instruments, and supplies are stored within each section of the crash cart.
[0012] Generally speaking, the present invention will be referred to as a “cart,” which may incorporate an enclosed cabinet for storing items, such as medical supplies used in responding to medical emergencies. However, the present invention may be used in conjunction with a variety of storage structures, as well as other utility carts that have general application outside of the medical field. Accordingly, the present invention is not limited to crash or other medical carts, but may be used in conjunction with any structure that can benefit from a locking assembly that may be actuated to open a single section of the cart and also can be actuated to open all sections of the cart simultaneously.
[0013] The cart in accordance with a preferred embodiment of the present invention includes a housing having a top section and a front section. The top section includes a tub for storing items that are needed most frequently during emergencies. The front section includes one or more bins for storing additional items that may be required during an emergency.
[0014] The top section and the front section are secured in a locked condition by a common locking structure that nevertheless permits the top and front sections to be unlocked independently of each other. Therefore, if, for example, in the context of use of the invention as a medical emergency crash cart, only the top section need be unsealed and opened to access those items most frequently needed in an emergency, then the front section may remain closed and sealed. Inventory and restocking of the top section is all that is then required to ready the cart for its next use.
[0015] More particularly, a first breakable seal provided at an upper portion of the locking structure can provide quick visual confirmation that, if unbroken, the complements of the top section are complete. A second breakable seal provided at a lower portion of the locking structure can provide quick visual confirmation that, if unbroken, the complements of the front section of the cart are complete. The locking structure is designed to shear the first seal for accessing the contents of the top section quickly. In addition, the locking structure is designed to shear the first and second seals and unlock all sections of the cart for accessing the contents of all sections of the cart quickly.
[0016] A more complete appreciation along with an understanding of other objects, features, and aspects of the present invention will become apparent from the following detailed description when considered in conjunction with the accompanying drawings.
[0017] Accordingly, in one aspect, the present invention is directed to a cart comprising a housing having a top and at least one side, a recessed tray for storing items provided in the top of the housing, a top cover mountable with the top of the housing for covering the tray to prevent removal of items stored in it, but being removable from or slidable off of the top of the housing thereby to permit access to items stored in the tray, and at least one compartment, also for storing items, associated with and accessible from the one side of the housing. The compartment is movable between (a) a closed position for preventing removal of items stored therein, and (b) an open position to permit access to items stored therein. A seal and lock mechanism are capable of (a) simultaneously locking the top cover to cover the tray and locking the compartment in the closed position, (b) unlocking the cover to permit its removal from the top, but not unlocking the compartment from the closed position, and (c) simultaneously unlocking the top cover to permit its removal from the top and unlocking the compartment permitting it to be moved to the open position.
[0018] Accordingly, in another aspect, the present invention is directed to a cart including a housing having a top that defines a recessed tray, a cover for covering the tray but providing access to the interior thereof when removed or otherwise moved away therefrom. The cover includes a first cover retaining portion having a lock seal aperture formed therethrough. At least one compartment is mounted on one side of said housing and being movable between an open position providing access to its interior and a closed position with its interior enclosed. A lock can lock the compartment in the closed position, the lock includes a stationary member and a slide member having a lock seal aperture formed therethrough. The slide member is movable to (a) a first position where the lock seal aperture of the slide member is aligned with the lock seal aperture of the first cover retaining portion and where the compartment is locked in the closed position, and (b) a second position where the lock seal aperture of the slide member is not aligned with said lock seal aperture of said first cover retaining portion and where the compartment is not locked in the closed position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIGS. 1A , 1 B, 1 C, 1 D, 1 E, and 1 F are a front view, a right side view, a top view, a perspective view taken from the front right, a partial top view, and a partial cross-sectional view taken along line 1 F- 1 F in FIG. 1C and looking in the direction of the arrows, respectively, of certain external and internal features of a preferred embodiment of a crash cart in accordance with the present invention.
[0020] FIGS. 2A and 2B are top and bottom views, respectively, of a top frame or component illustrated in FIGS. 1A through 1D .
[0021] FIGS. 3A , 3 B, and 3 C are front, top, and right side views, respectively, of a top cover hold-down bracket of the present invention.
[0022] FIGS. 4A and 4B are top and right side views, respectively, of a tub illustrated in FIG. 1B .
[0023] FIG. 5 is top view of a sliding top cover illustrated in FIG. 1C .
[0024] FIGS. 6A , 6 B, and 6 C are top, right side, and front views, respectively, of a sliding top cover pull plate illustrated in FIG. 1C .
[0025] FIGS. 7A and 7B are top and front views, respectively, of a sliding top cover retainer bar illustrated in FIG. 1C .
[0026] FIGS. 8A and 8B are top views of a lock seal illustrated in FIG. 1C , shown in an unsealed state and a sealed state, respectively.
[0027] FIGS. 9A and 9B are front and right side views, respectively, of a lock bar of the present invention.
[0028] FIGS. 10A and 10B are front and right side views, respectively, of a front frame illustrated in FIG. 1A .
[0029] FIG. 11A is a right side view of a left front frame, and FIG. 11B is a left side view of a right front frame of the present invention.
[0030] FIGS. 12A and 12B are right side and top views, respectively, of a tilt-out bin illustrated in FIG. 1B .
[0031] FIGS. 13A , 13 B, and 13 C are front, right side, and top views, respectively, of a tilt-out bin lock bar clip of the present invention.
[0032] FIGS. 14A , 14 B, and 14 C are front, right side, and top views, respectively, of a manual lock handle of the present invention.
[0033] FIGS. 15A , 15 B, and 15 C are right side, top, and bottom views, respectively, of a thumb latch of the present invention.
[0034] FIG. 16 illustrates attachment of the manual lock handle illustrated in FIGS. 14A through 14C to the lock bar illustrated in FIGS. 9A and 9B .
[0035] FIGS. 17A and 17B are front and right side views, respectively, of the lock bar illustrated in FIGS. 9A and 9B with the manual lock handle illustrated in FIGS. 14A through 14C attached and a plurality of the tilt-out bin lock bar clips illustrated in FIGS. 13A through 13C attached.
[0036] FIGS. 18A , 18 B, and 18 C are front, right side, and top views, respectively, of a manual lock bracket of the present invention.
[0037] FIGS. 19A , 19 B, and 19 C are front, right side, and top views, respectively, of a vertical channel of the present invention.
[0038] FIGS. 20A and 20B illustrates right side and front views, respectively, of a bushing used to slidably attach the lock bar illustrated in FIGS. 9A and 9B to the vertical channel illustrated in FIGS. 19A , 19 B, and 19 C.
[0039] FIGS. 21A , 21 B, 21 C, and 21 D illustrate front, right side, top, and enlarged partial right side views, respectively, of the lock bar illustrated in FIGS. 9A and 9B attached to the vertical channel illustrated in FIGS. 19A , 19 B, and 19 C.
[0040] FIGS. 22A and 22B illustrate top and front views, respectively, of a drawer of the present invention.
[0041] FIGS. 23A and 23B illustrate top and front views, respectively, of a drawer lock tab of the present invention.
[0042] FIG. 24 illustrates a partial three-quarter perspective view, taken from the front and right side of the cart shown in FIGS. 1A through 1F with sections removed to show certain external and internal features.
DETAILED DESCRIPTION OF THE INVENTION
[0043] Initially, the principal features of the present invention will be described generally in order to provide an overview of its various aspects. Then those features will be described in detail.
[0044] FIGS. 1A through 1E illustrate a front view, a side view, a top view, a perspective view taken from the front right, and a partial top view, respectively, of external and internal features of one embodiment of a crash cart 100 according to the present invention. More particularly, FIGS. 1A through 1E show the cart 100 with certain external enclosures removed so that internal operating mechanisms can be illustrated. In addition, while the present invention is described in the environment of a cart, structures for mounting the cart for movement on a floor, for example, like wheels or casters have been omitted. The unshown features are well within the skill of the art and are not part of the present invention.
[0045] As shown in FIG. 1A , the crash cart 100 in accordance with the invention includes a top frame 102 , a front frame 104 , a left front frame 106 , and a right front frame 107 . The left front frame 106 and the right front frame 107 support four substantially identical tilt-out bins 108 , in which medical supplies may be stored.
[0046] FIGS. 2A and 2B illustrate top and bottom views, respectively, of the top frame or component, which may be a molded part, 102 of the cart 100 . An upper portion of the top frame 102 includes a tub opening 102 a, a lock bar opening 102 b, sliding top cover retainer bar openings 102 c, screw openings 102 d, screw openings 102 e, and a flange 102 f, as shown in FIG. 2A . A lower portion of the top frame 102 also can be considered to be formed with the tub opening 102 a, the lock bar opening 102 b, and screw openings 102 g, as shown in FIG. 2B .
[0047] A sliding top cover 110 is removably attached to the top frame 102 to enclose a tub that is described below. Attachment of the sliding top cover 110 to the top frame 102 is described with reference to FIGS. 1C and 2 through 10 . More particularly, a top cover hold-down bracket 112 is illustrated in FIGS. 3A through 3C . The top cover hold-down bracket 112 includes a retaining flange 112 a and screw apertures 112 b. A first top cover hold-down bracket 112 is attached to the top frame 102 using a pair of screws (not illustrated) that are inserted through the screw apertures 112 b of the top cover hold-down bracket 112 and advanced into the screw openings 102 d of the top frame 102 . A second top cover hold-down bracket 112 is similarly attached to the top frame 102 using a pair of screws (not illustrated) that are inserted through the screw apertures 112 b of the top cover hold-down bracket 112 and advanced into the screw openings 102 e of the top frame 102 .
[0048] FIGS. 4A and 4B illustrate top and side views, respectively, of the tub 114 . A flange 114 a is disposed about an upper periphery of the tub 114 . A plurality of screw apertures 114 b are formed through the flange 114 a. The tub 114 is attached to the top frame 102 using a plurality of screws (not illustrated) that are inserted through the screw apertures 114 b of the flange 114 a and advanced into the screw openings 102 g of the top frame 102 . The tub 114 may be used to store medical items that are required most often during emergencies.
[0049] As shown in FIG. 1C , the sliding top cover 110 is disposed over the tub 114 when an upper section of the cart 100 is locked, thereby preventing access to the tub 114 . When the upper section of the cart 100 is unlocked, the sliding top cover 110 may be removed to provide access to items stored in the tub 114 . The sliding top cover 110 includes a first end 110 a, an opposing second end 110 b, and four rivet apertures 110 c formed through the first end 110 a, as shown in FIG. 5 .
[0050] FIGS. 6A , 6 B, and 6 C illustrate top, side, and front views, respectively, of a sliding top cover pull plate 116 , with which the sliding top cover 110 is equipped and which includes a main portion 116 a, a first retaining flange 116 b, a handle portion 116 c, a second retaining flange 116 d, and a locking flange 116 e, which includes a lock seal aperture 116 f formed therethrough. A plurality of rivet apertures 116 g are formed through the main portion 116 a of the sliding top cover pull plate 116 .
[0051] The sliding top cover pull plate 116 is fixed to the sliding top cover 110 using a plurality of rivets (not illustrated) that are inserted through the rivet apertures 110 c of the sliding top cover 110 and the rivet apertures 116 g of the sliding top cover pull plate 116 . A plurality of nuts (not illustrated) are attached to the plurality of bolts to securely attach the sliding top cover pull plate 116 to the sliding top cover 110 . Of course, any suitable fasteners such as bolts, rivets, screws, and the like may be used in the various applications.
[0052] FIGS. 7A and 7B illustrate top and front views, respectively, of a sliding top cover retainer bar 118 , with which the top cover is also equipped and which includes a top cover retaining portion 118 a, horizontal extension portions 118 b, and vertical extension portions 118 c. Push fasteners or push nuts are secured to lower portions of the vertical extension portions 118 c, which are inserted into the openings 102 c of the top frame 102 thereby securely attaching the sliding top cover retainer bar 118 to the top frame 102 .
[0053] FIGS. 8A and 8B illustrate a lock seal 120 in an unsealed state and in a sealed state, respectively, for sealing and locking the sliding top cover 110 in place. The lock seal 120 , which is known, per se, and commercially available, includes a severable or frangible locking portion 120 a, which has a first end 120 b, and a retaining portion 120 c. As shown in FIG. 8A , when the lock seal 120 is not sealed, the locking portion 120 a is not connected to the retaining portion 120 c. As shown in FIG. 8B , when the lock seal 120 is sealed, the locking portion 120 a is fixed to the retaining portion 120 c. The seal 120 may also include a depending tab 120 d on which a serial number may be printed or embossed. The serial numbers may be used by, for example, hospital staff to monitor how many times portions of the cart have been accessed in order to track carefully items or supplies used from the cart.
[0054] FIGS. 9A and 9B illustrate front and side views, respectively, of a lock bar 122 . The lock bar 122 includes a main portion 122 a, a lock seal aperture 122 b, a sliding flange 122 c, a rectangular aperture 122 d, screw apertures 122 e, retaining flanges 122 f, oval-shaped apertures 122 g, and screw apertures 122 h. The interengagement and interaction of these components will now be described further below as a first storage section of the crash cart.
First Storage Section of Crash Cart
[0055] The first storage section of the cart 100 may be defined by the top frame 102 , the tub 114 , and the sliding top cover 110 . To secure the first storage section in a closed and locked state, the second end 110 b of the top cover 110 is inserted between the retaining portion 118 a of the top cover retainer bar 118 and the top frame 102 , as shown in FIG. 1C . The first end 110 a of the top cover 110 then is positioned so that the first retaining flange 116 b and the second retaining flange 116 d of the top cover pull plate 116 are disposed beneath the retaining flanges 112 a of the cover hold-down brackets 112 , which prevent the first end 110 a of the top cover 110 from being lifted upwardly, as shown in FIG. 1F .
[0056] When the top cover 110 is positioned as shown in FIG. 1C , the lock seal aperture 116 f of the locking flange 116 e of the pull plate 116 (shown in FIG. 6C ) is aligned with the lock seal aperture 122 b of the lock bar 122 (shown in FIG. 9A ). The first section may be locked or sealed by inserting a first end 120 b of a locking portion 120 a of a lock seal 120 through the lock seal apertures 116 f and 122 b and into the retaining portion 120 c of the lock seal 120 .
[0057] During an emergency, an operator may remove the sliding top cover 110 from covering the top of the cart 100 by pushing the handle portion 116 c of the cover pull plate 116 toward the cover retainer bar 118 , which causes the lock bar 122 and the locking flange 116 e of the cover pull plate 116 to sever the locking portion 120 a of the lock seal 120 . When the handle portion 116 c engages the cover retainer bar 118 , the top cover 110 may tilt downwardly and hang from the side of the cart. Further, once the locking portion 120 a of the lock seal 120 is broken, an operator is then able to slide the first end 110 a of the top cover 110 toward the sliding top cover retainer bar 118 until the first retaining flange 116 b and the second retaining flange 116 d of the pull plate 116 are no longer disposed beneath the retaining flanges 112 a of the hold-down brackets 112 . The operator can then lift the sliding top cover 110 upwardly and remove it.
[0058] After the emergency, the cart 100 may be sent to the pharmacy department for taking of inventory and restocking. If the operator recloses or replaces the sliding top cover 110 prior to returning the cart 100 to the pharmacy department, the lock seal 120 will no longer be within the lock seal apertures 116 f and 122 b, which indicates that the first section must be checked for its inventory, restocked, and resealed with a new lock seal 120 prior to returning the cart 100 .
[0059] A second storage section of the cart will now be described.
Second Storage Section of Crash Cart
[0060] A second storage section of the cart 100 is defined by the front frame 104 , the left front frame 106 , the right front frame 107 , and the tilt-out bins 108 . FIGS. 10A and 10B illustrate front and side views, respectively, of the front frame 104 . The front frame 104 includes side walls 104 a, which have rectangular apertures 104 b formed therethrough. Circular indentations 104 c are formed in inner surfaces of the side walls 104 a.
[0061] FIG. 11A is a right side view of the left front frame 106 . The left front frame 106 includes recesses 106 a. FIG. 11B is a left side view of the right front frame 107 . The right front frame 107 similarly includes recesses 107 a and a lock aperture 107 b.
[0062] FIGS. 12A and 12B illustrate side and top views, respectively, of one tilt-out bin 108 . The bin 108 includes a handle 108 a, partially cylindrical projections 108 b, and locking tabs 108 c. Each locking tab 108 c includes a lip 108 d formed at an outer, forward surface thereof.
[0063] Each tilt-out bin 108 is mounted into the front of the cart 100 . Opposed projections 108 b of the tilt-out bins 108 are received in the recesses 106 a and 107 a of the left front frame 106 and the right front frame 107 , respectively. Accordingly, the projections 108 b act as pivots for tilting the tilt-out bins 108 with respect to the front frame 104 .
[0064] FIGS. 13A , 13 B, and 13 C illustrate front, side, and top views, respectively, of a tilt-out bin lock bar clip 124 . The bin lock bar clip 124 includes a base portion 124 a, which has a pair of screw apertures 124 b formed therethrough. The bin lock bar clip 124 also includes an extension member 124 c that extends from the base portion 124 a. A locking tab 124 d is formed at the forward end of the extension member 124 c. The locking tab 124 d includes a lip 124 e formed at an inner surface thereof. The lips 124 e of the bin lock bar clips 124 cooperate with the lips 108 d of the locking tabs 108 c of the bins 108 to securely lock them in a closed position.
[0065] Four tilt-out bin lock bar clips 124 are securely attached to the lock bar 122 illustrated in FIGS. 9A and 9B . More particularly, each lock bar clip 124 is secured to the lock bar 122 using a pair of screws (not illustrated) that are inserted through the screw apertures 122 h (shown in FIG. 9A ) of the lock bar 122 and advanced into the screw apertures 124 b of the tilt-out bin lock bar clips 124 .
[0066] A third storage section of the cart will now be described.
Third Storage Section of Crash Cart
[0067] The third storage section of the cart 100 is defined by the top frame 102 and one or more drawers 144 that are slidably mounted in the cart 100 . FIGS. 22A and 22B illustrate top and front views, respectively, of a drawer 144 in which medical supplies may be stored. A front wall of the drawer 144 includes a plurality of bolt apertures 144 a formed therethrough. A back wall (not shown) of the drawer 144 also includes a plurality of bolt apertures 144 a formed therethrough. The bolt apertures 144 a are used to attach slide rails 146 (one of which is shown in FIG. 24 ) using a plurality of nuts and bolts (not shown). The front wall of the drawer 144 includes a pair of screw apertures 144 b.
[0068] FIGS. 23A and 23B illustrate top and front views, respectively, of a drawer lock tab 148 . The drawer lock tab 148 includes a main portion 148 a, and a notch 148 b that extends from the main portion 148 a. The drawer lock tab 148 also includes apertures 148 b and 148 c, which are used to secure the drawer lock tab 148 to the drawer 144 . More particularly, a screw (not shown) is inserted through each of the apertures 148 b and 148 c of the drawer lock tab 148 , and advanced into corresponding screw apertures 144 b of the drawer 144 . The screw (not shown) that is inserted into 148 d of the drawer lock tab 148 prevents the drawer lock tab 148 from flexing away from the drawer 144 , which prevents the drawer lock tab 148 from becoming caught on the frame of the cart 100 as the drawer 144 is opened and closed. It will also be appreciated that the tab 148 can flex inwardly when the drawer is closed permitting it to be overridden by a retaining flange 122 f, as described below.
[0069] FIG. 24 illustrates a partial three-quarter view of the cart 100 taken from the front and right side, with a drawer 144 slidably attached thereto. The drawer 144 is accessible from the right side of the cart 100 . An operator may pull on a handle (not shown) attached to the drawer 144 , which causes the slide rail 146 and an opposing slide 146 rail (not shown) mounted to a back wall of the drawer 144 to slide within slide members (not shown) that are attached to the cart 100 and receive the slide rails 146 . The lock bar 122 is shown in a locked position. In the locked position, one of the retaining flanges 122 f of the lock bar 122 is disposed directly in front of the notch 148 b of the drawer lock tab 148 , which prevents the drawer 144 from being moved to the open position. Although not shown in FIG. 24 , multiple drawers 144 may be slidably mounted within the cart 100 . When the drawers 144 are closed and the lock bar 122 is moved to the locked position, each of the retaining flanges 122 f of the lock bar 122 is disposed in front of one of the notches 148 b of the drawer lock tabs 148 , which prevents all of the drawers 144 from being opened until the lock bar 122 is moved to an open position. It is noted that the shape of the notch 148 b of the drawer lock tab 148 enables the drawers 144 to be closed, even when the lock bar 122 previously has been moved to the locked position.
[0070] Assembly of the sealing mechanism of the present invention will now be described.
[0071] FIGS. 14A , 14 B, and 14 C illustrate front, side, and top views, respectively, of a manual lock handle 126 , which includes a base portion 126 a, having a pair of standoff apertures 126 b formed therethrough. A locking portion 126 c extends from the base portion 126 a and includes a lock seal aperture 126 e formed therethrough. A latch flange 126 d extends from the locking portion 126 c and includes a screw aperture 126 f formed therethrough.
[0072] The manual lock handle 126 is pivotably attached to the lock bar 122 . Attachment of the manual lock handle 126 to the lock bar 122 is described with reference to FIG. 16 . More specifically, a hex head standoff 130 includes a cylindrical shaft 130 a and a hexagonally shaped end portion 130 b. The cylindrical shaft 130 a is inserted into an aperture of a washer 132 and a center portion of a spring 134 and is advanced until the washer 132 contacts the spring 134 and the end portion 130 b contacts the washer 132 . The standoff apertures 126 b of the base portion 126 a of the lock handle 126 then are aligned with screw apertures 122 e of the lock bar 122 . A screw 135 is inserted through one of the screw apertures 122 e of the lock bar 122 and a corresponding standoff aperture 126 b of the base portion 126 a of the manual lock handle 126 , and is advanced into the center of the cylindrical shaft 130 a of the hex head standoff 130 . This procedure is repeated for the other screw aperture 122 e of the lock bar 122 and the corresponding standoff aperture 126 b of the base portion 126 a of the manual lock handle 126 .
[0073] FIGS. 17A and 17B illustrate front and side views, respectively, of the lock bar 122 with four of the tilt-out bin lock bar clips 124 and the manual lock handle 126 attached thereto.
[0074] FIGS. 18A , 18 B, and 18 C illustrate front, side, and top views, respectively, of a manual lock bracket 136 . The manual lock bracket 136 includes a base portion 136 a, which includes a pair of rivet apertures 136 b formed therethrough. A locking portion 136 c extends from the base portion 136 a and includes a lock seal aperture 136 d formed therethrough.
[0075] FIGS. 19A , 19 B, and 19 C illustrate front, side, and top views, respectively, of a vertical channel 138 . The vertical channel 138 includes a base portion 138 a. A side portion 138 b extends from one side of the base portion 138 a. A sliding flange 138 c extends from an opposite side of the base portion 138 a. A front portion 138 d extends from the sliding flange 138 c.
[0076] The base portion 138 a includes a first rectangular aperture 138 e, second rectangular apertures 138 f, third rectangular apertures 138 g, and bolt apertures 138 h. The side portion 138 b includes an aperture 138 i, a locking projection 138 j, and a pair of rivet apertures 138 k. The lock bracket 136 illustrated in FIGS. 18A , 18 B, and 18 C is attached to the side portion 138 b of the vertical channel 138 . More particularly, the rivets apertures 136 b of the base portion 136 a are aligned with corresponding rivet apertures 138 k of the side portion 138 b of the vertical channel 138 , and rivets are placed therethrough.
[0077] FIGS. 20A and 20B illustrate front and side views, respectively, of a bushing 140 that is used to slidably attach the lock bar 122 to the vertical channel 138 , as will be described below. The bushing 140 includes an end portion 140 a, a cylindrical portion 140 b, and a bolt aperture 140 c formed through the end portion 140 a and the cylindrical portion 140 b.
[0078] Assembly and operation of the locking structure of the present invention is described with reference to FIGS. 17A through 21D . The partially assembled locking structure shown in FIGS. 17A and 17B is slidably mounted in the vertical channel shown in FIGS. 19A through 19C . More particularly, the upper end of the lock bar 122 is inserted through the rectangular aperture 138 e of the base portion 138 a of the vertical channel 138 , and the locking portion 126 c of the manual lock handle 126 is inserted through the aperture 138 i of the side member 138 b of the vertical channel 138 , as shown in FIGS. 21A through 21D .
[0079] A cylindrical portion 140 b of a bushing 140 is inserted through one of the oval-shaped apertures 122 g of the lock bar 122 and aligned with one of the bolt apertures 138 h of the base portion 138 a of the vertical channel 138 . A washer (not illustrated) is inserted between the base portion 138 a of the vertical channel 138 and the lock bar 122 such that it contacts the end cylindrical portion 140 b that does not include the end portion 140 a. A bolt (not illustrated) is inserted through the bolt aperture 138 h of the vertical channel 138 , an aperture of the washer, and the bolt aperture 140 c of the bushing 140 . A nut 142 is secured to the end of the bolt, as shown in FIG. 21A . This process is repeated for the other oval-shaped apertures 122 g of the lock bar 122 . The lock bar 122 now is slidably attached to the vertical channel 138 .
[0080] When the lock bar 122 is positioned as described, the retaining flanges 122 f of the lock bar 122 protrude through the rectangular apertures 138 g. The retaining flanges 122 f and the rectangular apertures 138 g cooperate to ensure that the lock bar 122 slides only a predetermined distance with respect to the vertical channel 138 . In addition, the locking portion 126 c of the manual lock handle 126 is positioned above the locking projection 138 j of the vertical channel, as shown in FIG. 21D .
[0081] The assembled locking structure is positioned on the cart 100 such that the upper portion of the lock bar 122 extends through the lock bar opening 102 b of the top frame 102 and the tilt-out bin lock bar clips 124 extend through the rectangular apertures 104 b of the side walls 104 a of the front frame 104 . The locking portion 126 c of the lock handle 126 and the locking portion 136 c of the lock bracket 136 extend through the lock aperture 107 b of the right front frame 107 .
[0082] FIGS. 15A , 15 B, and 15 C illustrate side, top, and bottom views, respectively of a thumb latch 128 , which includes a curved upper surface 128 a, as shown in FIG. 15A . A lower surface of the thumb latch 128 includes a retaining portion 128 b, which has a screw aperture 128 c formed therein, as shown in FIG. 15C . The thumb latch 128 is attached to the lock handle 126 . More particularly, a screw (not labeled) is inserted through the screw aperture 126 f of the latch flange 126 d of the manual lock handle 126 and advanced into the screw aperture 128 c of the thumb latch 128 .
[0083] As shown in FIG. 1B , the vertical channel 138 is attached to an upper horizontal member 139 a and a lower horizontal member 139 b of the cart 100 using a plurality of nuts and bolts (not illustrated). When the locking portion 126 c of the manual lock handle 126 is disposed on the upper side of the locking projection 138 j of the vertical channel 138 , the locking portion 126 c rests on the locking projection 138 j and each of the locking tabs 124 d of the bin lock bar clips 124 is disposed in front of one of the locking tabs 108 c of one of the bins 108 , which prevents the bins 108 from being opened.
[0084] To unlock the bins 108 , an operator applies a force to the curved upper surface 128 a of the thumb latch 128 , which causes the locking portion 126 c of the lock handle 126 to pivot away from the lock bar 122 and slide downwardly next to the locking projection 138 j, which causes the lock bar 122 to move downwardly. When the lock bar 122 moves downward, the locking tabs 124 d of the tilt-out bin lock bar clips 124 are lowered from in front of the locking tabs 108 c of the tilt-out bins 108 , which enables the tilt-out bins 108 to be opened by pulling on the handles 108 a thereof.
[0085] The second section of the cart 100 may also be sealed with a frangible or severable lock seal 120 . More particularly, a locking portion 120 a of the lock seal 120 is inserted through the lock seal aperture 126 e of the locking portion 126 c of the lock handle 126 and the lock seal aperture 136 d of the locking portion 136 c of the lock bracket 136 , and into the retaining portion 120 c of the lock seal 120 . When an operator depresses the thumb latch 128 , movement of the lock bar 122 causes the lock seal 120 to be severed, thereby enabling access to the interior of the second section of the cart 100 . If the cart 100 also has a lock seal 120 attached to the first section, as described above, when the operator depresses the thumb latch 128 , movement of the lock bar 122 causes both lock seals 120 to be severed, thereby enabling access to the interior of both sections of the cart 100 .
[0086] While the present invention has been described with respect to what is presently considered to be the preferred embodiments, the present invention is not limited to the disclosed embodiments. Rather, the present invention covers various modifications and equivalent arrangements included within the spirit and scope of the appended claims. The scope of the appended claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
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An emergency crash cart includes a sealing structure that enables multiple storage sections of the cart to be locked and sealed simultaneously. The locking structure enables one of the storage sections to be unlocked and unsealed without unlocking or unsealing the other storage sections. The locking structure also can be actuated to unlock and unseal all storage sections simultaneously for rapid access to the contents of all storage sections of the cart.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of U.S. Provisional Patent Application No. 60/646,390 filed on Jan. 24, 2005, which is incorporated herein by reference.
FIELD OF INVENTION
[0002] The present invention relates to heating products.
BACKGROUND OF THE INVENTION
[0003] There is a need for a product that can be used to provide a warmed changing surface for changing a baby while also providing a means to warm pajamas, slippers, baby blankets or the like, in order to eliminate the uncomfortable feeling associated with wearing or using these items in their colder state.
SUMMARY OF THE INVENTION
[0004] The present invention meets the above-described need by providing an electrically-operated heating device that is capable of providing a warmed changing surface while heating items such as pajamas, slippers or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The invention is illustrated in the drawings in which like reference characters designate the same or similar parts throughout the figures of which:
[0006] FIG. 1 is a perspective view of a combined changing pad and blanket warming apparatus as shown in an embodiment of the present invention; and
[0007] FIG. 2 is an enlarged perspective view of the feature control unit of the present invention.
DETAILED DESCRIPTION
[0008] Referring to FIGS. 1 & 2 generally, and initially to FIG. 1 , the apparatus 10 of the present invention may be provided with a heating pad 13 which may contain a heating element which may be molded into a high density polyethylene with, by way of non-limiting example, a maximum temperature of 103 degrees Fahrenheit. The heating pad 13 may be covered or enveloped by a removable liner 16 which may be washable if it should become soiled. The removable liner 16 may also enclose side guards 19 which may aid in preventing a baby or objects from rolling off of the apparatus 10 .
[0009] The apparatus 10 may also contain a heating bag 22 which may be thermostatically controlled to warm pajamas, clothing, diapers, dry towels, or other objects. An interior of the heating bag 22 may be accessed by through a pocket opening 25 .
[0010] The temperature of the apparatus 10 is controlled by utilizing a feature control unit 28 which may have an auto on and off timer regulated by the user. The feature control unit 28 may have built-in circuitry to automatically shut it off if the temperature sensor fails to provide a correct value (i.e. is disconnected or breaks). As shown in FIG. 2 , the feature control unit 28 may be provided with a heating pad adjustment button 34 capable of adjusting the temperature of the heating pad 13 between various settings which may be displayed on the heating pad indicator LEDs 37 . Similarly, the feature control unit 28 may be provided with a heating bag 22 adjustment button 40 capable of adjusting the temperature of the heating bag 22 between various settings which may be displayed on the heating bag indicator LEDs 43 .
[0011] In alternative embodiments of the invention, the feature control unit 28 may also include an aroma diffuser, a music playing device or a light.
[0012] In use, the apparatus 10 may be placed on a typical changing surface 31 . Alternatively, the apparatus 10 may be placed on, by way of non-limiting example, a table, shelf or the ground.
[0013] In another embodiment of the invention, the apparatus 10 may be powered by a standard electrical outlet by means of a cord, or by batteries.
[0014] As another alternative, the present invention may be used to provide a warmed liner for a car seat, infant seat, or baby swing. Also, the present invention can be used on the ground in a larger version as a play area for a child.
[0015] While the invention has been described in connection with certain embodiments, it is not intended to limit the scope of the invention to the particular forms set forth, but, on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention.
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A combination changing pad/textile warmer apparatus that provides a warmed changing surface for changing a baby while also providing a means to warm pajamas, slippers, baby blankets, or the like.
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[0001] The present invention relates to the preparation of lysophosphatidyicholine, and more particularly to the preparation of lysophosphatidyicholine using dialkyltin derivatives.
[0002] A lysophospholipid is a glycerophospholipid having a single fatty acid acyl chain bound to the glycerol by an ester bond.
[0003] The existence of a polar part and of a lipophile in the molecule imparts particular properties to lysophospholipids and their presence modulates the rigidity and stability of the structures of the cell walls as well as that of artificial model membranes. Lysophospholipids are very widespread in nature, in both animals and plants, although they typically represent only a small fraction of the lipid components of cells.
[0004] Some of the most widespread and most thoroughly studied lysophospholipids are the lysophosphatidylcholines (lyso-PCs) whose general formula is shown in FIG. 1 in which R 1 OH=fatty acid and R 2 ═H or R 1 ═H and R 2 OH=fatty acid.
[0005] In addition to the structural function, lyso-PCs act as regulators of various enzyme activities, and can be used as biological markers to indicate pathological states (see for example JP2002-017398).
[0006] The use of lysophospholipids as ingredients in pharmacological formulations is widely documented; for example, lyso-PC has been studied as an ingredient of nasal formulations (Illum et al., Int. J. Pharmaceutic 319 (1992)) and oral formulations (U.S. Pat. No. 4,874,795).
[0007] Large quantities of lysophospholipids are also used as emulsiflers in the food industry.
[0008] In organic synthesis, they are important intermediates for the preparation of mixed-chain phospholipids (Phospholipids Handbook edited by G. Cevc (1993), pp. 154-155); for example, in the preparation of POPC 4, shown in FIG. 2 , lyso-PC is the final intermediate (3) of the synthesis.
[0009] In spite of the importance of lyso-PCs in the medical and biological fields and their use in the synthesis of other phospholipids, the preparation procedures are relatively limited.
[0010] This is because, although isolation from organic tissues is more useful for analysis than for preparation, the production of lyso-PCs is based primarily on methods described in the literature, which are not absolutely ideal.
[0011] These methods are substantially based on two different approaches to synthesis, namely (A) the hydrolysis of a single ester group of phosphatidylcholine or (B) the monoacylation of glycerophosphorylcholine (GC), in purely chemical or chemicallenzymatic experimental conditions and with a greater or lesser degree of selectivity.
[0012] The most widely used hydrolytic method (A) exploits the selective hydrolysis of the only ester group linked to position sn-2 of phosphatidylcholine in the presence of phospholipase A 2 as shown in FIG. 3 .
[0013] The reaction is carried out in an aqueous medium in which the subsequent equilibrium between the two forms of lyso-PC derived from the migration of the acyl group is established. The ratio between the two forms is typically 9:1 with the predominance of the form with the acyl group linked to position sn-1 (Dennis et al., Biochemistry 1743(1982)).
[0014] However, this reaction, even if carried out on an industrial scale, is not entirely optimal, since it presents the difficult problem of recovering the product from the aqueous reaction mixture from which can only be extracted or isolated with difficulty, because of its characteristics of solubility and surface-active properties. Another unfavourable aspect is the fact that the principal source of phospholipase A 2 is pig pancreas, which may lead to viral contamination which is highly undesirable when the end product is intended for pharmaceutical use.
[0015] On the other hand, another enzymatic hydrolytic method for preparing lysophospholipids makes use of the selective hydrolysis of the acyl group linked to position sn-1 of the glycerol of the phospholipids; in this case, however, in order to prepare the lyso-PCs acylated at sn-1 it is necessary to make the acyl substitute migrate subsequently from sn-2 to position sn-1.
[0016] Among the selective monoacylation processes described in the literature, we shall mention that disclosed by Paltauf and others in EP 161519, centred on the use of the triphenylmethyl group for the selective protection of the primary alcohol function of the glycerophosphorylcholine (GPC) (I); this method advantageously eliminates the use of phospholipase A 2 , and of water as the solvent, but on the other hand it is rather laborious, the yield is not always satisfactory, it requires the chromatographic isolation of the intermediate, and, because of the mass of the triphenylmethyl group, generates considerable quantities of by-products.
[0017] Selective monoacylation in the presence of immobilized enzymes has been proposed as an alternative for the preparation of some deacylated phospholipids (Adlercreutz et al., Enz. Microb. Technol. 630 (2000)). In this case the selectivity is good, but the low specific activity of the enzyme makes it necessary to use such large quantities of it as to make this method unsuitable for industrial application.
[0018] We have now discovered that it is possible to overcome the disadvantages associated with the methods of preparation described above, and to synthesize lyso-PCs advantageously on a large scale with a single chemical process, with generally high yields, using inexpensive reagents which are readily available on the market, and avoiding the use of water as a solvent, with consequent simplification of the final isolation procedure.
BRIEF DESCRIPTION OF THE INVENTION
[0019] The process to which the present invention relates comprises selective monoacylation at position sn-i of GPC (I), a commercially available substance, with an acylating agent in the presence of dialkyltin derivatives according to the diagram in FIG. 4 .
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a general formula of lysophosphatidylcholines;
[0021] FIG. 2 is POPC (4) and palmitoyl lysoPC (3);
[0022] FIG. 3 is the selective hydrolysis of phosphatidylcholine in the presence of phospholipase A 2 ;
[0023] FIG. 4 is the selective monoacylation of GPC (I) with an acylation agent in the presence of dialkyltin derivatives; and
[0024] FIG. 5 is the formation of a stannylene using dibutyltin oxide.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The process proposed by the present invention comprises the selective monoacylation of GPC (I) in the presence of dialkyltin derivatives.
[0026] The use of dialkyl derivatives of tin in diol acylation reactions has been reported in the literature (see for example Hanessian, Tetrahedron 643 (1985)) and is applied mainly to the selective protection of carbohydrates.
[0027] The tin compound is considered to have the function of selectively activating one of the oxygen atoms of the substrate by forming a stannylene of the type shown in FIG. 5 .
[0028] The most commonly used reagent is dibutyltin oxide, but dimethyltin oxide and dimethyltin dimethoxide have recently been proposed as more reactive substitutes. The reaction solvent most commonly used in the prior art for the formation of stannylene is toluene. A procedure based on the use of microwaves to enable dibutyltin oxide to be used in catalytic quantities has also been described (Herradon and others, Synlett 455 (1995)).
[0029] GPC (I) has a very low solubility in apolar organic solvents, such as toluene, commonly used in reactions of acylation in the presence of tin derivatives; furthermore, the phosphate group present in its structure interacts strongly with dialkyltin compounds (see Appl. Organometal. Chem. 443 (2000)), altering their reactivity. In view of these characteristics, it would perhaps be logical to conclude that GPC (I) is not a suitable substrate for this kind of acylation.
[0030] Surprisingly, however, we have found that, in spite of these unfavourable presumptions, it is possible to carry out the aforesaid monoacylation reaction with high yields, and also that this can be done even with catalytic quantities of tin compound, without the need to use microwave equipment or the dimethyltin derivatives which have undesirable toxicity characteristics.
[0031] Anhydrides or chlorides of fatty acids, preferably chlorides, can be used as acylating agents in the reaction; the fatty acids can be saturated, unsaturated or polyunsaturated, with chains varying in length from 6 to 30 carbon atoms. The said acylating agent is generally used in quantities in the range from 100% to 200%, and preferably from 100% to 120%, in terms of moles per mole of glycerophosphorylcholine.
[0032] These compounds are generally commercially available or can be prepared by known procedures.
[0033] The tin derivative to be used in this process has a structure in which two alkyl groups are bonded to the tin atom; these groups can be identical to or different from each other, can contain 1 to 18 carbon atoms or can be polymeric in nature. In the last-mentioned case, the tin derivative can be removed at the end of the reaction by simple filtration, and the reagent can be recycled in the next reaction. The tin atom is also bonded to two halogens (for example dialkyltin dichlorides) or two alkoxy groups (dialkyltin dialkoxides) or acyloxy groups (for example dialkyltin diacetates), or to an oxygen atom with a double bond (diallcyltin oxides, for example dibutyltin oxide).
[0034] According to the present invention, the preferred tin derivatives are dialkyltin oxides, of which dibutyltin oxide and dioctyltin oxide are most preferable.
[0035] These compounds are generally commercially available or can be prepared by known procedures.
[0036] Tin derivatives with long alkyl chains, particularly octyl derivatives, are particularly preferable in the present procedure, since they are less toxic, as indicated by the following values of acute oral toxicity in rats (Sax and others, Dangerous Properties of Industrial Materials, edition VII).
dibutyltin oxide LD50 = 44.9 mg/kg dioctyltin oxide LD50 = 2500 mg/kg
[0037] The tin derivative is used in a quantity ranging from 0.1 to 110 mol % with respect to the substrate, preferably from 5 to 100%, and more preferably from 20 to 100%.
[0038] In order to be able to use the dialkyltin derivative in catalytic quantities, it is generally sufficient to increase the quantity of acylating agent until the reaction is completed. Normally, with a stoichiometric ratio, in moles, of dialkyltin to substrate of 0.2:1, an excess of acylating agent of approximately 50% is sufficient. In the monoacylation process proposed by the present invention it is advantageous to use a base, preferably an amine base, to control the increase in acidity in the medium in the course of the reaction.
[0039] The quantity of the base during acylation can range from 30 to 140 mol % with respect to the substrate, and preferably from 100 to 120%.
[0040] Various amines, such as triethylamine or 4-diinethylaminopyridine (DMAP), which may affect the selectivity of the reaction, can be used as the base.
[0041] In particular, if triethylamine is used, the ratio between the acylation product in positions sn-l and sn-2 of the glycerol has been found to be 9:1, and thus equal to that obtained by the equilibration reaction in water of the monoacyl derivative and also, as mentioned above, in the hydrolytic process with phospholipase A 2 .
[0042] The product obtained with this new process can therefore directly replace that obtained by the conventional procedures as regards the composition of the final mixture.
[0043] In another embodiment of the present invention, a further improvement of selectivity was achieved by using 4-dimethylaminopyridine (DMAIP) as the base. In this case, the acylation ratio between the positions sn-1 and sn-2 in the final lyso-PC was found to be approximately 50:1.
[0044] According to the present invention, the preferred bases are amines, more preferably tertiary amines, and even more preferably triethylamine and DMAP. The reaction temperature can vary from 0° C. to the boiling point of the solvent used. Preferably, the temperature is in the range from 40° to the reflux temperature of the solvent in the stannylene formation stage, while it is in the range from 10 to 40° C. in the acylation stage.
[0045] The process can be carried out in various organic solvents such as alcohols, ethers, esters, aromatic or aliphatic hydrocarbons or chlorinated solvents.
[0046] The preferred solvents are alcohols, such as secondary alcohols, particularly isopropanol.
[0047] In a preferred embodiment of the present invention, we have found that isopropanol can be used advantageously as a solvent for the whole process, in other words both in the preliminary formation of the stannylene and in the subsequent stage of acylation, with a considerable simplification of the experimental procedure by comparison with what has been described in the prior art for similar reactions.
[0048] This is because, in the monoacylation of 1,2-diols with the aid of dibutyltin oxide, there is normally preliminary formation of stannylene in an aromatic solvent, such as toluene, by azeotropic removal of water, and it is only after this lengthy stage of the process that the acylation proper is continued in another solvent such as chloroform (see for example Roelens and others, JOC 5 132(1990))
[0049] There are also reports in the literature (Moffat and others, (JOG 24(1974)) concerning the monoacylation of nucleosides, using dibutyltin oxide in an alcohol solvent (methanol), but this transformation requires the use of an excess of acyl chloride ranging from 400 mol % to 900 mol % with respect to the substrate.
[0050] Surprisingly, however, we have found that, for the completion of the reaction of monoacylation of GPC (I), all that is required is a modest molar excess of acylating agent, normally approximately 20% when the solvent if isopropanol, the concomitant reaction between the acylating agent and the alcohol solvent being fairly limited.
[0051] In a variant of the present process, it is also possible to use a combined method, in which the stannylene is prepared in methanol, the reaction solvent is replaced with isopropanol, and the process is continued with the acylation in the latter solvent.
[0052] In a particularly preferred embodiment of the present invention, the GPC is made to react in methanol with I equivalent of dibutyltin oxide in methanol, and 1.2 equivalents of triethylamine and 1.2 equivalents of a fatty acid chloride are added after the methanol has been replaced with isopropanol.
[0053] The transformation yields of the present process are generally high, typically in the range from 80 to 100 mol % the reagents used are inexpensive and readily available on the market, and if necessary the fatty acid chlorides or the corresponding anhydrides can be prepared by the conventional methods reported in the literature. For these reasons, this procedure can conveniently be used to produce lyso-PCs on a large scale.
[0054] A further advantage of this process consists in the fact that the reaction is carried out without the use of water as a solvent, and this, as is known to those skilled in the art, enables the isolation of the lyso-PCs to be greatly simplified.
[0055] Conventional isolation techniques such as crystallization or chromatographic separation can be used. A particularly favourable aspect is the possibility of isolating the product with a high yield and high purity by crystallization, by adding a suitable organic solvent to the reaction mixture and cooling it.
[0056] In order to illustrate the present invention more clearly, the following examples will now be provided, these examples representing only some of the possible embodiments of the invention and not being intended to limit its scope in any way.
EXAMPLES
Abbreviations
[0000]
GPC=sn-glycero-3-phosphocholine (I)
DBTO=dibutyltin oxide
DOTO=dioctyltin oxide
TEA=triethylamine
DMAP=dimethylamine pyridine
IIPA=isopropanol
Example 1
Palmitoyl-lyso-PC
[0063] A suspension of 2.5 g of GPC (I) (1 eq.), 2.5 g of DBTO (1 eq) and 35 ml of methanol was stirred at reflux to form a clear solution (1.5 hrs.) and the methanol was evaporated to leave a residue of 5 ml. 25 ml of WA was added, the mixture was concentrated again at ordinary pressure to give a residual volume of 5 ml, and 25 ml of IPA was added. 1.6 ml of TEA (1.2 eq) and 3.2 g of palmitoyl chloride (1.2 eq) were dropped in at 25° C. At the end of the dropping, the conversion ( 31 P-NMR) was >99%, and the ratio between the two lyso-PCs was 1:9 in favour of the compound acylated at position sn-1.
Example 2
Stearoyl-lyso-PC
[0064] A suspension of 0.5 g of GPC, 0.5 g of DBTO (1 eq), and 10 ml of methanol was stirred at reflux until a clear solution was obtained (1 hr); the solvent was evaporated from the solution to give a residual volume of 1. ml. 5 ml of IPA was added, the mixture was concentrated again at ordinary pressure to give a residual volume of 1 ml, and 5 ml of IPA was added. 0.324 ml of TEA (1.2 eq) and 0.62 g of palmitoyl chloride (1.2 eq) were dropped in at 25° C. At the end of the dropping, the conversion ( 31 P-NMR) was 92%, and the ratio between the two forms of lyso-PC was 1:9 in favour of the compound acylated at position sn-1.
Example 3
Oleoyl-lyso-PC
[0065] A suspension of 10 g of GPC (I) and 10.65 g of DBTO in 350 ml of IPA was heated at reflux for 1 hr. 5.96 ml of TEA and 12.9 g of oleoyl chloride were dropped on to the resulting suspension after it had been cooled to 0° C. The solution was stirred for 15 mins. at ambient temperature and a specimen of the mixture was analysed by HPLC; the ratio of oleoyl lyso-PC to GPC was 97:3 (100 diol Lichrospher column, ELS detector).
Example 4
Palmitoyl-lyso-PC
[0066] A suspension of 2.5 g of GPC (I) (1 eq.), 0.5 g of DBTO (0.2 eq), and 35 ml of methanol was stirred at reflux for 1 hr, to produce a clear solution from which the methanol was evaporated to give a residual volume of 5 ml. 25 ml of IPA was added and the solution was evaporated to a volume of 5 ml, another 25 ml of IPA being added to the residue. 1.6 ml of TEA (1.2 eq) was dropped in, the temperature was raised to 40° C., and 3.2 g (1.2 eq) of palmitoyl chloride was dropped in, the reaction being sampled at the end of the dropping.
[0067] Another 0.8 eq. of TEA was added and 0.8 eq. of palmitoyl chloride was dropped in. The conversions ( 31 PNMR) were 90% after the first step and >99% after the second step of dropping (2 eq. total).
[0068] 25 ml of heptane was added to the solution, which was then cooled to 0° C. and filtered. This produced 7.6 g of wet product which was recrystallized by a mixture of heptanol and IPA, resulting in 4.4 g of lyso-PC after drying (a yield of 92%).
Example 5
Palmitovl-lvso-PC
[0069] 2.5 g of GPC (I), 3.5 g of DOTO (1 eq), and 35 ml of methanol were placed in a three-necked flask under a nitrogen flow, and were stirred at reflux temperature for two hours; the result was a white suspension to which 24 ml of IPA was added and then evaporated at ordinary pressure. IPA (50 ml) was added to the residue and the suspension was left to cool to 25° C. When the temperature was stabilized, 1.62 ml of TEA (1.2 eq) and 3.24 g of palmitoyl chloride (1.2 eq) were dropped in. The conversion ( 31 PNMR) was >99%, and the ratio between the two lyso-PCs was 1:9 in favour of the compound acylated at position sn-1.
Example 6
Palmitoyl-lyso-PC
[0070] A suspension of 2.5 g of GPC (I) and 2.5 g of DBTO in 125 ml of IPA was stirred at reflux temperature for 1 hr. After the temperature had been raised to 40° C., 1.62 ml of TEA and 3.24 g of palmitoyl chloride were dropped in. The conversion to palmitoyl-lyso-PC was 88% ( 31 P NMR).
Example 7
Palmitovl-lvso-PC
[0071] A suspension of 0.5 g GPC (I), 0.5 g DBTO (1 eq), and 10 ml methanol was stirred at reflux until a clear solution was obtained (1 hr.) and the methanol was evaporated to a residual volume of 1 ml. 5 ml of IPA was added and the solution was concentrated again at ordinary pressure to a residual volume of 1 ml, after which 5 ml of WA was added. At 25° C., 0.220 g of DMAP (1.2 eq) was added and 0.64 g of palmitoyl chloride (1.2 eq) was dropped in. At the end of the dropping, the conversion ( 31 PNMR) was 86%, and the ratio between the two forms of lyso-PC was 1:50 in favour of the compound acylated at position sn-1.
Example 8
Palmitoyl-lyso-PC
[0072] A suspension of 2.5 g GPC (I), 2.5 g DBTO (1 eq), and 35 ml methanol was stirred at reflux until a clear solution was obtained (1.5 hr.), after which the methanol was evaporated to a residue of 5 ml. 25 ml of WA was added, the mixture was concentrated again at ordinary pressure to a residual volume of 5 ml, and 25 ml of WA was added. 1.6 ml TEA (1.2 eq) and 3.2 g palmitoyl chloride (1.2 eq) were added by dropping at 25° C. The conversion ( 31 PNIvIR) at the end of the dropping was >98%. 25 ml of heptane was added to the suspension and, after cooling to 0° C. and holding at 0° C. for 30 minutes, 5.2 g of solid was obtained by filtration. The solid was recrystallized in heptanol/WA, giving 4.7 g of high-purity product after drying (a yield of 98%).
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What is described is a process for preparing lysophosphatidylcholine by selective monoacylation of glycerophosphoryleholine (1), in the presence of an acylating agent and of dialkyltin derivatives, according to the following diagram:
the process being particularly simple and having high overall yields.
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FIELD OF THE INVENTION
The present invention relates generally to dispensers for oral care compositions suitable for cleaning the oral cavity.
BACKGROUND OF THE INVENTION
Toothpaste dispensers are well known in the art. Most existing toothpaste dispensers are in the form of simple tubes that dispense toothpaste when users manually squeeze the tubes. Some of these tubes are formed of flexible plastic, and older ones of these tubes were formed of a soft, malleable metal. Alternatively, some toothpaste dispensers exist in a pump form. Simpler versions of these pump dispensers are manual and a user operates them by depressing the top of the dispenser, and other variants utilize a pump lever on the dispenser. Such toothpaste dispensers are not user-friendly for people who have arthritis in their hands or have other physical limitations such as Parkinson's disease.
In addition, such traditional tube and pump toothpaste dispensers are messy. It is easy to squeeze a tube of toothpaste or to press a manual pump type toothpaste dispenser with an incorrect amount of pressure and eject too much toothpaste that falls on a counter or, worse, on the floor. Further, the caps of tube type toothpaste dispensers often become messy and covered with toothpaste that dries out and thereby makes a worse mess.
In view of the shortcomings described above automatic toothpaste dispenser that can dispense toothpaste without manual operation have come into vogue. They are easier to use, thereby making it easier for young and old to brush their teeth. They are then subtly encouraged to brush their teeth more often. As a result automatic toothpaste dispensers promote oral hygiene.
While automatic toothpaste dispensers have made it easier to dispense toothpaste onto a brush they are still not user-friendly for people who have arthritis in their hands or who have other physical limitations such as Parkinson's disease. These people have difficulty in holding the bristle end of a toothbrush under the dispensing spout of the automatic toothpaste dispensers and the toothpaste too often does not go onto the bristles but, rather, onto the counter or floor.
Whether toothpaste tubes, manually operated toothpaste dispensers or automatic toothpaste dispenser, they all have a common problem. A person using them often touches the opening where the tooth is dispensed from such devices with the bristles of their toothbrush. This creates a hygienic problem because the bristles and handles of virtually all toothbrushes have germs, bacteria and sometimes viruses thereon. A fast rinse of a toothbrush under a running faucet after brushing does not properly clean a toothbrush. They still have germs, bacteria and viruses thereon. Very few families will have a separate toothpaste dispensers for each person in a family and germs, bacteria and viruses are thereby easily spread between members of a family or other group who share one of the many types of toothpaste dispensers described above. This problem is exacerbated when people with physical limitations, such as Parkinson's disease, must hold their toothbrush bristles against the opening where the toothpaste is dispensed in order to get the toothpaste on their toothbrush.
Therefore, there is a need for means to dispense toothpaste using a dispenser that is shared by people while minimizing the transfer of germs, bacteria and viruses between the people. In addition, there is a need in the art for means to help a person position their toothbrush to receive toothpaste only onto their toothbrush and thereby minimizing any messes caused during dispensing toothpaste.
SUMMARY OF THE INVENTION
The aforementioned needs in the prior art are satisfied by the present invention. A novel sanitary guard is provided which is easily attached to the dispensing spout of a dispenser of viscous oral care products such as an automatic toothpaste dispenser. The novel sanitary guard helps prevent a person using an automatic toothpaste dispenser with the sanitary guard attached from touching the dispensing spout of the dispenser with the bristles, head or handle of their toothbrush. In addition, the sanitary guard has means to help a person steady their toothbrush and position its bristles under the dispensing spout of the dispenser so that all toothpaste goes onto the bristles. Further, and very important, the sanitary guard is made of an antimicrobial plastic containing nanosilver compounds that kill microbes and microorganisms such as bacteria, germs, viruses and mold that attempt to grow on the surface of the sanitary guard, making its surface germicidal. This helps prevent the spread of such harmful microbes and microorganisms between people using the same toothpaste dispenser equipped with the sanitary guard.
The novel sanitary guard easily mounts to the outer side of a lip of the dispensing spout of an automatic toothpaste dispenser by frictional fit. The guard may easily be removed for cleaning or replacement. The sanitary guard has open sides that visually permit positioning the bristles of a toothbrush under the dispensing spout to receive toothpaste without touching the spout. In addition, the bottom edge of the sanitary guard has a notch in which the handle of the toothbrush is positioned, and the handle is slid along as toothpaste is dispensed onto the toothbrush bristles. This notch keeps the toothbrush bristles far enough away from the dispensing spout so that it ordinarily will not touch the spout. Use of the notch also helps steady a toothbrush to properly receive toothpaste, and this feature is valuable to people who have a physical limitation that hinders them from holding the toothbrush steady without the aid of the notch on the bottom of the sanitary guard.
DESCRIPTION OF THE DRAWINGS
The invention will be better understood on reading the following Detailed Description in conjunction with the drawings in which:
FIG. 1 is a front view of the novel sanitary guard;
FIG. 2 is a side view of the novel sanitary guard;
FIG. 3 is a side view of a toothpaste dispenser on which the novel sanitary guard is about to be mounted;
FIG. 4 is a side view of the toothpaste dispenser on which the novel sanitary guard is fully mounted for use;
FIG. 5 is a side of a toothbrush;
FIG. 6 is a side view of the toothpaste dispenser on which the novel sanitary guard is fully mounted for use, a toothbrush is positioned under the guard and the dispensing spout of the dispenser, and toothpaste is just commencing to be dispensed;
FIG. 7 is a side view of the toothpaste dispensing mechanism on which the novel sanitary guard is fully mounted for use, the toothbrush positioned under the guard has been moved along underneath the guard while toothpaste has been dispensed, and dispenser is turned off;
FIG. 8 is an enlarged front view of the novel sanitary guard mounted to the dispensing spout of a toothpaste dispenser with a toothbrush positioned thereunder and just about to received toothpaste onto the bristles of the toothbrush; and
FIG. 9 is an enlarged front view of the novel sanitary guard mounted to the dispensing spout of a toothpaste dispenser with a toothbrush positioned thereunder and just after toothpaste has been dispensed onto the bristles of the toothbrush.
DETAILED DESCRIPTION
FIG. 1 is a front view of the novel sanitary guard 10 in accordance with the teaching of the invention. FIG. 2 is a side view of novel sanitary guard 10 . While one shape of the sanitary guard 10 is shown in the drawings the exact shape of sanitary guard 10 is not critical, as long as it contributes to preventing the head and bristles 26 of a toothbrush 24 ( FIG. 5 ) from touching the dispensing spout 11 i and 11 f ( FIGS. 3 , 4 , 6 , 7 ) of a dispenser of viscous oral care products which in this Detailed Description is toothpaste dispenser 10 ( FIGS. 3 , 4 , and 6 - 9 ).
Before describing the novel sanitary guard 10 a toothpaste dispenser 11 ( FIGS. 3 , 4 , 6 and 7 ) with which guard 10 may function is first described. This is done first so that sanitary guard 10 will be better understood. In FIG. 3 is a side view of a toothpaste dispenser 11 on which a novel sanitary guard 10 may be mounted for use. Such fluid dispensers 11 are known in the art, particularly for dispensing soap. Accordingly, such prior art fluid dispensers are only described generally herein.
Toothpaste dispenser 11 comprises a base 11 a in which are typically mounted a pump and batteries for powering the pump (not shown). There is also a top or head piece 11 b in/on which are mounted an actuator button 11 e that powers an air pump (not shown) to dispense toothpaste, and a cap 11 d that may be easily opened to insert a viscous fluid toothpaste 12 into a clear plastic container 11 g that is mounted in middle section 11 c . The top surface of toothpaste 12 is shown rippled only to indicate it is a fluid. Positioned inside container 11 g is a hollow tube 11 h that is used to extract toothpaste 12 from container 11 g and move it to head 11 b where it is dispensed via the dispensing spout which comprises elements 11 f and 11 i . When actuator button 11 e is depressed an air pump (not shown) mounted in base 11 a pumps air into the top of container 11 g as shown at arrow W3 in FIGS. 6 and 7 . The air pressure causes toothpaste 12 to flow up tube 11 h as indicated by arrow W4. The toothpaste 12 then exits toothpaste dispenser 11 via the dispensing spout 11 f , and out spout 11 f , 11 i ( FIG. 3 ) and through novel sanitary guard 10 onto bristles 26 of toothbrush 24 positioned under the dispensing spout and the sanitary guard 10 as shown in FIGS. 6-9 .
Returning to the front view of novel sanitary guard 10 shown in FIG. 1 , it comprises a circular top piece 17 having a hole 18 therefore that is used to mount guard 10 onto dispensing spout 11 f , 11 i as shown in FIGS. 4 and 6 - 9 . The dispensing spout has a larger diameter portion 11 i that fits with an interference fit into hole 18 of sanitary guard 10 as shown in FIGS. 4 and 6 - 9 . Guard 10 has flared, open sides having four corner pieces 13 , 14 , 15 and 16 ( 16 not shown) that form a rectangle at the bottom of guard 10 . The front view of guard 10 shown in FIG. 1 is the almost the same as the rear view (not shown). In the front view shown in FIG. 1 front legs 13 and 14 are shown and there are two legs 15 , 16 on the rear side of guard 10 that are not seen in FIG. 1 . There is a front to rear hole through sanitary guard 10 shown in FIG. 1 as element number 22 . While the lower portion of guard 10 is shown in a rectangular form its shape can be square or oval. Similarly, the holes 22 , 23 etc. through the sides of guard 10 may be oval or another shape.
The front side of sanitary guard 10 has a front bottom edge 20 . Guard 10 also has a rear bottom edge that is not shown in any of the figures except as the line across the bottom of notch 19 in FIG. 1 . Notch 19 in the front bottom edge 20 shows in the side view of FIG. 2 as a dotted line, and shows in FIGS. 8 and 9 with handle 25 of toothbrush 24 resting therein.
FIG. 2 shows a left side view of sanitary guard 10 and it is almost the same as the right side view of guard 10 (just reversed) which is not shown. The front side leg is designated 13 and the rear side leg is designated 15 . Right side legs 14 and 16 are not seen in FIG. 2 but leg 14 is shown in FIGS. 8 and 9 . The description of hole 18 is the same as it is for FIG. 1 which is given above. There is a left to right hole through the left and right sides of guard 10 shown in FIG. 2 as element number 23 .
FIG. 3 shows the toothpaste dispenser 11 , which has already been described, with sanitary guard 10 about to be installed to dispensing spout 11 i and 11 f by moving guard 10 in the direction of arrow W1 until guard 10 is in friction fit with spout 11 i , 11 f as previously described.
FIG. 4 shows sanitary guard 10 fully mounted on dispensing spout 11 i and 11 f of toothpaste dispenser 11 and ready for use as described hereinafter.
FIG. 5 shows a toothbrush 24 having a handle 25 and a head with bristles 26 therein.
FIG. 6 shows a left view of sanitary guard 10 assembled to dispensing spout 11 i and 11 f of toothpaste dispenser 11 with toothbrush handle 25 positioned in the notch 19 ( FIGS. 1 & 2 ) in the bottom front edge of guard 10 as better shown in and described hereinafter with reference to FIGS. 8 and 9 . The bristles 26 are positioned under spout 11 f as shown. Toothbrush 25 may start in the position shown in FIG. 6 and be pushed in the direction of arrow W5, or it may start in the position shown in FIG. 7 and be pulled from under the dispensing spout (arrow not shown). In FIG. 6 actuator button 11 e is depressed by pressing it in the direction of arrow W2. This actuates an air pump (not shown) mounted in base 11 a and air is pumped into the top of container 11 g as shown as arrow W3 in FIG. 6 to dispense toothpaste 12 . This has previously been described. In FIG. 6 , toothpaste 27 is beginning to be dispensed but is not yet on bristles 26 . As toothpaste 27 is being dispensed by just exiting spout 11 f and the user slowly pushes the handle 25 of toothbrush 24 in the direction of arrow W5 until the proper amount of toothpaste 27 has been dispensed onto the toothbrush bristles as shown in FIG. 7 . Actuator button 11 e is then released. In an alternative embodiment of the invention, a timing mechanism may be embodied as known the prior art. When actuator button 11 e is momentarily pressed it activates the air pump (not shown) for a pre-programmed amount of time to dispense toothpaste 27 .
FIG. 7 shows toothpaste dispenser 11 with sanitary guard 10 mounted thereon after toothpaste 27 has been fully dispensed onto toothbrush bristles 26 and actuator button 11 e has been released. Toothbrush 24 is then lowered to clear guard 10 and is removed to brush one's teeth. With this operation no part of toothbrush 24 touches dispensing spout 11 i and 11 f to contaminate it. Any microbes that may be transferred to sanitary guard 10 by toothbrush 24 touching it are killed by the nanosilver compounds in the antimicrobial plastic from which guard 10 is fabricated. This assures a sanitary operation where microbes and microorganisms such as bacteria, germs, viruses and mold are not passed from one person who utilizes toothpaste dispenser 11 to another person who utilizes the same dispenser.
FIG. 8 is an enlarged front view of the novel sanitary guard 10 mounted to the dispensing spout 11 f , 11 i of a toothpaste dispenser 11 with a toothbrush 24 positioned thereunder and just about to receive toothpaste 27 onto the bristles 26 of the toothbrush 24 . The actuator button 11 e has been depressed and toothpaste 27 is commencing to flow out of spout 11 f , 11 i in the direction of arrow W6. Handle 25 of toothbrush 24 is in notch 19 on the underside of sanitary guard 10 and will be moved in or out of sanitary guard 10 to receive toothpaste 27 onto bristles 26 as shown in FIG. 7 .
FIG. 9 is an enlarged front view of the novel sanitary guard 10 mounted to the dispensing spout 11 f , 11 i of a toothpaste dispenser 11 with a toothbrush 24 positioned thereunder after finishing receiving toothpaste 27 onto the bristles 26 of the toothbrush 24 . The actuator button 11 e has been released and no more toothpaste 27 is flowing out of spout 11 f , 11 i . Handle 25 of toothbrush 24 is still in notch 19 on the underside of sanitary guard 10 and will be moved downward and then away from sanitary guard 10 in order to brush ones teeth.
As previously mentioned, the plastic from which sanitary guard 10 is made has nanosilver compounds therein giving it antimicrobial properties that kill microbes and microorganisms such as bacteria, germs, viruses and mold that attempt to grow on the surface of the sanitary guard. This helps prevent the spread of such harmful microbes and microorganisms between people using the same toothpaste dispenser equipped with sanitary guard 10 . One company that sells such nanosilver plastic is BASF Corp., of Florham Park, N.J. Their plastic is an acrylonitrile-styrene-acrylate copolymer called Luran S BX 13042 that comes with a special additive containing silver manufactured by Agion Technologies. Antibacterial polymers have the advantage of not being much more expensive than ordinary plastic and the extra cost is around 10%.
One important feature is that microorganisms are unable to develop immunity to silver. The germicidal properties of silver were used 6,000 years ago by the Sumers who kept water in silver pots so that it could stay fresh for longer, and dropped silver coins into pots with milk to prevent it from going bad. During great epidemics, people who used silverware were more likely to survive. Small children were fed with silver spoons in order to boost their immunity. Wounds were treated with silver compounds that accelerated healing.
In an alternative embodiment of the invention the toothpaste dispenser 11 will not have a dispensing spout 11 f , 11 i to which sanitary guard 10 will attach with an interference fit. To overcome this shortcoming an adapter is provided. The adapter has an adhesive strip attached thereto that is used to attach the adapter to the underside of top 11 b of dispenser 11 in registration with the opening from which toothpaste 12 is dispensed. The adapter has a dispensing spout 11 f , 11 i to which sanitary guard 10 will properly attach with an interference fit. Alternatively, a dispensing spout 10 may be made an integral part of dispenser 11 and need not be fitted to dispenser 11 .
While what has been described herein above is the preferred embodiment of the invention, numerous changes may be made without departing from the spirit and scope of the invention.
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A sanitary guard is disclosed which is attached to the dispensing spout of an automatic toothpaste dispenser with an interference fit. Toothpaste is dispensed through the sanitary guard onto a toothbrush positioned in a slot below the guard to assure the toothpaste will be on the toothbrush bristles. The sanitary guard helps prevent the toothbrush from touching the dispensing spout for sanitary protection. In addition, the sanitary guard is made from a plastic having nanosilver compounds therein that give it germicidal properties for sanitary protection.
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TECHNICAL FIELD OF THE INVENTION
[0001] The invention relates to a method and means for finding defects in materials. In particular, the invention relates to a method for finding holes, spots, edge defects and other related defects and measuring characteristics of sheets of industrial material.
[0002] Even more particularly the invention is related to industrial optical systems used for inspecting and measuring products manufactured in a continuous fashion, such as steel, aluminium, papers, foils and plastics.
BACKGROUND OF THE INVENTION
[0003] There are numerous optical methods for finding optically visible defects, such as holes or spots in industrial material sheets. Manufacturers of such strip or web materials use optical inspection and measurement systems e.g. for controlling the manufacturing process of the materials in order to improve yield in terms of improved quality, decreased waste and machine down time on the manufacturing line.
[0004] The optical measurement systems referred here typically operate online i.e. simultaneously with the product manufacturing and are non-contacting.
[0005] Detection of such quality defects as pinholes, holes, spots, scratches, streaks, cracks, cuts, tears or edge defects are important applications where aforementioned optical inspection and measurement systems may be used. Defects or material properties of other kinds may also be measured with the described systems. Web or strip sheet width, length or edge position measurements, are other examples of the possible uses of these systems.
[0006] One of the methods in accordance with prior art utilises CCD (Charge Coupled Device) cameras. The operation of a CCD camera cell can be divided into two distinctive periods: the integration period and the readout period. During the integration period the cell is active in terms of light intensity measurement and during the readout period it is not. In a typical CCD camera system each CCD camera cell records the integrated light intensity falling upon it during a certain integration period. The resulting integrated electrical charge is stored in each CCD cell until the cell is read out. Typically the total electric charge generated by the photons is stored in a capacitor in each pixel. As a photon hits a pixel, a small amount of charge is added to the capacitor. This process is called the integration period of the device.
[0007] The integration period continues until a certain time has elapsed, and after the completion of the integration, readout period starts. In the readout phase the charge proportional to the incident photon number is observed and recorded, and thus incident photon number can be deduced with certain accuracy. After the readout is complete, the CCD is flushed from the stored charges and a new integration period starts.
[0008] For example the ULMA product range from ABB Corporation has utilised CCD cameras in web inspection, please see “ULMA Nti tuote data” product publications for reference from ABB. Earlier ULMA products have also utilized phototransistors generating photocurrent.
[0009] FIG. 1 shows a flow diagram explaining the prior art. In phase 101 a material sheet is stationary or is traversed between and/or in front of one or more optical light sources and light detectors. In phase 111 a light source, or several emit light beams and shine the beams on a material sheet. In phase 121 light beam targeted towards the material interacts with the material sheet to be inspected or measured.
[0010] In phase 131 light is detected at a light detector or light detectors. The light detector or light detectors convert incident light into photocurrent signals in phase 141 . In phase 151 the photocurrent signal is processed and manipulated to determine characteristics of the material. Prior art solutions of this type are found for example from GB 2181834 and GB 2087544 which are cited as reference.
[0011] Photo multiplier tubes (PMTs) are also used for inspection and measurement of defects in materials manufactured in a continuous fashion. PMTs are most typically used for detection of pinholes in materials. Holes or pinholes in a material sheet may be detected by using a UV (Ultraviolet) light source or a scanning, laser light source on one side of a material and one or several PMTs on the other side. In this case the PMT or PMTs are used to detect the UV or laser light transmitted through the hole while the material traverses the measurement system.
[0012] There are several inherent disadvantages in the prior art. The prior art method of FIG. 1 is prone to ambient light, both optical and electrical noise and the level on signal strength is typically also a problem.
[0013] The CCD devices are integrating and imaging devices; there are strict limits on the speed of detection. If the material is traversed faster, the CCD equipment may be unable to photograph the whole surface area of the sheets, due to the latency in integration and image readout. The integration method CCD cameras are based upon is incremental, not continuous, and therefore undesirably slow and unreliable. The integration periods of CCDs are also typically quite long for the purposes of dynamical defect detection.
[0014] CCD systems also typically operate with visible wavelengths, and ambient light is therefore a problem. A significant disadvantage of the prior art is that either the system has to be covered from ambient light, or it must bear the errors caused by ambient light. Optical filtering is typically inefficient, as the measurements are done at the same wavelengths as ambient light.
[0015] CCD camera systems are imaging systems that produce photograph like, digital images of the material to be inspected or measured. All the image information produced by the CCD camera must typically first be stored in specialized image processing electronics or in computer memory and then transferred and/or analysed in a computer system to distinguish useful measurement information from all unnecessary information. The CCD camera itself cannot discriminate and select inspection or measurement data useful for the user of the system. Especially in large industrial inspection and measurement systems, extensive data storage, transfer and computing capacity is therefore required. In many factories or industrial facilities computer systems of this scale are very expensive and tedious to arrange.
[0016] PMTs are mechanically vulnerable and measurement systems based on PMTs are poor in terms of shock or vibration resistance. UV light based PMT systems are also notoriously unstable, as the UV-source lifetime is typically only 1-2 months. Despite basically different wavelengths of the system light source and ambient light, PMTs are also sensitive to ambient wavelengths and ambient light remains a problem. In the edge area of the material under inspection, separate, mechanical edge following light shields must be used along the sides of the material, to prevent the PMTs located at the edge of the material from becoming saturated and therefore non-operational. The mechanical edge following shields are unreliable since these light shields need to be mechanically moved in demanding industrial environments with possible harmful interference with the material to be inspected or measured.
[0017] Any moving parts or parts mechanically interacting with the material to be inspected or measured are undesirable because of reliability reasons. For example, the edge followers are prone to cause measurement errors as they are subject to mechanical shear, strain and stress, and may typically move to destroy the calibrations of the delicate measurement system. Design of PMT based UV inspection systems for wide material sheets is quite unpractical due to the extensive demands set on mechanical engineering and high cost.
[0018] For clarification the opportunity is taken to define the following terms:
[0019] “Light receiver” and “light detector” are used in this application interchangeably. “Light detector” refers with emphasis to the semiconductor part of the light receiving detector and its associated optical, mechanical and electronic parts. “Light receiver” refers foremost to the entire optical, mechanical and electrical arrangement for receiving the light and comprises at least one light detector.
[0020] “Synchronisation signal” is a signal that is used to synchronise an emitter and a receiver with respect to waveform, phase and/or frequency of the signal.
SUMMARY OF THE INVENTION
[0021] The object of the invention is to relieve and remove some of the aforementioned disadvantages. The invention exhibits an optical inspection and measurement method and means which is resistant to intense ambient light and noise and is capable of inspecting sheets of material continuously, without incremental integration, and without losing information.
[0022] It is a further object of the invention to produce only data required for the inspection or measurement, at data production rates that are relatively low compared to prior art. An even further embodiment of the invention is to measure a wide diversity of different properties from the material sheet with a single optical inspection and measurement method and means.
[0023] Various embodiments of the invention may be constructed of solid-state components and are therefore mechanically more reliable and shock and vibration resistant compared to the prior art. One object of the invention is not to require use of mechanically moving system parts and measure the samples in a non-contacting fashion.
[0024] Most of the aforementioned advantages of the invention are achieved with an inspection and measurement method where the basic measurement and inspection signal is the photocurrent generated in a light sensitive electrical component (photoelectric device). This photocurrent is used continuously and directly as the basic measurement and inspection signal. The photocurrent signal appears in the vicinity of a carrier frequency generated in the measurement system for the purpose of synchronised light emission and light detection. The photocurrent is modulated by light interactions with the material to be inspected or measured, and further demodulated in the receiver part to remove the effects of ambient interference, noise and the carrier frequency. Several emitters send beams to a single receiver, and the emitters are synchronised with the detector. The different beams typically have different carrier frequencies, and measure different properties from the sheet.
[0025] In one particular embodiment of the invented method, the system comprises at least one LED (Light Emitting Diode) based light source, at least one photodiode based light detector, at least one waveform generator device generating an AC sinewave or square wave control signal, the carrier signal for synchronisation of at least one LED based light source and at least one photodiode based light detector. In this embodiment several phases, processes and arrangements take place to accrue inventive advantages:
[0026] a sheet of material to be inspected or measured is traversed between and/or in front of at least one light source and at least one light detector,
[0027] at least one waveform generator generates an electrical signal (carrier) of a repeating AC waveform at a given frequency for synchronised control and operation of the light source and the light detector,
[0028] at least one light source emits light, intensity of which follows a carrier waveform of a waveform generator,
[0029] light emitted by at least one light source is targeted on the material sheet or a part of it and/or the edge of the sheet to be inspected or measured,
[0030] at least one beam of light is stopped by the sheet, reflects from the sheet, passes partly through the sheet, passes through apertures or holes or defects in the sheet, passes partly by the sheet or otherwise interacts with the material sheet to be inspected or measured in a manner which results in amplitude modulation (AM) of the intensity of the light beam by the material,
[0031] at least one light detector detects and measures an amplitude modulated light beam signal after it has interacted with the material sheet to be inspected or measured,
[0032] at least one light detector converts an amplitude modulated light signal it has received into continuous electrical photocurrent,
[0033] at least one light detector or following analog signal processing electronics of the system, utilize at least current-to-voltage conversion and synchronised detection or demodulation in the further signal processing of the photocurrent signal for improving the quality and signal-to-noise ratio of the inspection or measurement signals of the system,
[0034] analog signal processing part of the system produces one voltage signal (demodulated signal) for each light detector,
[0035] the momentary absolute value of the demodulated signal of a light detector is proportional to the amplitude of the modulating effect of the interaction between the light signal and the material sheet to be inspected of measured,
[0036] demodulated signal amplitude and/or a rapid change in the demodulated signal is observed, recorded and analysed by the inspection or measurement system to measure certain properties of the material sheet, such as sheet width, sheet length or edge position of the sheet, or to locate defects or imperfections in the sheet, such as pinholes, holes, spots, scratches, streaks, cracks, cuts, tears or edge defects in the material,
[0037] more than one beam from more than one emitter are synchronised with one detector, and different beams measure different properties.
[0038] The aforementioned is also considered at the moment to present the best mode of the invention. The best mode of the invention is especially applicable for the purpose of detecting the three-dimensional structure of the defects in the material sheet with multiple light beams synchronised to the same detector.
[0039] An optical measurement and inspection method in accordance with the invention comprises at least two light emitters, at least one light receiver, at least one signal generator connected to at least one light emitter and at least one light receiver and means for converting the received light to electrical current, and is characterised in that,
[0040] a sheet of material lies or traverses between and/or in front of at least two light emitters and at least one light receiver,
[0041] at least one signal generator controls at least one light emitter and at least one light receiver by sending them a synchronisation signal and thereby synchronises the emission and detection of light rays,
[0042] at least one signal generator drives at least two light emitters with different carrier frequencies, waveforms and/or phases, and at least one light receiver with both of these frequencies waveforms, and/or phases,
[0043] at least two light emitters emit at least two rays of light,
[0044] at least two rays are incident on the stationary or traversing sheet,
[0045] at least two grazing, transparent and/or reflected rays of light from the sheet or directly from the light emitters are detected by the same light receiver,
[0046] at least two rays of light are converted to photocurrent,
[0047] the processed photocurrent and/or changes in the processed photocurrent are diagnosed and observed to find defects and/or determine characteristics of the aid sheet of material.
[0048] An optical measurement and inspection arrangement in accordance with the invention comprises at least two light emitters, at least one light receiver, at least one signal generator connected to at least one light emitter and at least one light receiver and means for converting the received light to electrical current and is characterised in that,
[0049] a sheet of material is arranged between and/or in front of at least two light emitters and at least one light receiver,
[0050] at least two light emitters are arranged to emit at least two rays of light incident on at least one sheet,
[0051] at least two grazing, transparent and/or reflected rays of light are arranged to be detected by the same light receiver,
[0052] at least one ray of light is arranged to be converted to photocurrent by at least one photoelectric device,
[0053] at least one signal generator is arranged to control at least one light emitters and at least one light receiver by sending them a synchronisation signal and thereby synchronises the emission and detection of rays,
[0054] at least one signal generator is arranged to drive at least two light emitters with different carrier frequencies, waveforms and/or phases, and at least one light receiver with both of these frequencies, waveforms and/or phases,
[0055] the photocurrent and/or changes in photocurrent are arranged to be diagnosed and observed to find defects and/or determine characteristics of the said sheet of material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0056] Next the invention is described in greater detail with reference to exemplary embodiments in accordance with the accompanying figures, in which:
[0057] FIG. 1 shows a method 10 in accordance with the prior art as a flow diagram on a general level.
[0058] FIG. 2 shows an inspection and measurement method 20 based on synchronised optical detection in accordance with the invention as a flow diagram.
[0059] FIG. 3 shows a detailed exemplary embodiment 30 of the invented inspection and measurement method 30 based on synchronised optical detection in accordance with the invention.
[0060] FIG. 4 shows a front view of an arrangement 40 for measurement and/or defect inspection of a material sheet in accordance with the invention.
[0061] FIG. 5 shows a more detailed front view of an arrangement 50 and an optical ray diagram of an arrangement for measurement and/or defect inspection in accordance with the invention.
[0062] FIG. 6 shows an arrangement 60 and an optical ray diagram of an arrangement for measurement and/or defect inspection in accordance with the invention from a side view.
[0063] FIG. 7 shows a more detailed arrangement 70 and an optical ray diagram of an arrangement for measurements and defect inspection in accordance with the invention from a side view.
[0064] FIG. 8 shows an exemplary, functional block diagram for a fault detection circuit and method 80 in accordance with the invention.
[0065] Some embodiments of the invention are described in the dependent claims.
DETAILED DESCRIPTION
[0066] FIG. 2 displays an inspection and measurement method, where synchronous detection in accordance with the invention is used. In phase 200 a material sheet to be inspected or measured lies or traverses between and/or in front of at least one light source and at least one light detector. In phase 205 a controlling, constant frequency carrier signal is generated in a waveform generating device for the purpose of synchronisation of emission and detection of light beams in the measurement system. The carrier may have an AC sine wave, square wave or other waveform. The carrier signal is delivered to at least one light source and at least one light detector for the synchronised control of these system parts. In phase 210 a DC offset may be added to a carrier signal before using it for light source control to guarantee that some light intensity is emitted also at AC control signal values corresponding to lowest emitted light intensity. In some embodiments of the invention DC offset may not be required and phase 210 is therefore optional.
[0067] In some embodiments of the invention several waveform generating devices may be used to generate several waveforms and/or several frequencies in order to build measurement or inspection systems where a light detector may simultaneously detect, distinguish and separate light signals originating from different light sources operating at different waveforms and/or waveform frequencies. Several waveform generating devices and waveforms and/or frequencies may also be used for the purpose of isolating two, at least partly independent but closely spaced inspection or measurement systems from each other in terms of light signal disturbance from one system to another. Several emitters and beams may be focused to a particular detector that is synchronised with these emitters. The different beams and emitters may have different carrier frequencies and they may measure different properties from the material sheet. For example, a few beams may depict the three dimensional structure of a defect by measuring its area, height, width, depth, diameter, circumference, reflectivity or the like, properties from which the three dimensional structure may be deduced.
[0068] The intensity of a light beam emitted by a light source is controlled in phase 215 by the carrier signal which may have been DC shifted in optional phase 210 . The carrier signal is used for controlling at least one light source and/or at least one light detector. In phase 220 the carrier controlled light beam from the light source is shone on the material. The intensity of the light beam follows the waveform of the carrier signal. In phase 225 light beam or beams are incident on the material sheet to be inspected or measured, and light is absorbed and stopped by the sheet, reflects from the sheet, passes partly through the sheet, passes through apertures or defects in the sheet, passes partly by the sheet or otherwise interacts with the sheet. Typically several of the aforementioned or other interactions happen simultaneously or sequentially. Thus the sheet modulates the amplitude of the light signal initially appearing at the carrier frequency and following carrier waveform. In phase 230 interacted and modulated light signal is detected at a light detector. Depending on measurement geometry, inspection or measurement system structure and interactions with the material sheet, a varying amount of light originating from one or more light sources is received by each light receiver in phase 230 . In phase 235 , a light receiver collimates or focuses the light on a photodiode, APD (Avalanche Photodiode), any other semiconductor based photoelectric, light sensitive component or any other photoelectric device designed for the purpose of detecting light signals. The collimation and/or focusing may be implemented by using light pipes and/or lenses or other optical components. In phase 240 the photoelectric device converts the incident light into photocurrent. The photocurrent is then manipulated and demodulated or in other terms, synchronously detected in phase 245 in order to remove carrier frequency from the signal and to recover the lower frequency, modulated signal of interest. The resulting demodulated signal is proportional to the amplitude of the modulating effect of one or several interactions between the initial, carrier frequency light signal and the material sheet. In phase 250 the demodulated signal is fed into analysis electronics and software for the purpose identifying signals and signal events of interest and the signal is analysed. In phase 255 the absolute value and/or rapid changes in the demodulated signal are observed, recorded and analysed. Analysis results are exploited to measure selected properties of the material sheet, and/or to detect defects or imperfections in the material sheet.
[0069] It is clear that within the scope of the invention one or several light sources and one or several light detectors and receivers may be in any line of sight positions with respect to the inspected sheet. Transparent and reflected beams of light as well as light beams interacting by other means may be used in said measurement or inspection systems. In some embodiments phases 200 , 205 , 210 , 215 , 220 , 225 , 230 , 235 , 240 , 245 , 250 , 255 and 260 may take different permutations in accordance with the invention.
[0070] It is also clear that several light beams may have different carrier waveform frequencies in different methods. The different frequencies are useful in distinguishing signals from various emitters at the receiver end. It is therefore possible to route several beams to a particular receiver and use the same receiver in analysing measurements from different optical paths. This allows complex designs of three dimensional detection systems, applicable for detecting defect structures in three dimensions.
[0071] FIG. 3 displays one particular and typical embodiment of the invention at a more detailed level. In phase 300 a material sheet to be inspected or measured traverses between and/or in front of one or more light sources and light receivers. In phase 305 a controlling, constant frequency carrier signal of AC sine wave waveform is generated in an electronic signal generator for the purpose of synchronisation of one or several light sources and one or several light receivers in the measurement system. The AC sine wave carrier signal is delivered to at least one light source and at least one light receiver for synchronised operation of the measurement system. In phase 310 a DC offset is added to the AC sine wave carrier signal to guarantee the linearity of at least one emitter.
[0072] The intensity of a light beam emitted by a light source is controlled in phase 315 by the DC shifted, sine wave carrier signal. The DC shifted carrier signal is used for controlling one or several light sources. Light sources are LED based, solid state light sources. The DC shifted AC sine wave carrier is directly converted into forward currents signals of individual LEDs in order to implement emitted light intensity signal following the sine wave waveform of the carrier. The light signal intensity therefore consists of a DC component and an AC sine wave component. A square wave signal derived from the AC sine wave carrier signal is used for controlling one or several light detectors. In phase 320 an AC sine wave carrier controlled light beam from a light source is shone on the material. In phase 325 light beam or beams are incident on the material sheet to be inspected measured, and light is absorbed and stopped by the sheet, reflects from the sheet, passes partly through the sheet, passes through apertures or defects in the sheet, passes partly by the sheet or otherwise interacts with the sheet. Thus the material sheet modulates the DC shifted, AC sine wave amplitude of the light signal initially appearing at the sine wave carrier frequency. In phase 330 interacted and modulated light signal is detected at a photodiode based light detector. Light pipes and lenses are used for collimating and focusing light to the active area of a silicon photodiode in phase 335 .
[0073] In phase 340 the silicon photodiode absorbs the incident light photons and light is converted into photocurrent. A transimpedance amplifier may be used in phase 340 to convert the signal current produced by the photodiode into signal voltage and amplify it.
[0074] In phase 345 the control signal (carrier) received by the signal processing electronics from the waveform generator is utilized to perform first step of synchronized detection, rectification of the signal. In this typical embodiment the rectified signal is further low-pass filtered in phase 345 to finalize synchronized detection. The filter circuit used in this embodiment is typically a Bessel filter but may also be a Gaussian-, Chebyshev-, Butterworth- or an RC-filter. Phases 340 and 345 together perform the function of demodulation or synchronised detection in some embodiments.
[0075] Manipulation and synchronised detection of the photocurrent signal, which may also be called demodulation of the photocurrent signal, results in that low frequency signal components carried by the carrier frequency are therefore present in the photocurrent signal in the vicinity of the fixed frequency of the waveform generator (the carrier frequency) are effectively amplified and detected whereas signals, noise and disturbance at other frequencies, especially at low frequencies are effectively attenuated. In a typical embodiment of the invention, a fixed frequency AC sine wave voltage is generated by the waveform generator to act as the carrier and a symmetrical, 50% duty cycle, square wave signal, processed from the sine wave signal and carrying equal frequency and phase in term of zero-crossings, is used for rectifying the manipulated photocurrent signal in phases 340 , 345 after first removing any DC components of the signal. In this typical embodiment rectified signal is low-pass filtered to finalize synchronised detection, and demodulated voltage signal is produced in phase 350 .
[0076] In a typical embodiment the absolute value of the demodulated signal is measured and recorded in phase 360 by using an ADC electronics component.
[0077] In phase 365 the AC voltage produced is further fed into the signal processing electronics, which performs processing on the basic AC voltage signal. The signal processing electronics may be part of the light detector itself or a part of system level electronics of the inspection or measurement system. The purpose of signal processing is to remove and reduce noise and interference still present in the signal due to e.g. ambient light, other light sources and/or noise present in the signal electronics of the system in general. Synchronised detection heavily depresses the effect of ambient light.
[0078] The purpose of the signal processing is also to remove carrier frequency from the signal and to recover the lower frequency, modulating signal of interest phases ( 345 , 350 ). This step exhibits the key benefits of synchronous detection by removing and reducing noise and interference still present in the signal due to e.g. ambient light, other light sources or system electronics. The resulting signal, demodulated signal is proportional to the amplitude of the modulating effect of one or several interactions between the initial carrier frequency light signal and the material sheet.
[0079] It is clear that other waveforms than the aforementioned AC sine wave voltage may be generated by the waveform generator within the range of the invention and other means, including linear demodulation by using a linear signal multiplication instead of square-wave signal rectifying may be used for demodulation or synchronized detection of the photocurrent signal. Quite clearly, the signal that drives the emitter may have a different waveform to the one that synchronises the emitter and a receiver. In one preferable embodiment, sine wave signal is used to drive the emitters, and a square wave signal derived thereof is used to synchronise at least one emitter and receiver.
[0080] In some embodiments in phases 350 , 360 and 365 the signal output of the signal processing (demodulated signal) is further fed into and processed by system level electronics which may include dedicated electronics to track changes in the demodulated signal which are not normal for the material to be inspected or measured. In a typical embodiment demodulated signal may be further filtered by a low pass filter in one signal path and a comparator circuit may be used to track faster changes of the demodulated signal by subtracting low-pass filtered demodulated signal and the original demodulated signal from each other. In this exemplary embodiment a certain signal difference threshold may be used in the comparator to produce a digital defect pulse when e.g. a hole or a spot is measured by the system.
[0081] In some embodiments the absolute value of the demodulated signal may also be observed, recorded and analysed in phases 360 , 365 to deduce data intended for locating defects or imperfections in the material to be inspected or measured or especially if certain properties of the material, such as sheet width, sheet length or edge position of the sheet are to be measured.
[0082] The digitised signal values produced by the ADC are analysed in phase 365 , in the system level digital signal processing electronics and software. The analysis typically produces data depicting the properties of the sheet in phase 370 . This data can be made visible to the user of the inspection or the measurement system through a computer monitor but the invented optical detection system may also be integrated with any other production systems or factory automation systems to trigger automatic actions in the production of a materials manufactured in a continuous fashion, such as steel, aluminium, papers, foils and plastics. Likewise the data produced may be accessible to production management software, enterprise resource (ERP) management software or the like in some embodiments.
[0083] Quite clearly any electrical or system delays are taken into account when designing the synchronisation of at least one emitter and at least one receiver in accordance with the invention. In some embodiments phases 300 , 305 , 310 , 315 , 320 , 325 , 330 , 335 , 340 , 345 , 350 , 360 and 370 may take different permutations in accordance with the invention.
[0084] FIG. 4 shows an exemplary embodiment 40 of the invention where the sheet to be inspected or measured is traversed between a light source 400 and several light detector modules 430 . In FIG. 4 the sheet traverses in the direction perpendicular to the projection plane of the figure. In this embodiment the light source is composed of several solid-state, light emitting components such as LEDs (Light Emitting Diodes) and optical components such as light apertures, reflective surfaces, diffusing materials and other components to target the light towards the material sheet and to guarantee uniform light transmission from the light source. The LEDs typically emit light at red wavelengths but blue, white and IR (infrared) LEDs may also be used in some embodiments of the invention. The LEDs may be arranged in one or several rows and a required number of columns to cover the necessary measurement width in the inspection or measurement system. The light source 400 also comprises electronics to receive a controlling, synchronisation signal (carrier) from the waveform generator, and to control the intensity of the light emission from the LEDs or other light emitting components in such manner that the intensity follows the waveform of the waveform generator. In the exemplary embodiment 40 the waveform generated by the waveform generator is an AC sine wave voltage and a DC offset may be added to the synchronisation signal (carrier) before using it for light source control. This is sometimes required to guarantee that sufficient intensity of light is emitted also at the AC sine wave signal values corresponding to lowest emitted light intensity. Adding a DC offset is preferable in embodiments where the LEDs need to be stabilised, but the DC offset is by no means an imperative requirement of the inventive method.
[0085] The light detector array 420 consists of several detector modules 430 , each consisting of one or more individual light detectors. In this embodiment 40 the light detection of the inspection or measurement system is based on using a total of 18 detector modules. In this exemplary case each detector module 430 comprises 4 light detectors, and therefore a total of 18×4=64 light detectors are used in the system.
[0086] The material sheet to be inspected or measured 410 is traversed between the light source 400 and the light detector array 420 . In some embodiments the sheet may also be stationary during the measurement. In this embodiment light interactions of interest are those where light passes the sheet, is absorbed in the sheet, transmits through the sheet, passes through apertures or defects in the sheet or otherwise interacts with the sheet in such manner that at least some light detectors receive some intensity of light after those interactions. The material is typically paper, metal, metal foil, coated metal sheet, plastic, rubber, film, or any other sheet like material that could run on a continuous production line. In these materials the defects or imperfections to be detected are typically pinholes, holes, spots, scratches, streaks, cracks, cuts, tears or edge defects. The exemplary embodiment 40 may also be used for the measurement of running sheet width and/or location and/or orientation in an on-line fashion. If the material is produced in sheets of certain discrete length, the length of those sheets may also be measured with the inspection and/or measurement system of this embodiment. Placing the measurement system in a vertical direction would allow measurement of the height of the material with similar arrangement.
[0087] FIG. 5 displays a more detailed diagram of four closely spaced light detectors 520 in the exemplary embodiment 50 of the invention. The viewing angle in FIG. 5 is similar to FIG. 4 . In this embodiment the light detectors are arranged in detector modules 560 , each comprising four light detectors. FIG. 5 shows an exemplary measurement situation in which each light detector is optically arranged to have a certain, limited field-of-view (FOV). In this embodiment the light sensitive optical component is a silicon photodiode 530 .
[0088] By using other optical components such as a light pipe 540 and a lens 550 the photodiode is arranged to have a limited FOV and therefore only a certain, limited area of the material sheet or surface area of the light source, located behind the material, is viewed by the photodiode. The shape of the viewing area when projected on the surface of the material sheet may be circular, elliptical, rectangular or it may have any other shape as defined by the geometrical and dimensional characteristics of the photodiode and the other optical components. When projected on the surface of the material sheet, the viewing areas of neighbouring light detectors typically overlap. The other optical components 540 , 550 define the focusing properties of the optical path from the surface of the sheet to the active surface of the photodiode component. In some embodiments the optics of the light detector may include other optical components and any number of lenses. Optical filters may be used to limit the system operation to a distinct range of wavelengths. Several light detecting photodiodes may use one or more common lenses to comprise several light detectors.
[0089] In the exemplary application of detecting and measuring holes in the material sheet, a light detector 570 with FOV covered by the material sheet normally views a certain limited surface area of the material sheet. If the material is non-transparent to the wavelength of light used in the system, the photodiode typically does not receive any significant light intensity originating from the light source. If the material is somewhat transparent to the light used, a certain, but rather uniform amount of light, originating from the light source is transmitted through the material to the light detector. The uniformity of this light signal depends on the uniformity of light transmission through a normal, defect-free sheet of this material. A hole present in the material will inevitably pass through the FOV of one of the light detectors in the inspection or measurement system. This is guaranteed by the fact that the optical measurement system is wider than the material sheet and the FOVs of neighbouring light detectors somewhat overlap. When a hole is in the FOV of a light detector, some light originating from the light source will pass through the hole and will be focused on the photodiode. Depending on hole dimensions, FOV dimensions, material sheet traversing speed, measurement geometry, optics of the light detector and several other factors, this will result in a rapid, momentary change of varying amplitude and length in the total light intensity received by the photodiode. This result is a pulse type, rapid change in the photocurrent output of the photodiode. If this pulse is sufficiently large when compared to any pulse originating from normal variations in the light transmission properties of the material, a reliable hole detection signal may be deduced from the photocurrent output of the photodiode.
[0090] Any other defects or imperfections that have the property of transmitting light through the material in a manner clearly deviating from a normal material sheet, may be detected in a similar manner. Defects or imperfections which transmit less light than the normal material, like dark spots may be detected in a partly transparent material in similar manner as the holes except that the polarity of the signal is different. That is, the spot location would be seen as a fast, pulse type decrease in the total light intensity received by the photodiode.
[0091] In another exemplary application of measuring the width of a running material sheet, a light detector 520 with FOV located in edge area of the material sheet is viewing partly certain limited surface area of the material sheet and partly the light source 500 located behind the material sheet. If the material is non-transparent to the wavelength of light used in the system, the photodiode 530 typically receives only the light originating from the light source 500 and passing the material. If the material is somewhat transparent to the light used, the photodiode 530 typically receives a certain amount of light originating from the light source 500 and transmitting through the material and a certain amount of light originating from the light source and passing the material sheet. The uniformity of the transmitting light component depends on the uniformity of light transmission through a normal, defect-free sheet of this material. The dynamic range of the inspection or measurement system is arranged in such manner that the photodiode 530 and following electronics do not saturate when no material is present. Therefore the absolute value of the demodulated signal for this light detector may always be measured. The absolute value of the demodulated signal will be inversely proportional to the percentage of this light detector's FOV covered by the material sheet. Larger FOV coverage by the material sheet will result in smaller absolute value of the demodulated signal and vice versa. Less FOV coverage by the material sheet results in larger FOV coverage by the light source 500 , which results in higher light intensity in the photodiode and larger demodulated signal. By measuring, normalizing, and calibrating the response of the light detector in terms of demodulated signal values vs. location of the material sheet in the FOV of the light detector, the width of the material sheet may be deduced in the actual industrial measurement situation.
[0092] Any other material sheet dimension or location of material sheet edge position may be measured in a similar manner.
[0093] It is clear that the light detector 520 presented in this exemplary embodiment of the invention and located at the edge of the material sheet may be used for simultaneous measurement of material sheet dimensions and/or edge location and detection of defects or imperfections in the edge area of the sheet. The optical inspection or measurement system may be arranged to simultaneously record absolute values of the demodulated signal and to track rapid momentary changes in the demodulated signal. Detection and measurement of rapid momentary changes of demodulated signal in light detector 520 is performed in a manner similar to that of light detector 570 operating with a FOV fully covered by the material sheet.
[0094] It is also clear that several light beams may have different carrier waveform frequencies in different arrangements. The different frequencies are useful in distinguishing signals from various emitters at the receiver end. It is therefore possible to route several beams to a particular receiver and use the same receiver in analysing measurements from different optical paths. This allows complex designs of three dimensional detection systems.
[0095] FIG. 6 shows a third exemplary embodiment 60 of the invention where the sheet to be inspected or measured is traversed in front of a light source 600 and a light detector array 620 . In FIG. 6 the sheet 610 traverses from left to right or from right to left. In this embodiment the light source is composed of several solid-state, light emitting components such as LEDs (Light Emitting Diodes) and optical components such as light apertures, reflective surfaces, diffusing materials and other components to target the light towards the material sheet and to guarantee uniform light emission from the light source. Other light emitting devices may also be used in accordance with the invention. The LEDs typically emit light at red wavelengths but blue, white and IR (infrared) LEDs may also be used in some embodiments of the invention. The LEDs may be arranged in one or several rows and a required number of columns to cover the necessary measurement width in the inspection or measurement system. The light source also comprises electronics to receive a controlling, synchronization signal (carrier) from the waveform generator, and to control the intensity of the light emission from the LEDs or other light emitting components in such manner that the intensity follows the waveform of the waveform generator. In the exemplary embodiment 60 the waveform generated by the waveform generator is an AC sine wave voltage and a DC offset can be added to the synchronisation signal before using it for light source control. This is required to guarantee linearity of light emitters also at the AC sine wave signal values corresponding to lowest emitted light intensity.
[0096] The light detector array 620 comprises several detector modules 630 , each consisting of one or more individual light detectors. For example in embodiment 40 the light detection of the inspection or measurement system is based on using a total of 18 detector modules. In the purely exemplary case of using detector modules comprising 4 light detectors, a total of 18×4=64 light detectors are used in the system.
[0097] FIG. 7 displays a more detailed diagram of a light detector 720 in accordance with the invention, which is similar to arrangement 60 . The viewing angle in FIG. 7 is similar to FIG. 6 . In this embodiment the light detectors 720 are arranged in detector modules, each comprising four light detectors 720 . FIG. 7 shows an exemplary measurement situation in which each light detector is optically arranged to have a certain, limited FOV. In this embodiment the light sensitive optical component is a silicon photodiode 730 , but it may also be realised with an APD or any other photodetector in some embodiments. By using other optical components such as a light pipe 740 and a lens 750 the photodiode is arranged to have a limited FOV 760 and therefore only a certain, limited area of the material sheet is viewed by the photodiode. In this embodiment the light source 700 is arranged to emit light in a fan beam 770 , which covers a material sheet area larger than the total FOV area of the light detectors. The shape of the photodiode viewing area when projected on the surface of the material sheet may be circular, elliptical, rectangular or it may have any other shape as defined by the geometrical and dimensional characteristics of the photodiode and the other optical components. When projected on the surface of the material sheet, the viewing areas of neighbouring light detectors typically overlap. The other optical components define the focusing properties of the optical path from the surface of the sheet to the active surface of the photodiode component. In some embodiments the optics of the light detector may include other optical components and any number of lenses. Optical filters may be used to limit the system operation to a distinct range of wavelengths. Several light detecting photodiodes may use a common lens to comprise several light detectors, or one integrated detector.
[0098] In the exemplary application of detecting and measuring spots in the material sheet, a light detector 720 with FOV covered by the material sheet normally views a certain limited surface area of the material sheet in a 90-degree angle in respect to the material sheet. Depending on the reflectance characteristics of the material a certain, but rather uniform amount of light, originating from the light source is reflected from the material to the light detector. The uniformity of this light signal depends on the uniformity of light reflectance from a normal, defect-free sheet of this material. A spot present in the material will inevitably pass through the FOV of one of the light detectors in the inspection or measurement system. This is guaranteed by the fact that the optical measurement system is wider than the material sheet and the FOVs of neighbouring light detectors somewhat overlap. When a spot is in the FOV of a light detector 720 , light originating from the light source 700 will reflect from the spot area in a manner that differs from normal material. The light reflected from the material sheet into the FOV of the light detector 720 will be focused on the photodiode 730 . Depending on spot dimensions, FOV dimensions, material sheet traversing speed, measurement geometry, optics of the light detector 720 and several other factors, presence of the spot in the FOV will result in a rapid, momentary change of varying amplitude and length in the total light intensity received by the photodiode 730 . This results in a pulse type, rapid change in the photocurrent output of the photodiode. If this light pulse is considerably larger than any pulse originating from normal variations in the light reflectance properties of the material, a reliable spot detection signal may be deduced from the photocurrent output of the photodiode.
[0099] Any other defects or imperfections that have the property of reflecting light from the material in a manner clearly deviating from a normal material sheet may be detected in a similar manner. Defects or imperfections that reflect less light than the normal material, like holes, may be detected in a similar manner as dark spots. Defects or imperfections that reflect more light than the normal material may be detected in a similar manner, except that typically the polarity of the signal is different.
[0100] In another embodiment of the invention three dimensional defects or imperfections may be detected from the material sheet by using light detectors operating at different view angles in respect to the surface of the material sheet. Detection of such defects or imperfections is based on deducing the variations in the reflectance signals received by the light detectors and which originate from same surface locations of the material sheet. In an exemplary embodiment two sets of light detectors view the surface of the material sheet in 45 and 135-degree angles in respect to the speed vector of the traversing material in the plane defined by the speed vector and a vector perpendicular to the material sheet. In some exemplary embodiments the beams measure height, width and depth of the defect, in other embodiments the area, circumference or any other geometric properties of the defect.
[0101] In one preferable embodiment of the invention several emitters are synchronised to the same receiver and detector with different frequencies. The emitters and the detectors are focused to the same area. In this embodiment three dimension defects such as bumps and pits are distinguished from two-dimensional defect such as stains for example. The two-dimensional defects such as stains cause a uniform signal change for light emitted both from left and the right. However, when a three-dimensional defect, such as a bump is illuminated from the right, the defect causes a shadow to the left. Vice versa, a light from the left to a bump causes a shadow on the right. The shadows can be detected as depressions of the signal in accordance with the invention.
[0102] It is clear that the embodiments presented in FIGS. 4, 5 , 6 and 7 may be combined in one actual optical measurement system. All the presented embodiments may be combined in such exemplary manner that the transmittance measurement presented in exemplary embodiment 40 may utilize common light detectors with the reflectance measurement presented in exemplary embodiment 60 , and material sheet width may be measured utilizing light detectors performing transmittance and/or reflectance measurement and inspection of defects or imperfections in the material sheet. In such embodiment two light sources would emit light from opposing sides of the material sheet towards the material and light originating from both light sources would be received by the same set of light receivers and light detectors after interactions with the material sheet. It is also clear that light emitter arrays can be summed to produce signals and light detector arrays may be used to produce signals that are analysed in accordance with the invention.
[0103] Generally, in the typical embodiments of the invention the waveform (carrier) generated by the waveform generator is an AC sine wave voltage signal at a fixed frequency. However, it is clear that the waveform (carrier) signal may take a square wave form, saw tooth form, or the form of any periodic function. This control signal is utilized to synchronize the operation of one or more light sources and one or more light detectors. In the exemplary embodiments presented in FIGS. 4, 5 , 6 , and 7 the photoelectric currents produced by the photodiodes are fed into signal processing electronics that perform manipulation and processing on the basic photocurrent signals. The control signal (carrier) received by the signal processing electronics from the waveform generator is utilised to perform synchronised detection of the signals received from the photodiodes after signal manipulation. In some of the presented embodiments of the invention, a transimpedance amplifier is first used to convert the photocurrents of the photodiodes into photovoltages. DC components of the photovoltage signals are removed in AC coupled amplifiers. The waveform generator generates a fixed frequency AC sine wave voltage and a symmetrical, 50% duty cycle, square wave signal, processed from this sine wave signal and carrying equal frequency and phase in terms of zero-crossings, is used for rectifying the photovoltage signal after removal of the DC components. Rectified voltage signal is low-pass filtered to finalise synchronized detection or demodulation. The filter circuit used is typically a Bessel filter but it may also be a Gaussian, Chebyshev, Butterworth or an RC filter. The signal output of the signal processing (demodulated signal) is further fed into and processed by system level electronics which in these embodiments include dedicated electronics to track rapid momentary changes in the demodulated signal, which are not normal for the material to be inspected or measured. In these embodiments demodulated signal is further filtered by a low pass filter in one signal path and a comparator circuit is used to track fast changes of the demodulated signal by subtracting low-pass filtered demodulated signal and the original demodulated signal from each other. In these exemplary embodiments a certain signal difference threshold is used in the comparator to produce a digital defect pulse when e.g. a hole, a spot or other defect corresponding to the required signal threshold is measured by the system. In some embodiments several comparators with varying threshold levels are used.
[0104] In those embodiments where dimensions of the material sheet or locations of material sheet edge are measured, the absolute value of the demodulated signal is also observed and recorded. The absolute value of the demodulated signal is measured and recorded by using an analog-to-digital converter (ADC).
[0105] The digital pulses produced by the dedicated signal analysing electronics and/or digitised signal values produced by the ADC are analysed in the system level digital signal processing electronics and software. The analysis typically produces data visible to the user of the inspection or the measurement system through a computer monitor but the invented optical detection system may also be integrated with any other production systems or factory automation systems to trigger automatic actions in the production of materials manufactured in a continuous fashion.
[0106] FIG. 8 shows an exemplary, functional block diagram for a fault detection circuit and method 80 in accordance with the invention.
[0107] In 810 the demodulated voltage signal is received from the demodulation filtering. Next this signal branches to three different paths: to an amplifier 820 which adds or subtracts a selected hole detection threshold voltage, to another amplifier 823 which similarly adds or subtracts a selected spot detection threshold voltage, and to a low pass filter amplifier 825 . The outputs of 820 and 823 are compared with output of 825 in comparators 830 , 833 , and digital hole or spot signal pulses 840 , 843 will be deduced by the comparators in case analog signals exceeding the set thresholds enter the fault detection circuitry.
[0108] In many favourable embodiments the output of the low pass filter amplifier 825 needs to be reset fast in order to prevent dead time after defect pulse generation. This is required, for example, to deduce many nearly concurrent spots and/or holes in a dynamic inspection situation. In some embodiments this is achieved by feeding the digital defect signal pulses into a circuit 850 , which generates a reset pulse for the low pass filter amplifier 825 immediately after receiving a digital defect signal 840 or 843 . This effectively resets the fault detection circuitry right after a fault has been detected and, thus the detection of further faults may commence very dynamically indeed.
[0109] In any embodiments several beams may be used to measure several properties of the materials sheets simultaneously. This is effectively achieved in accordance with the invention when several emitters are synchronised with a detector, and the emitters emit beams with different carrier frequencies, which measure different properties from the material sheet. The different beams may also be effectively utilised in measuring the three dimensional structure of the defects.
[0110] The invention has been explained above with reference to the aforementioned embodiments, and several advantages of the invention have been demonstrated. The invention allows a more dynamical and reliable method for detecting optically visible defects, such as holes and spots in sheet materials. It has also been demonstrated that the invention may be used for the measurement of other characteristics of products manufactured in a continuous fashion, such as web or strip sheet width, length or edge position. The invention is capable of measuring several properties of the sheet and/or defect simultaneously. In addition the invention is capable of detecting the three dimensional structure of defects.
[0111] It is clear that the invention is not only restricted to those embodiments presented, but comprises all possible embodiments within the spirit and scope of the inventive thought and the following patent claims.
REFERENCES
[0000]
GB 2181834
GB 2087544
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A method for finding holes, and other related defects and measuring characteristics of sheets of industrial material. Optical detections systems are constantly plagued by intense ambient light and challenged in accuracy. The invention exhibits a defect detection method and apparatus that is resistant to intense ambient light and is capable of inspecting sheets of material ( 410, 510, 610, 710 ) continuously, without integration of long periods. In the invention, synchronous detection between the optical transmitters and receivers is utilized. The invention is applicable for inspecting and measuring materials like paper, metal, rubber, plastic, aluminum foil, copper foil, film, coated metal sheet or any other sheet-like material that could run on a production line. The invention is also applicable for finding special defects like holes, pinholes, scratches, spots, cracks, edge faults, streaks, surface faults or any other conceivable defects.
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FIELD OF THE INVENTION
The present invention generally relates to mobile rock crushers with electronic component vibration reduction mechanisms. It should be noted that any vehicle with high amplitude low frequency vibrations similar to the vibrations of a rock crusher could benefit from the present invention.
BACKGROUND OF THE INVENTION
In recent years, advancements in rock crusher controls have involved utilization of more complex electronics. However, this has also increased the concern for reducing the vibration experienced by electronic or other shake-sensitive components of such mobile rock crushers. Some designs have been improved by isolating the electronic control box or panel of the rock crusher from vibration. The high amplitude, low frequency vibrations generated by the crusher can cause problems with the electronic components inside the box. The fine wires mounting components inside the electronic devices can break due to fatigue and over time, can cause equipment shut-down conditions.
In the past, shock-absorbing mounts have been attempted to separate the control box from rigid structure on the mobile crusher. Because of the large amplitude of these vibrations, these mounts have been generally quite soft. While soft mounts can effectively reduce the vibration transmitted to the electric control box, they lead to instability on the highway as the control boxes may weigh around 1000 lbs or more with certain crusher designs. Having a 1000-lb package elevated above the ground and mounted on very soft mounts is less than optimal.
It is becoming common for crushing plant manufacturers to recommend that sensitive electronics be removed when the crusher is in operation. Recently, crusher manufacturers have employed a removable electronic control panel which is taken off the vehicle and placed on the adjacent surface of the ground. The ground acts to dampen the vibrations from the rock crusher and isolate the electronic control panel.
Common practice for many operators of crushing plants is to use an end loader to lift the electrical control panel or cabinet from a mounting position on the plant/vehicle and lower it to the ground. This often means the operator ties a chain, strap, cable, or other device to lifting eyes mounted to the top of the cabinet and the bucket of the loader. Once the panel is lifted from the mounting brackets on the plant, there are usually no guides to hold it in position (keep from twisting, etc). This can result in difficult handling and damage to the cabinet, wiring, or plant due to the tight clearances and “lack of finesse” associated with the loader controls. Because of these problems, some crusher operators resort to simply ignoring the recommendation to remove the panel from the plant during operation.
One improvement to the loader lift idea has been a special purpose crane boom built by James W. Bell Manufacturing of Cedar Rapids, Iowa. This device may hold two electrical cabinets side by side. A hydraulic cylinder extends and retracts to raise and lower the cabinet, but the swing toward and away from the plant is manual. It may employ a “loose” (chain, etc.) mount between the boom/arm and the cabinet to isolate vibration from the plant.
While removing the electronic control panel and placing it on the ground to enhance vibration isolation has been used successfully in the past, numerous problems exist with prior art removable electronic control boxes. The approach using a front end loader with a chain to lift the electronic control box off the vehicle and lower it to the ground has numerous drawbacks, including the need to have a front end loader available, as well as a skilled front end loader operator. While the James W. Bell unit has eliminated the need for a front end loader, it now requires a person to swing the electric box away from the vehicle. This involves pushing on the electrical box after it is lifted and is free to swing about. This step creates an opportunity for a personal injury or damage to the plant to occur by placing a person next to a 1000-lb elevated and swinging object. This design and others may require extra care during deployment to take up and let out extra electrical cabling which extends between the mobile rock crusher and the electronic control box.
Consequently, there exists a need for improved methods and systems for offloading an electrical control box from a mobile rock crusher, which simultaneously provides for increased safety and speed of downloading.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a system and method for offloading an electronic control box from a mobile rock crusher.
It is a feature of the present invention to provide a single action or single motion hydraulic actuator for lifting the electronic box of the vehicle, moving it away from the vehicle and lowering it to the ground.
It is still another feature of the present invention to include a continuous electrical connection between the electronic control box, while reducing the need for extra cable which potentially creates problems during deployment.
It is yet another feature to include an adjustable foot stop mechanism to keep the electronic control box stable while in the transport position.
It is an advantage of the present invention to provide for a single motion for lifting and securing an electronic control, thereby increasing the speed of downloading an electronic control box from a mobile rock crusher and decreasing the risk of personal injury to humans involved in the offloading process, while eliminating the need for a cable winch and limiting the amount of extra cabling required to facilitate the offloading.
The present invention is a system and method for offloading an electronic control panel from a mobile rock crusher which is designed to satisfy the aforementioned needs, provide the previously stated objects, include the above-listed features, and achieve the already articulated advantages.
Accordingly, the present invention is a system and method which includes a mobile rock crusher with a hydraulically actuated dual boom system which is configured for operation with a single continuous motion.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be more fully understood by reading the following description of the preferred embodiments of the invention, in conjunction with the appended drawings wherein:
FIG. 1 is a perspective view of the mobile rock crusher of the present invention with the electronic control box at an intermediate stage in the process of being offloaded.
FIG. 2 is a perspective view of the electronic control box and the pivoting boom structure, where the electronic control box is disposed in a stowed position for transportation.
FIG. 3 is a perspective view of the electronic control box and the pivoting boom structure, where the electronic control box is deployed in a ground resting position for operation of the mobile rock crusher.
FIG. 4 is an elevation view of the side of the electronic control box and the pivoting boom structure, where the electronic control box is disposed in a ground resting position for operation.
FIG. 5 is an elevation view of the side of the electronic control box and the pivoting boom structure, where the electronic control box is disposed in a stowed position for transportation.
FIG. 6 is an elevation view of the side of the electronic control box and the pivoting boom structure of FIG. 5 , where the electronic control box is disposed in a stowed position for transportation, and with a cover plate and a mechanical lock shown thereon.
FIG. 7 is an elevation view of the front of the electronic control box and the pivoting boom structure, where the electronic control box is disposed in a stowed position for transportation.
FIG. 8 is a schematic sketch of the mobile rock crusher of the present invention which includes a block diagram depiction of the control system for the pivoting boom structures.
DETAILED DESCRIPTION
The following description is focused upon the system and method of the present invention in association with electronic control boxes and mobile rock crushing equipment because it is believed that the advantage of the present invention would be readily apparent in such situations. However, the present invention is not intended to be so limited. The beneficial aspects of the present invention could be desirable for other construction equipment which has high amplitude low frequency vibration characteristics and for other equipment or structures besides electronic control boxes which have need for vibrational damping during operation of the equipment.
Now referring to the drawings wherein like numerals refer to like matter throughout, and more specifically referring to FIGS. 1 and 8 , there is shown a mobile rock crusher 100 with an electronic control box 120 . Mobile rock crusher 100 shows a cone crusher, but a jaw crusher or impact rock crusher could be used to crush rock, concrete or other aggregate-type material as well.
The electronic control box 120 is shown as a cabinet-like container for housing an electronic control, which may include components whose longevity can be adversely affected in a high amplitude low frequency vibration or shock environment. The electronic control box 120 is shown coupled to the cone crusher via several large electric cables from each side of the electronic control box 120 . Also shown is mobile rock crusher trailer structure 106 and mobile rock crusher wheels 110 . Mobile rock crusher 100 could be constructed to be independently moveable on tracks, and could be made either with or without a trailer arrangement. A first pivoting boom arm mechanical lock 108 is also shown for latching the electronic control box 120 in a stowed position for transport. The various components can be made of suitable materials, but steel may be preferred. The first pivoting boom main arm 102 and second pivoting boom main arm 104 must be constructed to carry the load of the electronic control box 120 which could weigh 1000 pounds or more.
The electronic control box 120 is shown suspended from above by first pivoting boom main arm 102 and second pivoting boom main arm 104 . First pivoting boom main arm 102 is shown having a first pivoting boom arm upper connecting member 1020 and a first pivoting boom arm central pivot point member 1022 . Second pivoting boom main arm 104 is constructed in a like manner to first pivoting boom main arm 102 . Second pivoting boom main arm 104 could be identical in construction and be a simple translation in position. A mirrored relationship could exist between first pivoting boom main arm 102 and second pivoting boom main arm 104 .
Now referring to FIG. 2 , there is shown a drawing of the electronic control box 120 in a stowed position on the mobile rock crusher trailer structure 106 for transport. The first pivoting boom stationary end pivot point member 1034 can be seen, as well as the first pivoting boom adjustable foot stop 1042 and the second pivoting boom adjustable foot stop 1044 and the boom connecting rod 1040 . Also shown are electric cable or cable conduit 111 which can connect the electronic control box 120 to other equipment on the mobile rock crusher 100 . Pivoting control box support 1041 is pivotally coupled to first pivoting boom main arm 102 and second pivoting boom main arm 104 , so that the electronic control box 120 pivots freely with respect to both booms 102 and 104 .
Now referring to FIG. 3 , there is shown the system of the present invention with the electronic control box 120 in a lowered position, such as when it rests upon the earth. Also shown are the first pivoting boom non-rigid connection 1046 , which could be a chain, some detachable links, a clevis or the like, or a combination of them. Also shown are first pivoting boom adjustable foot stop 1042 and second pivoting boom adjustable foot stop 1044 , each with the adjustable contact pads 11 which can be screw adjusted so as to automatically and precisely apply pressure onto the top surface of the electronic control box 120 when the first pivoting boom main arm 102 and the second pivoting boom main arm 104 lift and place the electronic control box 120 onto the mobile rock crusher 100 .
Also shown is the first pivoting boom arm lower connecting member 1024 , as well as the first pivoting boom linear actuator 1030 and the first pivoting boom linear actuator pivot only end 1032 .
Now referring to FIG. 4 , there is shown a side view of the apparatus of FIG. 3 in a deployed position where the electronic control box 120 has been lowered to the ground and where it can be seen that electronic control box 120 is suspended from first pivoting boom main arm 102 , which pivots about first pivoting boom stationary end pivot point member 1034 by extension or retraction of first pivoting boom linear actuator 1030 , which couples to first pivoting boom arm upper connecting member 1020 and first pivoting boom arm lower connecting member 1024 at first pivoting boom arm central pivot point member 1022 . First pivoting boom linear actuator 1030 could be a hydraulic cylinder, a pneumatic actuator, an electro-mechanical or mechanical linear actuator, etc. During storage for transport, the first pivoting boom linear actuator 1030 could be locked in place by a hydraulic locking valve or the like. First pivoting boom linear actuator 1030 has a translating and pivoting portion at first pivoting boom arm central pivot point member 1022 and a first pivoting boom linear actuator pivot only end 1032 .
Now referring to FIG. 5 , there is shown a side view of the electronic control box 120 similar to FIG. 4 , except that the electronic control box 120 is shown in a stowed position for transporting. In FIG. 5 , the first pivoting boom linear actuator 1030 is revealed and the first pivoting boom arm lower connecting member pivot only end 1026 is shown. First pivoting boom arm upper connecting member 1020 is shown coupled at the first pivoting boom arm central pivot point member 1022 and at the first pivoting boom main arm to upper connecting member pivot member 1028 .
Now referring to FIG. 6 , there is shown the electronic control box 120 of FIG. 5 with the addition of a first boom arm side stationary connection structure 602 and a first pivoting boom arm mechanical lock 108 which couples to a bolt, rod or other protuberance at first pivoting boom arm central pivot point member 1022 .
Now referring to FIG. 7 , there is shown a front view of the electronic control box 120 of the present invention, also shown in a stowed configuration for transport. Also shown is pivoting control box support 1041 , which extends between and pivotally couples to first pivoting boom main arm 102 and second pivoting boom main arm 104 , thereby allowing the electronic control box 120 to remain hanging vertically through the various stages of deployment. When first pivoting boom main arm 102 is fully deployed for transport, the first pivoting boom adjustable foot stop 1042 and second pivoting boom adjustable foot stop 1044 come in contact with a top surface of electronic control box 120 , thereby creating a restraining force on the electronic control box 120 , which helps to reduce movement of the electronic control box 120 relative to the boom connecting rod 1040 .
Electronic control box 120 is shown coupled to pivoting control box support 1041 by first boom side upper connection loop 1080 and first boom side lower connection loop 1070 , as well as the combination of second boom side upper connection loop 1082 and second boom side lower connection loop 1072 .
Now referring to FIG. 8 , there is shown the mobile rock crusher 100 , including pivoting boom structure 101 , as well as boom pivoting control and power system 800 , which may include a boom power source 802 and boom control station 804 with a boom control lever 806 and boom control up and down buttons 808 . However, a preferred embodiment may have either one of the boom control lever 806 or boom control up and down buttons 808 . It should be understood that other types of well-known controls for controlling hydraulic, pneumatic and electric or mechanical actuators could be used. Hydraulic locking valves could be used as well to secure the electronic control box 120 in place with the first pivoting boom adjustable foot stop 1042 and the second pivoting boom adjustable foot stop 1044 when being stored for transport.
DEFINITIONS
The term “rock crusher” is used throughout this description and is intended to be construed in the claims as a mechanism for crushing hard objects, such as rock, concrete, or other aggregate type materials.
The term “vibration transmissibility” is intended to suggest the ability of something to transmit vibrations from one location to another. For example, a taut chain has a high vibration transmissibility, while a slack chain has a lower vibration transmissibility.
The term “coupled” is intended to mean somehow operatively arranged, but not necessarily meaning in direct physical contact.
It is thought that the method and apparatus of the present invention will be understood from the foregoing description and that it will be apparent that various changes may be made in the form, construct steps, and arrangement of the parts and steps thereof, without departing from the spirit and scope of the invention or sacrificing all of their material advantages. The form herein described is merely a preferred exemplary embodiment thereof.
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A mobile rock crushing vehicle with a detachable electronic control box which can be automatically lifted, by a pair of hydraulic pivoting arms, off the vehicle, lowered and set upon any vibration damping and isolating mass, such as the earth, all by moving a hydraulic lever. The pair of pivoting arms further automatically configure a reduced-vibration transmitting connection when the electronic control box is set upon the ground.
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[0001] The invention broadly relates to a valve or valves or passageways, and more specifically, relates to valves and passageways adapted to control the flow of fluids. More specifically still, the invention relates to an injection, sealing, valving and passageway system adapted to direct and control the flow of fluids through hollow drill rods, hollow rock bolts or hollow self drilling rock bolts.
BACKGROUND TO THE INVENTION
[0002] The flow of fluids, typically water, or air, or cement grout or resin, is commonly pumped through hollow tubes, hollow drill rods, hollow rock bolts and hollow self drilling rock bolts in the mining and tunneling industries. Most commonly water or air is used to flush rock cuttings out of boreholes as they are being drilled by hollow drill rods. Also cement grout or resin is commonly pumped through the central hole in hollow injection rods to stabilise broken, fractured or weak rock or ground. In addition, cement grout or resin is also commonly pumped through hollow rock bolts or hollow self drilling rock bolts to anchor those rock bolts into rock or soil. An example of a hollow self drilling rock bolt with a drilling tip at one end is given in patent number PCT/AU91/00503.
[0003] The hollow drill rods or hollow rock bolts may be made from any suitable hollow bar including tubes, pipes or thick-walled hollow bars, and are typically made from steel but could be made from fibreglass or plastic or carbon fibre.
[0004] Where fluids are pumped through a hollow bar for any of the above applications, a sealing means is normally used between the hollow bar and the fluid pumping system. Typically, where drilling applications using drill rods are being used, the fluid pumping system is through the drilling machine using either water or air.
[0005] This sealing means can be as simple as a screw thread on the end of the hollow bar or hollow drill rod or hollow rock bolt which is screwed into a mating thread inside the drill chuck on the drilling machine. Alternatively this sealing means is typically an O ring either on the end of the hollow bar, or inside the drill chuck. The O ring prevents leakage of the fluids as they are being pumped through the hollow bar, and they are a simple, low cost and proven method of sealing fluids for this application.
[0006] In some applications two fluids are pumped through a hollow bar at the same time for drilling applications. Typically this may be water and air such that a fine “mist” is used for drilling to minimise the volume of water used. Alternatively, two fluids may be pumped through a hollow bar at different times, for example, water may be used for drilling cycle to flush rock cuttings out of the borehole, and then cement grout may be subsequently pumped through the same hollow bar to fill the borehole with cement grout and anchor the hollow bar into the borehole.
[0007] In the civil and tunneling industries this operation is typically undertaken by firstly screwing the end of a hollow bar or hollow drill rod or hollow rock bolt with a thread on the end of it into a drill chuck, and then rotating the bar during the drilling cycle. The rotational action of the drilling machine tightens the mating threads between the bar and the drill chuck and creates a seal for the fluids used for the drilling cycle. Once the drilling cycle is complete, the bar is unscrewed form the drill chuck and a screw fitting attached to a grout hose is typically screwed onto the end of the bar. This screw fitting is typically manually tightened up onto the end of the bar such that a fluid seal is created which then allows cement grout or resin or other chemical anchoring fluid to be pumped into and through the bar to fill the borehole. Once the borehole is full of the cement grout or other anchoring fluid, then the screw fitting is unscrewed from the bar and removed.
[0008] The use of screw threads or O rings are therefore the most common forms of sealing for pumping fluids through hollow bars, hollow drill rods or hollow rock bolts in the mining, civil and tunneling industries.
[0009] The screwing and unscrewing of screw threads is a cumbersome operation and where cement grout hoses and fittings are used, it is typically undertaken manually. This is a time consuming operation and is not suited to automation of the grouting process.
[0010] In addition, the use of either screw threads or O Rings for sealing of fluids being pumped through hollow bars is principally designed for sealing against leakage at the seal itself, and they are not designed to direct and control the flow of fluids either inside the drill chuck or inside the hollow bar.
[0011] In the particular case of self drilling rock bolts, water, or air, or water and air, known as the “drilling fluid” are typically pumped through the bolt to remove the rock cuttings from the drilling operation to drill a borehole. An example of a self drilling rock bolt is given in patent number PCT/AU2006/001775. A sealing device is used to prevent leakage of the drilling fluid between the drilling machine and the bolt. Once the borehole has been drilled, and all the rock cuttings have been removed from the borehole, pumping of the drilling fluid is then turned off. Then cement grout, or resin, or other chemical fluid, known as the anchoring fluid, is typically pumped through the bolt to fill the borehole and fully encapsulate the bolt in the borehole and once the anchoring fluid cures and hardens, it anchors and fixes the bolt in the borehole. Typically with current systems, the drilling fluid and the anchoring fluid are pumped into self drilling rock bolts through separate hoses and fittings which have to be separately attached and detached from the end of the self drilling rock bolt, and typically this is done manually.
[0012] Moreover, if a two part chemical resin is pumped into a hollow bar, or into a hollow bolt or into a hollow self drilling rock bolt, then the two part chemical resin normally consists of a hardenable component (known as a mastic component) and a hardening component (known as a catalyst component). Typically once the mastic component comes into contact with the catalyst component the resin will start to cure, and it may harden in less than 60 seconds, typically it will harden in less than 30 seconds. Clearly then the mastic component must be kept completely separate from the catalyst component, while these two components of the resin are being pumped through the drilling machine and through the drilling chuck of the drilling machine, otherwise it will cure and harden and clog the drilling chuck. In addition, if an injection nozzle is used in the drilling chuck to inject the two part resin into the hollow bolt, then the two parts of the chemical resin, the mastic component and the catalyst component, must also be kept separate immediately after or above the injection nozzle, otherwise premature curing can occur and cause blockages of this injection nozzle.
[0013] Furthermore if the pumping pressures within the mastic component and the catalyst component as they flow out of the injection nozzle are unequal, then it is possible to get backflow of either mastic or catalyst down the wrong passageway, and this can cause blockages within the injection nozzle. An injector for use with self drilling rock bolt which does not have a one way valving and passageway system as described this invention, is prone to blockages and an example of such an injector is given in patent number AU199959340 A1.
[0014] More particularly where an injection nozzle is used to pump one or more fluids into a hollow bar either simultaneously or sequentially, there is a considerable advantage in being able to use that one injection nozzle to pump one or more fluids into the hollow bar without the requirement to screw or unscrew different fittings onto the end of the bar to pump different fluids into the bar. However, the resin injection system as shown in patent number AU199959340 A1 is prone to blockages. The inventor has found that if the mastic part of a liquid resin and the catalyst part of a liquid resin are allowed to come together immediately at the end of an injector, then the end of the injector is likely to become clogged with resin that has cured and hardened. To prevent the injector becoming clogged with hardened resin it is necessary to keep the mastic part of the resin and the catalyst part of the resin completely separate as they leave the injector and force them to flow along their own separate passageways inside the end of the bolt. The mastic and catalyst then flow along their own separate passageways inside the bolt, and only come together and mix at some point further away from the end of the injector. In practice the distance between the end of the injector and the point where the mastic and catalyst come together and mix may be small and typically be between 5 mm and 50 mm but is not so limited.
[0015] Moreover, the inventor has further found that where two or more fluids are being pumped into a hollow bar either simultaneously or sequentially, it is often necessary to prevent back flow of one or more fluids in the wrong direction down a passageway used for another fluid, and or it is often necessary to prevent premature mixing of two or more fluids. Moreover, if two or more fluids are being pumped into a hollow bar simultaneously, the pumping pressures for each fluid may not be equal and this could cause back flow or flow through the wrong passageway. Therefore it is necessary to have a one way valving system that will prevent back flow of liquid resins along the wrong passageway, and typically this can be achieved by having separate one way valves along each passageway inside the bolt.
[0016] Furthermore, if separate passageways and one way valves are only used in the injector, clogging of the end of the injector by curing and hardening of two part liquid resins is still possible. For example patent number WO2006042530 shows an injection head with two separate passageways with two separate valves which then combine into a single passageway in a connecting piece which is then inserted into the end of a hollow bar or bolt. However this patent indicates that this single passageway in the connecting piece has to be flushed out after use, otherwise the two part liquid resins will cure and harden in the passageway entering the bolt making the injector unusable for subsequent bolts.
[0017] There is therefore a considerable advantage in having an injection, sealing, passageway and valving system for used with hollow self drilling rock bolts that enables:
drilling rotation of the bolt; water or air flushing of the drill cuttings; injection of a liquid resin mastic component and injection of a liquid resin catalyst component into and through the bolt to fill the borehole; mixing, curing and hardening of the two liquid resin components to anchor the bolt in the borehole; tensioning of a nut on the end of the hollow self drilling rock bolt; removal of the injector from the hollow self drilling rock bolt;
and all be accomplished without back flow of resin along the wrong passageway in the injector, or contamination or clogging of any part of the injector, and leaving the injector completely clean after it is removed from the bolt and be ready to install the next hollow self drilling rock bolt.
[0024] Even further, there is a considerable advantage in being able to maintain a hydraulic seal or seals between a stationary injector with one or more passageways and a rotating bolt in which the injector is inserted into or is coupled to.
[0025] The present invention relates to an injection, sealing, passageway and valving means which overcomes the problems of existing systems described above and allows one or more fluids to be simultaneously or sequentially pumped into and through a hollow bar, a hollow drill rod or hollow rock bolt, without back flow or contamination and enabling the resin in the bolt to cure and harden without clogging the injector, and also leaving the injector completely clean after it is removed from the bolt and be ready to install the next bolt.
[0026] There is a need for improved mechanism or device to overcome the above problems of manually changing over separate hoses and fittings to pump different fluids into hollow bars, and to control and direct the flow of those fluids inside the hollow bar. Moreover there is a need to have separate passageways with optional one way valves to control the flow of chemical resins to prevent back flow, flow along the wrong passageway and avoid premature mixing and curing of chemical resins, grouts or other anchoring fluids.
[0027] The present inventor has developed an injection, sealing, valving and passageway system that can be installed substantially in the end of a hollow bar or a hollow drill rod or a hollow rock bolt or hollow self drilling rock bolt and or partially within an external injector that overcomes these problems and enables one or more fluids to be pumped into and through a hollow bar or hollow drill rod or hollow bolt or hollow self drilling rock bolt without premature mixing or back flow or leakage such that these bars, rods or bolts can be installed with a minimum of manual handling and without blockage of the injector or the dill chuck.
[0028] Furthermore the injection, sealing, valving and passageway system enables water to be pumped through a hollow self drilling rock bolt during the drilling operation while the bolt is being rotated, and then enables resin or cement grout to be pumped through the bolt during the grouting cycle, without any change to the sealing or valving system. The injection, sealing, valving and passageway system can not only function and hydraulically seal while a hollow self drilling rock bolt is being rotated at drilling speeds of typically 500 rpm, but it can also hydraulically seal and separate two part resins, chemicals or grouts during the grouting cycle. This has the considerable advantage that there is no requirement to change over fittings on the end of the bolt between the drilling cycle and the grouting cycle as occurs with current practice.
SUMMARY OF THE INVENTION
[0029] The present invention provides an injection, sealing, valving and passageway system (the “valving system”) for use with hollow elongate members used in mining, civil engineering, tunneling and construction including use with self drilling rock bolts, where the valving system comprises a plurality of passageways whereby at least one of the passageways has at least one flow valve at some position along it. The flow valve is typically a one way flow valve.
[0030] The passageways can enable fluids to flow along them without cross contamination with the fluids in another passageway and where at least one of the passageways can accommodate the flow of one or more fluids along them either sequentially or simultaneously. Moreover, the passageways are typically substantially contained within a hollow bar or bolt and are also typically partially contained within an external injector that hydraulically seals with the hollow bar or bolt.
[0031] The passageways in the bar or bolt are then hydraulically connected and hydraulically sealed to the passageways in the injector both when there is no relative rotation between the bar and the injector and when there is relative rotation between the bar and the injector during the drilling cycle.
[0032] The side boundaries of the passageways could be formed by any means and are typically formed by one or more separate items or components. The inlet and outlet ends of the passageways are typically open, but also typically could have one or more one-way valves positioned anywhere along the length of the passageways. The passageways can be of unequal length and of unequal cross sectional area.
[0033] The passageways in an injector extend beyond the end of the injector such that fluids flowing along the separate passageways in the injector then subsequently flow along separate passageways in the bar or bolt and do not come together until after the end of the injector such that those fluids cannot mix at the end of the injector and harden and block the openings at the end of the injector.
[0034] The passageways within the hollow elongate member typically have a seal or seals to provide a hydraulic seal with the passageways contained within an external injection nozzle or nozzles.
[0035] Preferably the passageways have one or more one-way valve or valves that allow fluids to flow in one direction along the passageways but prevent flow of fluids in the opposite direction along the passageways.
[0036] Preferably the passageways can accommodate the flow of single or multiple fluids either sequentially or simultaneously.
[0037] Preferably, in practice, the passageway and valving assembly inside the bolt or bar (the “valving assembly”) is made from plastic and substantially consists of a plastic cylindrical shaped member with at least one internal passageway and a one-way valve, and at least one external passageway with another one-way valve such that one fluid can be pumped through the internal passageway, and another fluid can be pumped through the external passageway.
[0038] Preferably as the self drilling rock bolt is inserted into a drilling machine, the valving system which is substantially contained inside the self drilling rock bolt forms a mating and sealing fit with an injection nozzle inside the drilling machine such that a hydraulic seal or hydraulic seals are formed between the passageways in the injection nozzle and the passageways in the bolt. The hydraulically seal or seals can operate when the bolt is being rotated during the drilling cycle, or when the bolt is stationary during the grouting cycle. Water or air or resin or cement grout or other fluids can then be pumped into the self drilling rock bolt through the injection nozzle and into the correct passageway through the valving system without back flow or flow through the wrong passageway thus avoiding premature mixing of fluids or other problems.
[0039] Preferably part of the plastic valving system can substantially wipe the injection nozzle clean when the injection nozzle is withdrawn from the bolt.
[0040] Preferably the valving system is only used to install one self drilling rock bolt but is not so limited.
[0041] Preferably the valving system has two separate passageways but is not so limited and could have three or more separate passageways,
[0042] It is particularly preferred that the valving assembly substantially consists of one or more plastic cylinders with one or more circular plastic skirt or flap valves which close and hydraulically seal against a circular section of an injector. These skirt or flap valves open with fluid flow in one direction and close with any fluid flow in the opposite direction.
[0043] It is particularly preferred that the valving assembly in the bar or bolt can hydraulically seal against a stationary injector even if the valving assembly in the bar or bolt is being rotated.
[0044] It is particularly preferred that the valves in at least one passageway can allow multiple fluids to sequentially flow along it such that this passageway can be flushed out with a flushing fluid after resin or grout injection.
[0045] Persons skilled in the art would appreciate that different embodiments of the invention could be used with hollow self drilling rock bolts, hollow rock bolts, hollow injection tubes or any other device used for the flow of one or more fluids.
[0046] Throughout this specification, unless the context requires otherwise, the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
[0047] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed in Australia before the priority date of each claim of this specification.
[0048] In order that the present invention may be more clearly understood, preferred embodiments will be described with reference to the following drawings and examples.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] FIG. 1 is a schematic sectional view of an injection, sealing, valving and passageway system according to one preferred embodiment of the invention adapted to be used with a self drilling rock bolt showing a one way valve in a closed position.
[0050] FIG. 2 is a schematic sectional view of a section of an injection, sealing, valving and passageway system according to another preferred embodiment of the invention adapted to be used with a self drilling rock bolt showing a one way valve in an open position.
[0051] FIG. 3 is a schematic sectional view of an injection, sealing, valving and passageway system according to the same embodiment of the invention shown in FIG. 2 but with a one way valve in a closed position.
[0052] FIG. 4 is a schematic sectional view of a valving assembly which forms part of the same embodiment of the invention shown in FIG. 2 .
[0053] FIG. 5 is an end view of the valving assembly shown in FIG. 4 according to one preferred embodiment of the invention adapted to be used with a self drilling rock bolt.
[0054] FIG. 6 is a three dimensional view of the valving assembly shown in FIG. 5 according to one preferred embodiment of the invention adapted to be used with a self drilling rock bolt.
[0055] FIG. 7 is a schematic sectional view of an injection, sealing, valving and passageway system according to another preferred embodiment of the invention adapted to be used with a self drilling rock bolt with two one way valves shown in the closed position.
[0056] FIG. 8 is a schematic sectional view of an injection, sealing, valving and passageway system according to the preferred embodiment of the invention shown in FIG. 7 adapted to be used with a self drilling rock bolt with two one way valves shown in the open position.
[0057] FIG. 9 is a schematic sectional view of an injection, sealing, valving and passageway system according to yet another preferred embodiment of the invention adapted to be used with a self drilling rock bolt with two one way valves shown in the closed position.
[0058] FIG. 10 is a schematic sectional view of an injection, sealing, valving and passageway system according to the preferred embodiment of the invention shown in FIG. 9 adapted to be used with a self drilling rock bolt with two one way valves shown in the open position.
[0059] FIG. 11 is a schematic sectional view of an injection, sealing, valving and passageway system according to yet another preferred embodiment of the invention adapted to be used with a self drilling rock bolt with multiple one way valves shown in the closed position.
[0060] FIG. 12 is a schematic sectional view of an injection, sealing, valving and passageway system according to the preferred embodiment of the invention shown in FIG. 11 adapted to be used with a self drilling rock bolt with the one way valves shown in the open position to allow water flow and with the one way valves for mastic and catalyst flow shown in their closed position.
[0061] FIG. 13 is a schematic sectional view of an injection, sealing, valving and passageway system according to the preferred embodiment of the invention shown in FIG. 11 adapted to be used with a self drilling rock bolt with the one way valves shown in the open position to enable flow of mastic and catalyst and with the one way valves for water flow in the closed position.
[0062] FIG. 14 is a schematic sectional view of an injection, sealing, valving and passageway system according to the preferred embodiment of the invention shown in FIG. 11 adapted to be used with a self drilling rock bolt with the injector partially removed from the bar or bolt but with the injector still hydraulically sealing with the seals and one way valves in the bar or bolt.
[0063] FIG. 15 is a schematic sectional view of an injection, sealing, valving and passageway system according to the preferred embodiment of the invention shown in FIG. 11 adapted to be used with a self drilling rock bolt with the injector fully removed from the bar or bolt.
[0064] FIG. 16 is a schematic sectional view of an injection, sealing, valving and passageway system according to the preferred embodiment of the invention shown in FIG. 11 adapted to be used with a self drilling rock bolt whereby part or all of the valving and passageway system is contained within an injection sleeve screwed onto the end of the bar or bolt.
[0065] FIG. 17 is a schematic isometric sectional view of an injection, sealing, valving and passageway system according to the preferred embodiment of the invention shown in FIG. 11 adapted to be used with a self drilling rock bolt whereby part of the valving and passageway system is contained within an injection sleeve screwed onto the end of the bar or bolt and where the injector fully removed from the bar or bolt.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0066] Where the specification refers to a “bar or to a “hollow bar” or to a “hollow drill rod” or to a “hollow rock bolt” or to a “hollow self drilling rock bolt” or to a “hollow elongate member” or to a “hollow injection tube” or to a “tube” or to a “pipe” it is to be understood that the invention includes all such variations and modifications of the above including any long hollow elongate member including self drilling rock bolts.
[0067] Where the specification refers to an “injection nozzle” or to a “nozzle” or to “nozzles” or to an “injector” or to an “external injector” it is to be understood that the invention includes all such variations and modifications of one or more injection nozzles that may have one or more passageways which can separate the flow of one or more fluids.
[0068] Where the specification refers to an “injection sleeve” or to a “sleeve” it is to be understood that the invention includes all such variations and modifications of an injection sleeve that can accommodate and seal with an external injector and the injection sleeve may contain one or more passageways and one or more one way flow valves and one or more seals.
[0069] Where the specification refers to an “seal” or to “seals” or to a “sealing device” it is to be understood that the invention includes all such variations and modifications of a seal including threads, O rings, flaps, valves, or any other device that can hydraulically seal a fluid against leakage or flow in an undesired direction.
[0070] Where the specification refers to a “valve” or to “valves” or to “one way valves” or to “one way flow valves” it is to be understood that the invention includes all such variations and modifications of a valve including one way flow valves or any device that can control or direct the flow of fluids.
[0071] Where the specification refers to a “flap valve” or to a “skirt valve” it is to be understood that the invention includes all such variations and modifications of a one way valve that opens by the flow of fluid in one direction and closes by the flow of fluid in the opposite direction.
[0072] Where the specification refers to a “passageway” or to “passageways” it is to be understood that the invention includes all such variations and modifications of the above, including tubes, pipes, holes of any shape, any assemblage of components that could form a through hole or through passageway, and any other member or assemblage of members that could contain fluids and enable fluids to flow through it. The passageways may be formed both during drilling rotation and when there is no drilling rotation.
[0073] Where the specification refers to a “valving system” or to a “valving and passageway system” it is to be understood that the invention includes an injection, sealing, valving and passageway system which could be formed by multiple parts and all such variations and modifications of the above,
[0074] Where the specification refers to a “valving assembly” or to a “valving and passageway assembly” it is to be understood that the invention includes a valving and passageway assembly that includes at least one passageway and includes at least one one way valve and is typically formed by an assembly of plastic tubes and one way valves but includes all such variations and modifications of the above and could be formed in any way.
[0075] For consistency, in the Figures, item numbers refer to the same feature or design component.
[0076] The preferred embodiments shown in FIGS. 1 to 17 show the injection, sealing, valving and passageway system (the “valving system”) whereby rotational movement can occur between the injector 2 and the bar 1 and a hydraulic seal can still be maintained between the passageways in the injector 2 and the passageways in the bar 1 . Typically the bar 1 is rotated around the stationary injector 2 .
[0077] One embodiment of the injection, sealing, valving and passageway system (the “valving system”) shown in FIG. 1 comprises a hollow elongate bar 1 which can hydraulically seal with an external injection nozzle 2 by means of a seal or seals 3 and the external injection nozzle 2 may have one or more separate passageways 7 and 8 within it. The hollow elongate bar 1 has a central hole 12 which can accommodate a valve and passageway assembly 4 . The valve and passageway assembly 4 may have one or more separate passageways within it 10 or around it 11 . The valve and passageway assembly 4 has at least one valve 13 within it or around it. The valve 13 may be operated by a spring 14 or any other means.
[0078] In operation the injection nozzle 2 is fitted over or into the end of the hollow bar 1 such that at least one passageway 7 in the injection nozzle 2 hydraulically connects with a passageway 10 in the valve and passageway assembly 4 . Additional passageways 8 in the injection nozzle 2 also hydraulically connect with passageways 11 inside or around the valve and passageway assembly 4 inside the hollow bar 1 .
[0079] FIG. 2 shows a sectional view of another embodiment of the valving system whereby the injection nozzle 2 has three separate passageways 7 , 8 and 9 . FIG. 2 also shows the valve 13 open allowing fluid from passageway 7 to flow into passageway 10 in the valve and passageway assembly 4 and subsequently flow through the valve and passageway assembly 4 and into the central passageway 12 in the hollow bar 1 . FIG. 2 also shows that fluid from passageway 8 can flow into passageway 10 in the valve and passageway assembly 4 and subsequently flow through the valve and passageway assembly 4 and into the central passageway 12 in the hollow bar 1 . FIG. 2 further shows that the passageway 9 in the injection nozzle 2 hydraulically connects with passageway 11 which in turn connects to the central hole 12 in the hollow bar 1 . Passageways 9 and 11 are separate from passageways 7 , 8 and 10 .
[0080] FIG. 3 shows a sectional view of the valving system whereby the valve 13 is closed by a spring 14 which prevents back flow of fluids down passageway 7 .
[0081] FIG. 4 shows a sectional view of the valve and passageway assembly 4 with a valve 13 which is operated by a spring 14 .
[0082] FIG. 5 shows an end view of the valve and passageway assembly 4 shown in FIG. 4 with a valve 13 and with an internal passageway 10 and another internal passageway 11 .
[0083] FIG. 6 shows a three dimensional view of the valve and passageway assembly 4 shown in FIGS. 4 and 5 with a valve 13 and an internal passageway 10 and another internal passageway 11 .
[0084] FIG. 7 shows a sectional view of another embodiment of the valving system whereby the injection nozzle 2 has two separate passageways 7 and 8 which hydraulically connect with passageways 10 and 11 in or around the valve and passageway assembly 4 . The valve and passageway assembly 4 has an internal valve 13 which is shown in its closed position in FIG. 7 . FIG. 7 also shows that the valve and passageway assembly 4 also has an external valve 15 which is also shown in its closed position.
[0085] FIG. 8 shows a sectional view of the same embodiment as shown in FIG. 7 except that the valves 13 an 15 are now shown in their open, position allowing fluids to pass from passageway 7 into passageway 10 and through to the central hole 12 in the bar 1 , and also from passageway 8 into passageway 11 and through to the central hole 12 in the bar 1 . FIG. 8 also shows that the valve and passageway assembly 4 is held in position inside the hollow bar 1 by a locating lug 17 on the assembly 4 which clips into a groove 16 inside the hollow bar 1 .
[0086] FIG. 9 shows a sectional view of another embodiment of the valving system whereby the injection nozzle 2 has two separate passageways 7 and 8 which hydraulically connect with passageways 10 and 11 in or around the valve and passageway assembly 4 . The valve and passageway assembly 4 has an internal valve 13 which is activated by an internal spring 14 and which is shown in its closed position in FIG. 9 . FIG. 9 also shows that the valve and passageway assembly 4 also has an external valve 15 which is also shown in its closed position.
[0087] FIG. 10 shows a sectional view of the same embodiment as shown in FIG. 9 except that the valves 13 and 15 are now shown in their open position allowing fluids to pass from passageway 7 into passageway 10 and through to the central hole 12 in the bar 1 , and also from passageway 8 into passageway 11 and through to the central hole 12 in the bar 1 .
[0088] FIG. 11 shows a sectional view of another preferred embodiment of the valving system whereby an injection nozzle 2 is substantially inserted into a hollow bar 1 and is hydraulically sealed inside the hollow bar 1 by hydraulic seals 3 and 23 . Seals 3 and 23 are circular in end view (not shown) and seal against circular parts of the injector 2 . The injection nozzle has two internal passageways 24 and 25 which are connected to passageway 8 by two one way valves 19 and 20 . The injection nozzle also has another internal passageway 26 which is connected to passageway 7 by a one way valve 18 . Bar 1 also contains the valving assembly 4 which has three one way valves 15 , 13 and 22 . Valves 15 , 13 and 22 are preferably circular plastic flap or skirt valves which close against circular parts of the injector 2 . The injector 2 has a circular central bar 21 to seal against valves 13 and 22 . In this embodiment the valving assembly 4 has two passageways 10 and 11 formed from two tubular sections which are held apart by a member 29 . FIG. 11 shows that the injection nozzle 2 has two separate passageways 7 and 8 which hydraulically connect with passageways 10 and 11 respectively. The injection nozzle 2 has two separate passageways 7 and 8 that may also have one or more one way valves 18 , 19 and 20 along their length. The one way valves 18 , 19 and 20 could be any type of one way flow valves but are preferably spring loaded valves (not shown). FIG. 11 also shows that passageway 8 in the injection nozzle 2 has two one way valves 19 and 20 which are shown in their closed position but which when open allow two different fluids to flow into the passageway 8 from passageways 24 and 25 . Valve 19 is typically opened by fluid pressure from passageway 24 . Valve 20 is typically opened by fluid pressure from passageway 25 . Valve 18 is typically opened by fluid pressure from passageway 26 . FIG. 11 also shows that passageway 8 is hydraulically connected to passageway 11 through a one way valve 15 in the valve and passageway assembly 4 which is shown in its closed position. FIG. 11 also shows that passageway 7 is hydraulically connected to passageway 10 through two one way valves 13 and 22 in the valve and passageway assembly 4 which are also shown in their closed position. FIG. 11 also shows that the valve and passageway assembly 4 is inserted into the end of the hollow bar 1 and is prevented from falling out of the hollow bar 1 by the seal 3 .
[0089] FIG. 12 shows a sectional view of the same embodiment as shown in FIG. 11 except that the valves 13 , 22 and 18 are all in their closed position preventing flow from either direction into passageway 7 . Valve 19 is also in its closed position preventing any backflow of fluid back past valve 19 . Valves 20 and 15 are in their open positions allowing fluid to flow through valve 20 into passageway 8 and through valve 15 into passageway 11 and then into the central hole 12 in the bar 1 . Typically FIG. 12 shows the valve configuration during the drilling cycle where water is pumped through valve 20 and into passageway 8 and then the water pressure opens valve 15 allowing the water to flow through passageway 11 and then into the central hole 12 in the bar 1 . The valves 13 and 22 being closed prevent any water from flowing back down passageway 7 .
[0090] FIG. 13 shows a sectional view of the same embodiment as shown in FIG. 11 except that the valves 18 , 13 and 22 are open allowing fluids to flow through passageway 7 and into passageway 10 and into the central hole 12 in the bar 1 . Valves 19 and 15 are also open allowing fluids to flow through passageway 8 and into passageway 11 and into the central hole 12 in the bar 1 . Valve 20 is closed preventing any back flow of fluids past valve 20 . Typically FIG. 13 shows the valve configuration during the resin pumping cycle where one part of a resin, typically a non-water soluble component referred to here as part A, is pumped through passageways 7 and 10 , and a second part of a resin, typically a water soluble component referred to here as part B, is pumped through passageways 8 and 11 . Valve 15 prevents any back flow of part A into passageway 8 which is the part B passageway. Valves 13 and 22 prevent any back flow of part B into passageway 7 which is the part A passageway.
[0091] FIG. 14 shows a sectional view of the same embodiment as shown in FIG. 11 except that the injection nozzle 2 has been partially removed from the bar 1 and from the valve and passageway assembly 4 but that the injection nozzle 2 is still hydraulically sealing with the bar 1 and with the valve and passageway assembly 4 by means of seals 3 and 23 .
[0092] FIG. 15 shows a sectional view of the same embodiment as shown in FIG. 11 except that the injection nozzle 2 has been fully removed from hydraulically sealing with the valve and passageway assembly 4 and the bar 1 . The valve 18 in the passageway 7 is closed, and also the valve 19 in passageway 8 is also closed. The valve 20 in passageway 8 is open. Typically FIG. 15 shows the valve configuration during the water flushing operation where water is pumped through valve 20 and flushes out part B of the resin from passageway 8 . Part B of the resin is forced out of passageway 8 by the water and flows past and mixes with any residual part A of the resin remaining near the front of passageway 7 or on the central bar 21 . As part B of the resin is rapidly mixes with part A of the resin, the water flow flushes both part B and part A of the resin away from the injection nozzle 2 . FIG. 15 also shows that as the flushing water (not shown) flows out of passageway 8 , some of this water will also flush and clean the end of the valve and passageway assembly 4 . Moreover as the injector is withdrawn from the bar 1 , the seals 3 tend to wipe the external surface of passageway 8 clean and remove any excess resin from it. Similarly, seal 23 and skirt valve 15 tend to wipe the external surface of passageway 7 clean and remove any excess resin from it. In addition, skirt valves 13 and 22 tend to wipe the external surface of the central bar 21 clean and remove any excess resin from it.
[0093] FIG. 16 shows a sectional view of the same embodiment as shown in FIG. 11 except that all of the valving assembly 4 is contained within a hollow injection sleeve 27 which is attached to the bar 1 by a thread 28 or by a weld (not shown) or by any other suitable means.
[0094] FIG. 17 shows a schematic isometric sectional view of the same embodiment as shown in FIG. 11 except that the injector 2 is fully removed from the injection sleeve 27 . FIG. 17 shows that the valving assembly 4 is fully contained within the hollow injection sleeve 27 , and that the inner and outer tubes of the valving assembly 4 are held apart by a member 29 . FIG. 17 also shows that the valves 15 , 13 and 22 are circular skirt valves, and that seal 23 is a circular lip seal, and that the seals 3 are O rings. The valves 15 , 13 , and 22 , and the seal 23 , and the seals 3 , are all circular in end view (not shown) and therefore can rotate about the injector 2 which is also circular in end view (not shown) and still maintain a hydraulic seal. FIG. 17 also shows that the injector 2 has internal passageways 24 , 25 and 26 which have one way valves 19 , 20 and 18 which control the flow of fluids from passageway 26 into passageway 7 and from passageways 24 and 25 into passageway 8 . FIG. 17 further shows that the valving assembly 4 is retained inside the injection sleeve 27 by the O ring 3 .
[0095] In preferred embodiments, the present invention does not require the use of separate hoses or connectors or other grouting systems and hence removes considerable manual labour as well as reducing injuries to operators. The present invention makes it possible to automatically drill and resin inject or cement grout self drilling rock bolts using automatic or semi-automatic drilling machines.
[0096] In preferred embodiments, the present invention enables two or more component chemical resins or grouts to be injected into and through hollow bars or hollow bolts or hollow self drilling rock bolts without premature mixing or back flow, and hence prevents unwanted blockages occurring.
[0097] In a particularly preferred embodiment, at least one part of the anchoring fluid is water soluble and can flow into one passageway through a one way valve, and flushing water can then be pumped into the same passageway through a separate one way valve such that the water soluble anchoring fluid can be flushed away with water.
[0098] In a preferred embodiment, the valve and passageway assembly and the one way valves used in the valve and passageway assembly are made from plastic, but could be made from any suitable material. The valve and passageway assembly typically comprises two or more substantially tubular components which are assembled together.
[0099] In a preferred embodiment, some of the one way valves are flap valves or skirt valves. These flap or skirt valves are opened and closed by the flow of the fluid, and seal against a circular injector or a circular bar.
[0100] In a particularly preferred embodiment, there is at least one central circular bar or circular tube that enables at least one flap or skirt valve to close against the external surface of this bar or tube.
[0101] In a particularly preferred embodiment, the skirt valves and seals and injector are all designed such that the injector can be partially withdrawn from the bar and still hydraulically seal against the bar and valve assembly.
[0102] In a particularly preferred embodiment, part or all of the passageways are contained within a hollow injection sleeve which is threadably attached to the hollow bar and which can be removed from the hollow bar by unscrewing it.
[0103] It should be noted that the present invention enables water or air or water and air to be pumped through hollow bars or hollow bolts or hollow self drilling rock bolts with either left hand or right hand drilling rotation. The present invention then also enables two or more component chemical resins or grouts to be injected into and through hollow bars or hollow bolts or hollow self drilling rock bolts without removal of the bar or bolt from the drilling chuck and without back flow of fluids along the wrong passageway. The invention further enables water soluble chemical resin or grout to be flushed away from the leading end of the injector and the end of the bar or bolt by removing the injector from the bar or bolt and turning on water flow as the injector is removed. The present invention even further enables the circular tube and bar sections of the injector to be wiped clean by the skirt valves and by the lip seal and by the O rings as the injector is removed from the bar or bolt. The present invention even further enables the valving assembly to be retained inside the injection sleeve or bar by the O ring seals.
[0104] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.
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The invention provides an injection, sealing, valving and passageway system for use with hollow rock bolts and hollow injection bars used in mining, civil engineering, tunneling and construction including use with hollow self drilling rock bolts. The invention comprises a plurality of passageways with one or more one way flow valves along the passageways. The invention enables one or more fluids to be pumped into a hollow rock bolt or other hollow elongate member either sequentially or simultaneously without cross contamination of fluids in another passageway or back flow of fluids along the wrong passageway. The invention is typically used to install self drilling rock bolts whereby a drilling fluid is initially pumped through the hollow bolt during the drilling cycle, and then a two part chemical resin or cement grout is pumped through the hollow bolt to anchor the bolt in the borehole.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application claims priority under 35 U.S.C. §119 of German Patent Application No. 196 35 202.9 filed Aug. 30, 1996, the disclosure of which is expressly incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process to drain a fibrous pulp suspension that includes feeding a layer of suspension to be drained between two converging surfaces and relatively moving the two surfaces with respect to each other at a desired velocity. In this manner, the suspension may be drained toward both surfaces. The present invention may utilize a draining device including an inner arched surface including a pivoting cylinder having a sleeve with openings, and an outer arched surface including a screen belt guided around a portion of the inner arched surface. The pivoting cylinder may be driven. Alternatively, the screen belt may be an endless belt guided around an non-driven pivoting cylinder. Further, the inner arched surface may include a stationary arched shoe and the outer arched surface may include an endless screen belt moved around a portion of the stationary arched shoe.
2. Discussion of the Background Information
WO 96/08660 describes a device in which a process for draining a fibrous pulp suspension may be performed. This device contains a suction roll that can be driven and includes a permeable surface, a portion of its circumference being surrounded by an impermeable plastic belt. The suspension is inserted between these two surfaces and drained.
Processes of the above-type generally attempt to achieve the best possible drainage with the highest possible throughput. However, the obstacle in achieving this goal is that the impermeable belt in the first part of the draining zone only allows drainage toward one side. In this manner, a substantial vacuum is required to achieve a sufficient drainage capacity and to compensate the centrifugal forces.
Another disadvantage of the prior art is that solid matter can accumulate on the stationary and impermeable screen surface, which and can quickly lead to clumps that can seriously interfere with the proper operation of the entire device. Further, cleaning of these surfaces during operation is not possible.
SUMMARY OF THE INVENTION
The present invention provides a process, similar in general to the process described above, which achieves an efficient draining capacity and high operational reliability.
Thus, the present invention provides a process to drain a fibrous pulp suspension. The process may include feeding a layer of suspension to be drained between two converging surfaces and relatively moving the two surfaces with respect to each other at a given velocity, and draining the suspension towards both surfaces. With this process, one can already achieve a very efficient drainage in an initial drainage section, i.e. where the suspension is fed between converging surfaces. The drainage is further enhanced, as is generally known, by introducing shear forces in the fiber mat. Further, control of the draining effect may be possible by selecting a relative speed of the surfaces, as well as a speed of the supplied suspension.
The more or less dry pulp, which is extracted from the fibrous pulp suspension, may be present in the form of a sheet. In some cases, the pulp may be formed in the shape of fibrous pulp rolls, having axes extending transverse to the direction of movement of the surfaces and having a diameter of between approximately 1 mm and several millimeters.
Another advantage of the present invention is that essentially no cleaning problems are created in the area of the converging surfaces. The converging surfaces are designed to be essentially permeable and may be continuously washed off during operation. One of the converging surfaces may remain completely stationary, i.e., the surface performs no translational movement at all. Alternatively, instead of being stationary, the one converging surface may be driven at a variable speed, e.g., at a creeping speed, to even out wear and/or to perform a cleaning.
A number of alternative embodiments are possible for carrying out the process of the present invention. The relative speed between the two converging surfaces can be created in a number of ways, each way having certain unique effects on the system operation. The suspension may be conventionally fed into a draining device having one flow velocity. The low velocity, among other factors, may determine an amount of the suspension that machine may drained within a certain time period. In practice, the user may determine the speed in the direction of the flow (i.e., downstream) for at least one of the surfaces in contact with the suspension. This flow velocity substantially corresponds, generally, to the flow velocity of the suspension at the inflow location. By selecting a differential speed, possibilities to influence the draining effect of the machine arise. In this manner, the two converging surfaces move past each other at a relative velocity at which the suspension is moved. In its simplest configuration, one surface may be held stationary. However, the present invention has found certain advantages resulting from moving both surfaces, although the second surface is driven at a low velocity (i.e., creeping speed). Accordingly, a more beneficial result with respect to wear is achieved. Further, this arrangement enables the potential for cleaning both surfaces during operation. Thus, as the machine velocity increases, the second surface may be moved faster in order to maintain the desired relative velocity.
The surface with which the suspension contacts may also have an influence on the process. That is, due to the relative motion of the two contact surfaces, the suspension, located between the two surfaces, tends to create little rolls, which may be desirable. By selecting particular surfaces to use, the user may easily control the roll production so that it is, e.g., strong enough to assist the draining, but not strong enough, e.g., to create undesirable clumping or excessive wear.
The present invention is directed to a process to drain a fibrous pulp suspension. The process may include positioning two surfaces to converge in a downstream direction, feeding the fibrous pulp suspension between the two converging surfaces, driving at least one of the two converging surfaces to move the suspension with a relative translational velocity, and draining the fibrous pulp suspension through each of the two surfaces.
In accordance to another feature of the present invention, the feeding may include distributing the fibrous pulp suspension in a wide stream between the two converging surfaces at a velocity that substantially corresponds velocity of the at least one driven converging surface.
In accordance with another feature of the present invention, the process may further include exerting a pressure of at least approximately 0.01 bar on the suspension, due to screen tension, when located between the converging surfaces. The relative translational velocity may be at least approximately 18 m/min, and preferably at least approximately 50 m/min.
In accordance with a further feature of the present invention, the process may further include holding stationary at least one of the two converging surfaces.
In accordance with still another feature of the present invention, one of the converging surfaces may be smooth and the other converging surface may include a surface that increases an abrasion force in the downstream direction.
In accordance with a still further feature of the present invention, the process may further include oscillating at least a portion of the two converging surfaces relative to each other. Further, the process may include oscillating the two converging surfaces relative to each other at a plurality of locations.
In accordance with another feature of the present invention, one of the two converging surfaces may be an outer arched surface and the other of the two converging surfaces may be an inner arched surface.
In accordance with a still further feature of the present invention, one of the two converging surfaces may be an arched surface and the other of the two converging surfaces may be substantially flat.
The present invention may be directed to a draining device for draining a fibrous pulp suspension. The draining device may include two arcuate surfaces positioned to form converging surfaces. One of the two arcuate surfaces may include a drivable, pivotable, and rotatable cylinder having an outer sleeve with openings, and the other of the two arcuate surfaces may include a screen positioned to be guided around at least a portion of the outer sleeve. The screen and the openings forming drains for draining the fluid pulp suspension.
In accordance with another feature of the present invention, the openings may communicate with an interior of the cylinder.
In accordance with still another feature of the present invention, the openings may include blind holes.
In accordance with another feature of the present invention, the screen may be resistant to bending. The screen may include a joint, the joint being pivotably mounted to pivot toward the cylinder.
In accordance with a further feature of the present invention, the draining device may include an a device for exerting adjustable pressure and the screen being pressed against the cylinder by the adjustable pressure device.
In accordance with a still further feature of the present invention, the screen may include elastic. Further, the screen may be mounted to be stationary when viewed in the run direction of the cylinders. Still further, the screen may include a plurality of sections, the sections including at least one of different curvatures and different screen tensions. The plurality of sections may include a slidable dividing line separating the sections.
In accordance with another feature of the present invention, the screen may include different zone and openings in each zone, the openings in each zone being different than the openings in the other zones.
In accordance with still another feature of the present invention, the screen may include joints and the screen may include at least two pieces coupled by the joints.
In accordance with a further feature of the present invention, the draining device may include a pulp headbox to inject a wide stream of suspension to be drained between the two arcuate surfaces.
In accordance with a still further feature of the present invention, the draining device may include an arc screen positioned upstream of the two arcuate surfaces. The suspension may be pre-drained by the arc screen.
In accordance with still another feature of the present invention, the draining device may include a pulsating device coupled to create oscillating pressure impulses on at least one of the two arcuate surfaces.
In accordance with another feature of the present invention, the other of the two arcuate surfaces may provide a dewatering pressure.
In accordance with a still further feature of the present invention, the sleeve may include a porous layer providing a void volume. The openings may communicate with the porous layer, however, the porous layer does not communicate with an interior of the cylinder.
The present invention is directed to a draining device for draining a fibrous pulp suspension. The draining device may include two arcuate surfaces positioned to form converging surfaces. A first of the two arcuate surfaces may include a drivable, rotatable cylinder having an outer sleeve with through openings and a second of the two arcuate surfaces may include a screen having an endless screen to be guided around a circumferential portion of the outer sleeve. The screen may be drivable along the circumferential portion of the outer sleeve, and the screen and the openings may form drains for draining the fluid pulp suspension.
In accordance with another feature of the present invention, the draining device may further include one of a press roll and a press shoe. The one of a press roll and a press shoe may be positioned to press one of the two arcuate surfaces against the other arcuate surface. Further, the press roll may include a felted surface. Also, the press roll may be rotatably mounted to rotate in a direction counter to the surface to be pressed.
The present invention may also be directed to a draining device for draining a fibrous pulp suspension. The draining device may include a first and a second arcuate surface positioned to form converging surfaces. The first surface may include a stationary arched shoe and the second surface may include an motor driven endless screen.
In accordance with yet another feature of the present invention, the draining device may further include one of a press roll and a press shoe. The one of a press roll and a press shoe may be positioned to press one of the first and second arcuate surfaces against the other of the first and second arcuate surfaces. Further, the press roll may include a felted surface. Also, the press roll may be rotatably mounted to rotate in a direction counter to the surface to be pressed.
The present invention is directed to a draining device for draining a fibrous pulp suspension. The draining device may include a first and a second surface positioned to form converging surfaces. The first surface may include an acuate portion having a plurality of openings and the second surface may include a screen positioned along at least a portion of the arcuate portion. At least one of the first and second surface may be driven to move with respect to the other of the first and second surface and the screen and the openings may form drains for draining the fluid pulp suspension.
Other exemplary embodiments and advantages of the present invention may be ascertained by reviewing the present disclosure and the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of preferred embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:
FIG. 1 illustrates a schematic view of a draining device for performing the draining process of the present invention;
FIG. 2 illustrates an alternative draining device to the draining device depicted in FIG. 1;
FIG. 3 illustrates another alternative draining device to the draining device depicted in FIGS. 1 and 2;
FIG. 4 illustrates an alternative draining device having an arched shoe;
FIG. 5 illustrates an alternative draining device having a suction cylinder;
FIG. 6 illustrates a draining device having a sectioned exterior screen;
FIG. 7 illustrates a detailed view of a screen belt;
FIG. 8 illustrates a detailed view of a press device;
FIG. 9 illustrates a detailed view of a flat draining surface;
FIG. 10 illustrates a detailed view of a draining surface with press rails;
FIG. 11 illustrates a detailed view of a draining device with an exterior screen positioned on the bottom.
DETAILED DESCRIPTION OF THE INVENTION
The particulars shown herein are by way of example and for purposes of illustrative discussion of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for the fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.
FIG. 1 shows a draining device for performing the process of the present invention. As shown in FIG. 1, the draining device may include two surfaces 1 and 2 which are positioned to converge, in a direction of suspension flow, around a substantially arcuate or circular path. A first converging surface, e.g., surface 2, may be formed by an inner arched surface of, e.g., a cylinder 4. Cylinder 4 may rotate in a direction indicated by arrow R, at a velocity sufficient to move a suspension S through the converging surfaces at a velocity substantially similar to the velocity at which the suspension S exits a pulp headbox 3. A second converging surface, e.g., surface 1, may be positioned outside of inner arched surface 2 and may be formed by an outer arched surface of, e.g., a screen 6. Screen 6 may be clamped or anchored at both ends, and, therefore, may be practically stationary with respect to the neighboring circumference of cylinder 4. Both outer and inner arched surfaces 1 and 2 may be provided with openings 5 and 7, respectively. The openings depicted in FIG. 1 are exemplary only, and the specifics of the openings may be determined by the user, e.g., the openings within cylinder 4 may be blind holes or may extend into the cylinder interior. Suspension S may be fed between the inner and outer arched surfaces, which are moved relative to each other, and drained. The suspension S is moved at a predetermined or desired translational speed between the relatively moving converging surfaces. Suspension S may be drained in both directions through the openings in both the inner and outer surfaces, as indicated by arrows W1 and W2. Drained suspension S' may fall into a collection container. If necessary, drained suspension S' may be removed from the circumferential surface of cylinder 4 with a scraper 9.
FIG. 2 differs from FIG. 1 in that screen 6 may be formed as an endless loop. In accordance with this embodiment of the present invention, screen 6 may be driven to move in a direction indicated by R' as a desired speed. In accordance with this embodiment, screen 6 may be circulated at a creeping speed, i.e., substantially slower than the rotation of cylinder 4, so as to facilitate cleaning screen 6 with, e.g., a spray pipe 8, or to even out wear on the screen surface. The desired relative translational speed, i.e., the overall velocity at which the suspension S is to be moved between the converging surfaces 1 and 2 (or the speed differential between rotation of cylinder 4 and rotation of screen 6), may be selected to substantially correspond to the speed of inflowing suspension S. Further, cylinder 4 may remain stationary or may be driven to move at an adjusted speed. If cylinder 4 moves, an interior surface of cylinder 4 may be cleaned, e.g., via a spray pipe 8'. If cylinder 4 is stationary or set to a creeping speed, the speed of screen 6 may be increased to provide the desired translational movement of suspension S.
Suspension S may have a pressure of, e.g., approximately 0.1 bar, and at least 0.01 bar, exerted upon it by screen tension due to converging surfaces 1 and 2. The relative translational velocity or speed of suspension S between the converging surfaces, as noted above, may be set in accordance with the output rate of the suspension inlet, however, in accordance with the present invention, the translational velocity should be at least 18 m/min, and preferably at least 50 m/min.
Another alternative embodiment of the device for performing the draining process of the present invention is illustrated in FIG. 3. In FIG. 3, screen 6 may be guided through two press rolls 10. The passage through press rolls 10 may further enhance the draining effect of the present invention. Further, one of the press rolls 10 may be utilized to remove the thickened pulp from the surface of screen 6. It is noted that the above-discussion with respect to the relative speeds between screen 6 and cylinder 4 in FIG. 2 are applicable with the embodiment depicted in FIG. 3.
FIG. 4 illustrates a further variation for the draining device of the present invention. In FIG. 4, inner arched surface 2 may be formed by an arched shoe 11. Arched shoe 11 may remain stationary in space, and, accordingly, relative translational movement between screen 6 and the outer surface of arched shoe 11 may be achieved via circulating screen 6 at the desired speed. Further, arched shoe 11 may be provided with a suction device to create a vacuum within arch shoe 11. In accordance with a further alternative to the embodiment of FIG. 4, a press roll 12 may be located to provide an additional contact pressure. Press roll 12 may be pressed against screen 6 in a direction toward arched shoe 11, as indicated by a force arrow 11' to further increase or enhance the draining capacity of the draining device. Press roll 12 may be smooth, felted, or may be provided with openings. In a further alternative, a press shoe may be utilized in place of press roll 12.
When using a cylinder as the inner arched surface, it may be further advantageous to utilize a partial vacuum within the drainage zone, as illustrated, e.g., in FIG. 5. In this embodiment, two suction chambers 12 and 12', which may be pressurized at different pressures, may be located within cylinder 4 opposite the outer arched surface. In this manner, the draining of suspension S may be enhanced by aspiration to draw additional drained fluid into cylinder 4. The specific number of chambers depends upon the requirements of the desired draining, and, therefore, the selection is left up to the expert. FIG. 5 further shows another potential feature for improving the discharging of drained suspension S'. A blow box 13 may be located within cylinder 4 downstream of the suction chambers, and substantially adjacent the scraper, to provide an over-pressure from the inside of cylinder 4 to improve the effectiveness of the scraper by blowing drained suspension S' from the outer surface of the cylinder. It is further noted that the present invention contemplates utilizing the suction chambers and/or blow box within the previously discussed embodiments, e.g., as depicted in FIGS. 3 and 4. For the sake of completeness it must be mentioned that the variation possibilities mentioned up to now in regard to the outer arched surface also exist in the embodiments shown in FIGS. 3 and 4.
In a further advantageous alternative, the draining zone may be divided into at least two sections such that one of the arched surfaces is divided into at least two sections, each section having a different curvature and/or angle. This particular embodiment may be seen, e.g., in FIG. 6. A stiff screen forming the outer arched surface may include two sections 6' and 6" that may be coupled together by a joint 14. Joint 14 may be formed to be slidable, so that a boundary formed by sections 6' and 6" of the screen may be changed. Of course, more than two sections may be utilized in accordance with the present invention. Further, sections 6' and 6" of the screens may be formed by, e.g., elastic screens instead of the stiff screens. Elastic screens have the advantage that they may be clamped into position on one end and enable the user to select various screen tensions in accordance with the desired draining to be performed. The screens may further be coupled to a line, e.g., mounting rod, that may be held in position and that may be slidable.
FIG. 7 shows the portion of a screen 6 that may be utilized for carrying out the process of the present invention, however, this depiction is somewhat exaggerated for the sake of explanation and clarity. Screen 6, as depicted in FIG. 7, is utilized for stationary mounting, i.e., exhibits substantially no translational movement. Screen 6 includes a plurality of zones, each zone including a different mesh width or texture. For example, the screen mesh width or texture becomes larger when viewed in the flow direction of the suspension.
The draining effect may be further increased or enhanced by utilizing a special press device 20, as illustrated in FIG. 8. Press device 20 may include a pressure element 21, e.g., an air tube, for pressing rails 22 against, e.g., a substantially stationary flexible screen 6. Press device 20 may be designed such that, between the rails, chambers having different pressures may be formed or created by switching pressurization. For example, an overpressure may be formed via air pressure in a first chamber. In an adjacent second chamber, a partial vacuum may be formed to suction off water or moisture. In a next adjacent third chamber, another over-pressure, etc. through press device 20. As an alternative/enhancement to this embodiment, rinse water may be utilized to create or form the over-pressure. In this manner, a particular rinsing effect may further be produced. However, this rinsing effect will accordingly reduce the draining capacity of the machine. Further, pressure element 21 may create or generate pressure pulses to further improve the draining capacity.
In principle, the process of the present invention may be performed if at least one of the converging surfaces is arched. As illustrated in FIG. 9, an arched surface, which is generally the surface that is driven to move, interacts with a flat surface to provide the above-discussed two-sided draining.
In a manner similar to FIG. 8, FIG. 10 illustrates a draining area that utilizes pressure rails 24. Pressure rails 24 may be pressed, e.g., with springs, against an interior of a permeable surface of the inner arched surface. It is noted that this additional pressure may further enhance the draining. Due to wear considerations, pressure rails 24 are preferably utilized in conjunction with the substantially stationary screen or the screen which is driven to move at the creeping speed. Further, or alternatively, pulsating pressure devices 23 may be utilized with, or instead of, pressure rails 24, which exhibit a constant pressure force. Use of pulsating pressure devices 23 will increase the draining capacity of the machine and further, help prevent the pulp from sticking to the arched surface.
FIG. 11 shows a device similar to that depicted in FIG. 2, however, this embodiment has be substantially rotated 90°. In this manner, the draining area may be located, e.g., below the cylinders, thus additionally utilizing gravity in draining the suspension.
In accordance with the present invention, it may be advantageous to form both converging surfaces with flexible screens. In principle, this arrangement is utilized in double-screen molding devices in paper machines, however, these devices do not exhibit any significant relative translational speeds. As clearly indicated above, the relative rotational movement, in combination with the other discussed features of the draining device, significantly improves the final dryness of the thickened suspension.
It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the invention has been described with reference to a preferred embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the invention in its aspects. Although the invention has been described herein with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed herein; rather, the invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.
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Process and device for draining a fibrous pulp suspension. The process may include positioning two surfaces to converge in a downstream direction, feeding the fibrous pulp suspension between the two converging surfaces, driving at least one of the two converging surfaces to move the suspension with a relative translational velocity, and draining the fibrous pulp suspension through each of the two surfaces. The device may include two arcuate surfaces positioned to form converging surfaces. One of the two arcuate surfaces may include a drivable, pivotable, and rotatable cylinder having an outer sleeve with openings, the other of the two arcuate surfaces may include a screen positioned to be guided around at least a portion of the outer sleeve. The screen and the openings may form drains for draining the fluid pulp suspension.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of copending U.S. patent application Ser. No. 07/791,881 filed on Nov. 13, 1991 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to the method of manufacturing a lens for use in an aircraft, such as a lens cover for a navigation light that may typically be placed at an aircraft wing tip. Lenses for use in aircraft have three demanding basic requirements. First, the lens must be exceedingly strong to sustain the impact from hail, foreign objects, etc. and thermal shock to which a lens on an aircraft is subjected, especially to which a lens on a modern high-speed jet aircraft is subjected. Second, an aircraft lens typically is of a complex configuration to meet the aerodynamic requirements of an aircraft exterior design. A third requirement is that the lens must be highly transparent to permit a substantial portion of light from a light source to pass therethrough and therefore must resist the erosion effects of ice crystals, sand and rain.
Lenses for aircraft application are typically manufactured of plastic material, such as polycarbonate, acrylic or the like. A lens is made by first forming a pattern in a sheet of base translucent material. The pattern, after being cut to its prescribed dimensions in the form of a flat blank member, is then molded, formed and contoured into the desired ultimate configuration. After the configuration of the lens is formed, the edge is finished to match the requirements of the lens to fit in its location within a lens receptacle of an aircraft.
Since aircraft lenses typically must be formed in contoured aerodynamic shapes, there is a tendency to develop stress in the edge of the lenses when the lenses are mounted to an aircraft, and failure of aircraft lenses typically begins with cracks forming in an edge of the structure.
The main objective of this disclosure is to provide an improved method of manufacturing a lens for use on an aircraft that resists erosion from hail, sleet, sand and the like and that also resists cracks, from thermal excursions, originating at the lens edge.
SUMMARY OF THE INVENTION
This invention provides a method of manufacturing a lens for use as a part of an aircraft.
To form a lens according to the principles of this invention it is first necessary to form a laminate in a flat sheet which is subsequently used in configuring the aircraft lens. To successfully form a laminate, a clean room facility must be available and an autoclave capable of reaching temperatures up to about 400° F. and pressures up to about 150 psi. A blank of flat sheet of polycarbonate material, such as LEXAN polycarbonate, having a thickness of about 0.25 inches and a flat sheet of comparable size of acrylic material having a thickness of about 0.06 inches are obtained. The blank of acrylic must be dried at about 150° F. for about 48 hours and the polycarbonate dried at about 260° F. for 48 hours. If the acrylic and polycarbonate blanks are not to be used within eight hours or so after drying, they should be stored in a vacuum or in a chamber having humidity of 15 or less. When cutting the acrylic and polycarbonate blanks the corners are rounded and smoothed using sandpaper.
The polycarbonate and acrylic blanks are laminated together using a fusion bonding process. A sandwich is formed utilizing two sheets of tempered glass that function as buffers, the tempered glass sheets being about 0.5 inches in thickness. The sandwich is composed of a glass buffer, a polycarbonate sheet, an acrylic sheet and a glass buffer. The prepared sandwich is placed in a vacuum bag and the bagged material is then placed in an autoclave.
The autoclave temperature is set to about 380° F., plus or minus 10° F., and to a pressure of about 100 psi, plus or minus 10 psi. After the above pressure and temperature are reached, which will require about 1/2 hour, the cycle is held for two hours. Thereafter, the autoclave is permitted to cool to less than 130° F. and the autoclave pressure released. The sandwich is permitted to cool to room temperature and removed from the vacuum bag. The glass buffers are removed, leaving the polycarbonate and acrylic fusion bonded to each other.
The laminate has many characteristics that are advantages in forming an aircraft lens compared to the use of a single material of either polycarbonate or acrylic. Polycarbonate has the advantage of being tough, strong and resistent to fatigue or thermal failure. On the other hand, the exterior surface of a lens formed solely of polycarbonate tends to cloud or become opaque when subject to erosion caused by hail, sleet, sand, etc. encountered by high-speed aircraft. Acrylic, on the other hand, is more resistent to becoming clouded or opaque but does not have the toughness and resistance to fatigue failure or thermal cracking as does polycarbonate. The acrylic layer also reduces oxidation and moisture absorption of the polycarbonate, both of which are responsible for service life degradation of the material. Therefore, the lamination takes advantage of the best characteristics of each of these materials.
After the laminate of polycarbonate and acrylic is formed, the flat sheet is cut to the pattern required to form the lens to fit the aerodynamic requirements of the aircraft on which the lens is to be used. The sheet of laminate of the required pattern is then heated and contoured on a mold to form the shape of the required lens, with the acrylic on the outside surface. After the shaped lens is cooled and removed from the mold, the basic lens having a desired size and configuration and having an uninterrupted circumferential edge is provided.
A seal is then affixed to the circumferential edge on the lens inner surface. The seal may be formed of synthetic rubber of, by way of example, 1/32 inch thickness and about 1 inch in width.
After the seal has been applied to the lens circumferential edge, the edge is trimmed to the desired ultimate configuration, attachment holes are drilled and bushings installed therein. The lens is then ready for use in an aircraft.
A better understanding of the invention will be obtained from the attached specification and claims, taken in conjunction with the attached drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a lens for use in an aircraft manufactured according to the method of this invention.
FIG. 2 is a view taken along the line 2--2 of FIG. 1 looking up on the lens of FIG. 1.
FIG. 3 is a view taken along the line 3--3 of FIG. 1 looking down on the lens of FIG. 1.
FIG. 4 is a cross-sectional view of the lens of FIG. 1 taken along the line 4--4 of FIG. 1.
FIG. 5 is an enlarged partial cross-sectional view taken along the line 5--5 of FIG. 2 showing an edge construction of the lens.
FIG. 6 is a cross-sectional view as in FIG. 5 but showing the cross-section taken in the area of the lens having an opening therethrough and showing an alternate arrangement wherein undercut of the lens body is provided to meet application limitations.
FIG. 7 is an isometric projection of an aircraft illustrating typically wing tip and landing light lens positions.
FIG. 8 is a partial cross-sectional view similar to FIG. 6 illustrating another embodiment which employs a straight sided bushing in each of the mounting openings as a means of securing the lens to an aircraft.
FIG. 9 is a cross-sectional view similar to FIG. 8 illustrating use of a domed washer in conjunction with a retention member which extends through the straight bushing in order to secure the lens to an aircraft.
FIG. 10 is a cross-sectional view similar to FIG. 8 illustrating use of a countersunk bushing in each of the mounting openings as a means of securing the lens to an aircraft.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and first to FIGS. 1, 2 and 3, a typical lens manufactured according to the method of this invention is illustrated.
The lens as illustrated in the drawing is formed in the manner as described in the summary of the invention, that is, a laminate is first formed by fusion bonding of a sheet of polycarbonate and a sheet of acrylic in an autoclave subjected to heat and pressure. The flat sheet of laminate after being removed from the autoclave is cut to the lens configuration to form a pattern. The pattern is heated and formed with a mold to obtain the configuration of the lens having the shape as shown in FIGS. 1, 2 and 3 of the drawings. Lens body 10, as previously described, is a laminate in which the inner layer 10A is polycarbonate of typically about 0.24 inches thick and the outer layer of the laminate 10B is acrylic of about 0.06 inches thick. The total thickness may vary and the ratio may vary, but typically the acrylic is of thickness of about 1/4 that of the polycarbonate.
As shown in FIGS. 1, 2, and 3 a typical lens for use in an aircraft is a complex irregular item. The complexity of the shape is required by virtue of the fact that a lens must fit and conform to the exterior configuration of the aircraft and must meet the aerodynamic requirements of the aircraft. The lens of the type shown in FIGS. 1, 2 and 3 is typical of the shape of lenses employed for an aircraft wing tip navigational light, however, the method of this invention is not related to the specific ultimate configuration of the lens. The lens illustrated in FIGS. 1, 2 and 3 is given by way of example only and to illustrate the unique requirements of transparent coverings that are formed for aircraft lenses.
The lens body 10 has an uninterrupted circumferential edge 12 extending around the full perimeter of the lens. It has been learned that in constructing lenses of the type illustrated in FIGS. 1, 2 and 3, the propensity for failure typically occurs due to the fatigue caused by stresses induced in the lens body at the time of installation and from thermal stress. An object of this disclosure is to provide an improved lens having improved resistance to clouding caused by the impact of hail, sleet, sand, etc. and improved resistance to environmental failure, and particularly to improved resistance to the formation of cracks occurring at the lens periphery or edge 12.
Resistance of the clouding of the lens is achieved by providing a lens formed of a laminate in which the outer surface is acrylic, as previously described.
As shown in FIG. 4, lens body 10 has an interior surface 14 and an exterior surface 16. Affixed to the interior surface 14 is a retainer strip 18. Such retainer strip may be of width from about 3/4 to 1 inch and extends around the full interior edge 14 of the lens body. The retainer strip 18 is formed of glass fiber cloth that may, for example, have Mil Spec Mil-C-9084, Type B, and is available from M.C. Gill Corporation. The retainer strip 18 is affixed to the lens inner surface 14 by means of a bonding agent.
In addition, a retainer strip 20 is secured around the entire peripheral edge 12 of the lens on the exterior surface 16. Like retainer strip 18, retainer strip 20 on the exterior surface is preferably formed of glass fiber cloth and may be, by example, about 3/4 to 1 inch wide, although the width can vary. The retainer strip 20 is secured to the lens body exterior surface 16 with a bonding agent as previously mentioned.
It has been shown that glass fiber cloth retainer strips 18 and 20, when securely bonded to the edges of the lens body, serve to substantially strengthen the lens body and reduce the tendency to the formation of cracks in the lens body as originating from the lens edge 12.
The retainer strips 18 and 20 may be of single ply or may be of two ply thickness. When a first retainer strip is applied using the bonding material thereafter bonding material is applied to the exterior surface of the first strip and a second ply of the retainer strip is applied. Obviously, more than two plies can be employed if desired, however, it has been determined that normally two plies of the glass fiber cloth retainer strips is sufficient to provide the structural reinforcement of the lens body edge.
After retainer strips have been applied, it is normally necessary to provide a seal for the peripheral edge of the lens body. This is accomplished by affixing a seal strip 22 around inner surface 14 and around the entire periphery of the lens. The seal 22 may be formed as an elongated strip of synthetic rubber of a width such as about 1 inch and a thickness of about 1/32 of an inch. The seal is applied by bonding material, such as rubber adhesive or thin, double back tape as available from 3M. The seal strip 22 is applied directly over retainer strip 18.
In order to comply with the mounting requirements of the lens and to accommodate the increased thickness of the edge of the lens by the application of reinforcing retainer strips 18 and 20 to the inner and outer surfaces and in addition seal strip 22, it may be necessary, as shown in FIG. 6, to undercut lens body 10 in the area thereof that receives strip 18. The undercut is indicated by the numeral 24 and is of a thickness necessary to offset, at least in part, the thickness of retainer strip 18. The use of an undercut in lens 10 may be particularly important when the lens is being manufactured as a replacement item, that is, to replace a lens in which the lens holder was not designed to accept a lens having the reinforced edge as provided by the method herein.
After retainer strips 18 and 20, and seal strip 22 are applied, edge 12 of the lens is finished to final form. Such finishing may include tapering 26 and when such is required, retainer strip 18 and seal strip 20 are shaped to conform to the ultimately desired configuration of the lens edge.
The lens as herein described has increased strength and service life and in a way which does not diminish the light transparency characteristics of the lens.
In order to secure the lens in position, retention members such as screws, bolts, rivets, etc. are employed and for that reason, openings 28 are formed in the lens around the peripheral edge. Such openings pass through retainer strips 18 and 20 and seal member 22, as shown in FIG. 6.
FIG. 7 is a picture of an aircraft 30 which illustrates two locations 32 and 34 on the aircraft 30 where lens bodies 10 may be employed. First, lens bodies 10 may be employed in a wing tip location 32 in order to cover a wing tip light (not illustrated). Second, lens bodies 10 may be employed in a landing light lens position 34 in order to cover a landing light (not illustrated).
An alternate embodiment of the present invention is shown in FIG. 8. In this embodiment, the polycarbonate 10A is fusion bonded with the acrylic 10B forming a laminate. The laminate is then cut and formed into a lens body 10, as previously described above. Next, instead of securing the interior retainer strip 18 and the exterior retainer strip 20 at the edge 12 of the interior and exterior surfaces 14 and 16 respectively, the seal strip 22 is instead directly affixed to the interior surface 14 of the edge 12. The seal strip 22 is applied by bonding material, such as rubber adhesive or thin, double back tape such as available from 3M. The seal strip 22 is applied directly over the interior surface 14 of the edge 12.
After the seal strip 22 is applied, the edge 12 of the lens body 10 is finished to final form. Although not illustrated in FIGS. 8-10, such finishing may include providing a taper 26 on the edge 12 similar to the taper 26 illustrated in FIG. 6. When a taper 26 is required, the seal strip 22 is shaped to conform to the ultimate desired configuration of the edge 12 of the lens body 10.
Next, openings 28 are formed in the peripheral edge 12 of the lens body 10 and rigid bushings 36 are installed therein. FIGS. 8 and 9 illustrate use of a straight sided bushing 36A, whereas, FIG. 10 illustrates use of a countersunk bushing 36B.
When the straight sided bushing 36A is employed with a retention member 38, such as a screw, bolt, rivet, etc., it is generally desirable to employ a domed washer 40. The domed washer 40 abuts the exterior surface 16 to prevent the retention member 38 from slipping through the straight sided bushing 36A as the retention member 38 is torqued down to secure the lens body 10 to the aircraft 30.
The bushings 36A and 36B each have a bushing length 42, as illustrated for the straight sided bushing 36A. It is important that the bushing length 42 slightly exceed a laminate depth 44 of the polycarbonate 10A and the acrylic 10B at the edge 12 where the bushing 36 is installed. Also, it is important that the bushing length 42 not exceed a laminate plus seal depth 46, also measured at the edge 12 where the bushing 36 is installed. The laminate depth 44 is a distance measured perpendicularly between the interior and exterior surfaces 14 and 16 at the edge 12. The laminate plus seal depth 46 is a distance measured perpendicularly between the exterior surface 16 and an unsecured outwardly oriented face of the seal strip 22.
Because the bushing depth 42 exceeds the laminate depth 44, when the retention member 38 is torqued up in order to mount the lens body 10 to the aircraft 30, the retention member 38 exerts a compressive force on the rigid bushing 36 instead of on the plastic lens body 10. In general, compressive loads due to the torque-up of retention members 38 appear to be a significant, if not the major, cause of lens cracking. Thus, by providing bushings 36 in the mounting openings 28 in order to receive compressive stress loads exerted by the retention members 38, lens cracking in the lens body 10 can be reduced, thus extending the useful service life of the lens body 10.
At the same time, the bushing length 42 is less than the laminate plus seal depth 46, thus, causing the flexible seal strip 22 to be compressed as the retention members 38 are torqued up. This compression of the seal strip 22 forms a weather-tight seal between the lens body 10 and the aircraft 30 without creating significant stress on the lens body 10.
The claims and the specification describe the invention presented and the terms that are employed in the claims draw their meaning from the use of such terms in the specification. The same terms employed in the prior art may be broader in meaning than specifically employed herein. Whenever there is a question between the broader definition of such terms used in the prior art and the more specific use of the terms herein, the more specific meaning is meant.
While the invention has been described with a certain degree of particularity, it is manifest that many changes may be made in the details of construction and the arrangement of components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification, but is to be limited only by the scope of the attached claim or claims, including the full range of equivalency to which each element thereof is entitled.
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A method of manufacturing a lens for use as a part of an aircraft including the steps of fusion bonding a sheet of acrylic to a sheet of polycarbonate to form a sheet of laminate, cutting the laminate into a blank having a configuration required by the ultimate lens configuration, heating the blank and forming it around a mold to provide a three dimensional lens body of desired size and configuration having an uninterrupted circumferential edge and having an inner polycarbonate surface and an outer acrylic surface, applying a narrow strip seal to the lens body inner surface in a narrow strip portion adjacent substantially the full circumferential edge thereof in order to bond the strip seal to the lens body, shaping the circumferential edge of the lens body around substantially the full circumferential edge thereof, and providing bushings in the lens body and strip seal so the bushings are spaced around the circumferential edge as a means of securing the lens to an aircraft.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to a control device for an automatic transmission for a vehicle, and more particularly to a control device for an automatic transmission for a vehicle for performing the slip control of a lock-up clutch at a predetermined gear position before kickdown.
[0003] 2. Description of the Related Art
[0004] In general, an automatic transmission having a torque converter includes a lock-up clutch for directly connecting an output shaft of an engine and an input shaft of the automatic transmission in the condition where the gear position of the automatic transmission is a predetermined gear position and the rotational speed of the engine is greater than or equal to a predetermined rotational speed, in order to improve the fuel economy. A lock-up clutch engagement characteristic line is set in a shift map, and the lock-up clutch is controlled to be engaged at a vehicle speed higher than that corresponding to the lock-up clutch engagement characteristic line. In the case of kickdown, the lock-up clutch is controlled to be disengaged at the time the accelerator pedal angle becomes larger than that corresponding to the lock-up clutch engagement characteristic line. Further, in the case of running on an uphill road, the lock-up clutch engagement characteristic line is shifted toward higher vehicle speeds to limit the engagement of the lock-up clutch in a high vehicle speed region.
[0005] As mentioned above, the lock-up clutch engagement characteristic line is fixedly set in the shift map in the prior art. Accordingly, in the case that the lock-up clutch engagement characteristic line is shifted toward higher vehicle speeds to reduce the range of the lock-up region, smooth running can be attained. However, the fuel consumption is increased. Conversely, in the case that the range of the lock-up region is set wide, the fuel consumption can be reduced. However, smooth running becomes difficult to attain in this case. Thus, it is difficult to attain both the reduction in fuel consumption and the improvement in drivability.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of the present invention to provide a control device for an automatic transmission for a vehicle which can attain smooth running and low fuel consumption by performing the slip control of a lock-up clutch before kickdown.
[0007] In accordance with an aspect of the present invention, there is provided a control device for an automatic transmission for a vehicle, including a torque converter interposed between an output shaft of an engine and an input shaft of the automatic transmission, the torque converter having a lock-up clutch for mechanically connecting the output shaft and the input shaft in a direct manner; lock-up clutch engagement control means for engaging the lock-up clutch by a predetermined engagement force in a predetermined operational region determined by a throttle angle and a vehicle speed; and a shift map having a slip region for the lock-up clutch set in relation to a plurality of shift characteristics preliminarily set according to vehicle speeds, the slip region being defined by a downshift line and a slip start line deviated from the downshift line by a predetermined range of throttle angle toward lower throttle angles; wherein when the throttle angle falls within the slip region before kickdown, the slip control of the lock-up clutch is performed by the lock-up clutch engagement control means.
[0008] With this configuration, the lock-up clutch can be slipped at an optimum throttle angle before kickdown. Accordingly, smooth running and low fuel consumption can be attained.
[0009] Preferably, when downshift is not performed within a predetermined period of time from the start of the slip control of the lock-up clutch, the slip control of the lock-up clutch is canceled to engage the lock-up clutch. By canceling the slip control of the lock-up clutch to engage the lock-up clutch in such a case, the fuel economy can be improved.
[0010] Preferably, the predetermined range of throttle angle is set wider on an uphill road than on a level road. By changing the range of the slip control of the lock-up clutch according to the slope of a road surface, the drivability both on a level road and on an uphill road cab be improved.
[0011] The above and other objects, features and advantages of the present invention and the manner of realizing them will become more apparent, and the invention itself will best be understood from a study of the following description and appended claims with reference to the attached drawings showing some preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a schematic plan view showing a general configuration of a vehicle including a slip control device for a lock-up clutch according to a preferred embodiment of the present invention;
[0013] FIG. 2 is a block diagram of an electronic control unit;
[0014] FIG. 3 is a hydraulic circuit diagram of a torque converter in disengaging the lock-up clutch;
[0015] FIG. 4 is a hydraulic circuit diagram of the torque converter in engaging the lock-up clutch;
[0016] FIG. 5 is a flowchart showing the control sequence of the slip control of the lock-up clutch before kickdown according to the preferred embodiment of the present invention;
[0017] FIG. 6 is a table showing a pre-kickdown lock-up clutch slip determination ΔAP amount according to a vehicle speed and a road surface slope in the case of a fifth gear position;
[0018] FIG. 7 is a table similar to FIG. 6 in the case of a fourth gear position;
[0019] FIG. 8 is a graph showing a lock-up clutch slip control region on a shift map for a level road;
[0020] FIG. 9 is a graph showing a lock-up clutch slip control region on a shift map for a heavy uphill road; and
[0021] FIG. 10 is a time chart showing the pre-kickdown lock-up clutch slip control according to the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] FIG. 1 is a schematic plan view showing a general configuration of a vehicle including the control device according to the present invention. This vehicle is a front-wheel drive vehicle, which includes a pair of left and right drive wheels 6 a and 6 b to which the torque of an engine 2 is transmitted through an automatic transmission 4 and a pair of left and right driven wheels 8 a and 8 b rotating with running of the vehicle. A known torque converter 14 is interposed between a crankshaft 10 of the engine 2 and a main shaft 12 of the automatic transmission 4 . Referring to FIG. 3 , there is shown a hydraulic circuit diagram of the torque converter 14 in disengaging a lock-up clutch. FIG. 4 is a hydraulic circuit diagram of the torque converter 14 in engaging the lock-up clutch.
[0023] As shown in FIG. 3 , the torque converter 14 includes a pump impeller 16 connected to the crankshaft 10 , a turbine runner 18 connected to the main shaft 12 , a stator 20 supported through a one-way clutch 22 to a fixed portion, and a lock-up clutch 24 adapted to connect the pump impeller 16 and the turbine runner 18 . The lock-up clutch 24 includes a clutch piston 28 adapted to abut against the inner surface of a torque converter cover 26 . A first oil chamber 30 and a second oil chamber 32 are formed on both sides of the clutch piston 28 .
[0024] When pressurized oil is supplied to the first oil chamber 30 to bring the clutch piston 28 into abutment against the torque converter cover 26 , the lock-up clutch 24 is engaged to thereby transmit the torque of the crankshaft 10 directly to the main shaft 12 . Conversely, when pressurized oil is supplied to the second oil chamber 32 to bring the clutch piston 28 into separation from the torque converter cover 26 , the lock-up clutch 24 is disengaged to thereby break the mechanical connection between the crankshaft 10 and the main shaft 12 .
[0025] The hydraulic circuit of the torque converter 14 includes an oil pump 36 for pumping up a hydraulic fluid from an oil tank 34 and a regulator valve 38 for regulating the pressure of the hydraulic fluid from the oil pump 36 to a predetermined regulator pressure. A lock-up shift valve 40 functions to transmit the regulator pressure to the second oil chamber 32 of the torque converter 14 and to connect the first oil chamber 30 to the oil tank 34 when the lock-up clutch 24 is disengaged, whereas functions to transmit the regulator pressure to the first oil chamber 30 of the torque converter 14 and to connect the second oil chamber 32 to a lock-up control valve 42 which will be hereinafter described when the lock-up clutch 24 is engaged.
[0026] The lock-up control valve 42 functions to relieve the pressure of the hydraulic fluid supplied from the second oil chamber 32 through the lock-up shift valve 40 and to thereby regulate the pressure in the second oil chamber 32 , thereby controlling an engagement force of the lock-up clutch 24 . A lock-up timing valve 44 is operated by a throttle pressure at a high vehicle speed to thereby operate the lock-up control valve 42 , thereby making the second oil chamber 32 open to the atmosphere to fully engage the lock-up clutch 24 .
[0027] A first solenoid valve 46 is an on/off controlled valve. When the first solenoid valve 46 is turned off, a modulator pressure is transmitted to the left end of the lock-up shift valve 40 to rightward move the spool of the lock-up shift valve 40 , so that the regulator pressure is transmitted to the second oil chamber 32 of the torque converter 14 , and the first oil chamber 30 is connected to the oil tank 34 , thereby disengaging the lock-up clutch 24 . When the first solenoid valve 46 is turned on, the modulator pressure is relieved to leftward move the spool of the lock-up shift valve 40 , so that the regulator pressure is transmitted to the first oil chamber 30 of the torque converter 14 , and the second oil chamber 32 is connected to the lock-up control valve 42 , thereby engaging the lock-up clutch 24 .
[0028] A second solenoid valve 48 is a linear solenoid valve. When the second solenoid valve 48 is turned off, the modulator pressure is transmitted to the lock-up control valve 42 and the lock-up timing valve 44 to rightward bias the spool of the lock-up control valve 42 and the spool of the lock-up timing valve 44 . When the second solenoid valve 48 is turned on, the modulator pressure is relieved to cancel the above-mentioned biasing force. The degree of opening of the lock-up control valve 42 can be steplessly controlled by changing the value of a current supplied to the second solenoid valve 48 . When the degree of opening of the lock-up control valve 42 is increased, the back pressure in the second oil chamber 32 of the torque converter 14 is decreased to thereby increase the engagement force of the lock-up clutch 24 . Conversely, when the degree of opening of the lock-up control valve 42 is decreased, the back pressure in the second oil chamber 32 of the torque converter 14 is increased to thereby decrease the engagement force of the lock-up clutch 24 .
[0029] Referring again to FIG. 1 , the engine 2 is provided with engine speed detecting means 50 for detecting an engine speed Ne, and the automatic transmission 4 is provided with main shaft speed detecting means 52 for detecting a main shaft speed Nm and shift position detecting means 54 for detecting a shift position P. A throttle valve 58 is provided in an intake passage 56 . The throttle valve 58 is provided with throttle angle detecting means 60 for detecting a throttle angle θ TH . Further, each of the rear wheels 8 a and 8 b as the driven wheels is provided with vehicle speed detecting means 62 for detecting a vehicle speed V. Reference numeral 53 denotes slope detecting means for detecting the slope of a road surface on which the vehicle is running. In this preferred embodiment, a G sensor for computing the slope from a longitudinal acceleration G of the vehicle is used as the slope detecting means 53 . As a modification, the slope detecting means 53 may be provided by means for directly detecting the angle of inclination of a vehicle body with respect to a horizontal plane.
[0030] FIG. 2 shows an electronic control unit (ECU) 64 for performing computations on output signals from the various detecting means mentioned above according to a control program and driving the first and second solenoid valves 46 and 48 to control the speed ratio of the torque converter 14 . The electronic control unit 64 includes a central processing unit (CPU) 66 for performing the computations, a read only memory (ROM) 68 preliminarily storing the control program and data such as various tables, and a random access memory (RAM) 70 for temporarily storing the output signals from the various detecting means and the results of the computations.
[0031] The electronic control unit 64 further includes an input circuit 72 to which the engine speed detecting means 50 , the main shaft speed detecting means 52 , the slope detecting means 53 , the shift position detecting means 54 , the throttle angle detecting means 60 , and the vehicle speed detecting means 62 are connected, and an output circuit 74 to which the first solenoid valve 46 and the second solenoid valve 48 are connected. Thus, the CPU 66 in the electronic control unit 64 performs computations on the various signals input through the input circuit 72 and on the data stored in the ROM 68 according to the control program to be hereinafter described, and controls the values of currents supplied through the output circuit 74 to the first and second solenoid valves 46 and 48 . Accordingly, the engagement force of the lock-up clutch 24 can be changed to control the speed ratio of the torque converter 14 .
[0032] The slip control of the lock-up clutch before kickdown according to the preferred embodiment of the present invention will now be described in detail with reference to the flowchart shown in FIG. 5 . In step S 10 , it is determined whether or not the lock-up clutch (LC) is under the slip control, i.e., whether or not a pre-kickdown LC slip control flag F_LCOFPKD is on. If the answer in step S 10 is negative, the program proceeds to step S 11 to retrieve a pre-kickdown LC slip determination ΔAP amount DAPPKD.
[0033] For example, when the present gear position is a fifth gear position, DAPPKD is set according to the slope of a road surface as shown in FIG. 6 , whereas when the present gear position is a fourth gear position, DAPPKD is set according to the slope of a road surface as shown in FIG. 7 . In FIGS. 6 and 7 , N is a level road, L is a light uphill road, M is a medium uphill road, H is a heavy uphill road, and H2 is a double heavy uphill road. In FIG. 6 , for example, 0.2 indicates that the throttle angle is 0.2/8, and 0.5 indicates that the throttle angle is 0.5/8.
[0034] Referring again to the flowchart shown in FIG. 5 , the program proceeds to step S 12 after retrieving DAPPKD in step S 11 . In step S 12 , it is determined whether or not DAPPKD is 0. If the answer in step S 12 is negative, the program proceeds to step S 13 to determine whether or not downshift is to be performed at the present accelerator pedal angle (AP angle)+DAPPKD. If the answer in step S 13 is affirmative, the program proceeds to step S 14 to start the slip control of the lock-up clutch that has been engaged. Further, the pre-kickdown LC slip control flag F_LCOFPKD is set, and a timer A is set to a predetermined time.
[0035] Further, the accelerator pedal angle is set to a reference accelerator pedal angle, i.e., a pre-kickdown LC slip control starting accelerator pedal angle APPKDS. By starting the slip control of the lock-up clutch in step S 14 , the engine speed is increased, so that a reduction in linearity due to the engagement of the lock-up clutch can be prevented. Accordingly, smooth running and low fuel consumption can be both attained. If the answer in step S 12 is affirmative, i.e., if DAPPKD=0, it is unnecessary to perform the slip control of the lock-up clutch, and the program is therefore ended. Further, if the answer in step S 13 is negative, the program is ended.
[0036] After starting the slip control of the lock-up clutch in step S 14 , the determination in step S 10 with the next timing is that the lock-up clutch is under the slip control. Accordingly, the program proceeds to step S 15 to determine whether or not kickdown (KD) has been performed. If the answer in step S 15 is affirmative, the program proceeds to step S 16 to finish the slip control according to the present invention. In other words, the lock-up clutch is reengaged and the pre-kickdown LC slip control flag F_LCOFPKD is reset to 0.
[0037] If the answer in step S 15 is negative, the program proceeds to step S 17 to determine whether or not the predetermined time set in the timer A has elapsed. If the answer in step S 17 is affirmative, the program proceeds to step S 16 to finish the slip control according to the present invention. If the answer in step S 17 is negative, the program proceeds to step S 18 to determine whether or not the accelerator pedal has been returned, i.e., whether or not AP angle<APPKDS−DAPPKDF, where DAPPKDF stands for a pre-kickdown LC slip control finishing ΔAP amount. If the result in step S 18 is affirmative, the program proceeds to step S 16 to finish the slip control according to the present invention, to reengage the lock-up clutch, and to reset the pre-kickdown LC slip control flag F_LCOFPKD.
[0038] Referring to FIG. 8 , there is shown a pre-kickdown LC slip control region on a shift map for a level road according to the preferred embodiment of the present invention. In FIG. 8 , each heavy line shows an LC slip control start line. In this preferred embodiment, the pre-kickdown LC slip control region on the level road shift map includes an LC slip control region 76 before kickdown from the sixth gear position to the fifth gear position, an LC slip control region 78 before kickdown from the fifth gear position to the fourth gear position, and an LC slip control region 80 before kickdown from the second gear position to the first gear position.
[0039] As apparent from this shift map, in the condition where the vehicle can be accelerated without slipping the lock-up clutch, the slip control of the lock-up clutch is not performed. In other words, in this condition, each downshift line coincides with the corresponding LC slip control start line. In contrast, in the LC slip control regions 76 , 78 , and 80 , the lock-up clutch is slipped before reaching the respective downshift lines. Accordingly, the engine speed can be increased to thereby increase the drive force, so that a reduction in linearity due to the engagement of the lock-up clutch can be prevented.
[0040] Referring to FIG. 9 , there is shown a pre-kickdown LC slip control region on a shift map for a steep upward slope (heavy uphill road) according to the preferred embodiment of the present invention. In this preferred embodiment, the pre-kickdown LC slip control region on the heavy uphill road shift map includes an LC slip control region 82 before kickdown from the fifth gear position to the fourth gear position, an LC slip control region 84 before kickdown from the fourth gear position to the third gear position, an LC slip control region 86 before kickdown from the third gear position to the second gear position, and an LC slip control region 88 before kickdown from the second gear position to the first gear position.
[0041] In FIG. 9 , each heavy line shows an LC slip control start line similar to that shown in FIG. 8 . However, as apparent from the comparison between FIG. 8 and FIG. 9 , the slip control of the lock-up clutch on an uphill road is started at an accelerator pedal angle smaller than that on a level road. In other words, the range of the LC slip control region on an uphill road is set wider than that on a level road.
[0042] The pre-kickdown LC slip control according to the preferred embodiment of the present invention will now be described more specifically with reference to the time chart shown in FIG. 10 . In FIG. 10 , SH stands for a gear position. At the time t 1 , it is determined that downshift is to be performed at AP angle+DAPPKD. Accordingly, the slip control of the lock-up clutch is started with ΔAP=DAPPKD before kickdown. At the time t 2 , kickdown is performed, and the slip control of the lock-up clutch is therefore finished to reengage the lock-up clutch. At the time t 3 , the downshift line is crossed to pass through the upshift line, so that the gear position is upshifted by one.
[0043] At the time t 4 , the AP angle becomes the pre-kickdown LC slip control starting accelerator pedal angle APPKDS, so that the slip control of the lock-up clutch is started. When the accelerator pedal is returned as shown by a broken line 90 , the change in accelerator pedal angle from the time t 4 to the time t 5 becomes the pre-kickdown LC slip control finishing ΔAP amount=DAPPKDF. Accordingly, at the time t 5 , the slip control of the lock-up clutch is canceled to reengage the lock-up clutch as shown by a broken line 92 . Also when the predetermined time set in the timer A as shown by an arrow 94 has elapsed at the time t 6 , the slip control of the lock-up clutch is canceled to reengage the lock-up clutch.
[0044] The present invention is not limited to the details of the above described preferred embodiments. The scope of the invention is defined by the appended claims and all changes and modifications as fall within the equivalence of the scope of the claims are therefore to be embraced by the invention.
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A control device for an automatic transmission for a vehicle including a torque converter interposed between an output shaft of an engine and an input shaft of the automatic transmission, the torque converter having a lock-up clutch for mechanically connecting the output shaft and the input shaft in a direct manner, and a lock-up clutch engagement control unit for engaging the lock-up clutch by a predetermined engagement force in a predetermined operational region determined by a throttle angle and a vehicle speed. The control device further includes a shift map having a slip region for the lock-up clutch set in relation to a plurality of shift characteristics preliminarily set according to vehicle speeds, the slip region being defined by a downshift line and a slip start line deviated from the downshift line by a predetermined range of throttle angle toward lower throttle angles. When the throttle angle falls within the slip region before kickdown, the slip control of the lock-up clutch is performed by the lock-up clutch engagement control unit.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to systems and methods for transporting digital multimedia signals, such as television programs, to customer equipment, and more particularly to audio-video program distribution systems that convert a plurality of single program transport streams into a multiple program transport stream.
[0005] 2. Description of the Related Art
[0006] Today television programs are distributed digitally using the MPEG2 protocol defined by ISO/IEC 13818-1 standard that describes a method and data format of packetizing compressed digital audio-video information for serial transmission. According to the MPEG2 protocol, the compressed video and audio program data are divided into transport packets having a common length of 188 bytes. The transport packets for the same program form a single program transport stream (SPTS) and when the packets from more than one SPTS, i.e. more than one program, are multiplexed onto a common carrier the result is a multiple program transport stream (MPTS).
[0007] Besides the program signal data, each transport packet includes a packet identifier (PID) field containing a value that distinguishes each kind of transport packet for a given program from other kinds, e.g. video packets from audio packets. The MPEG2 transport packets also carry program specific information (PSI), which includes a program association table, a program map table, and a program clock reference. The program map table (PMT) lists the packet identifiers associated with one single program transport stream and the program association table (PAT) lists the packet identifiers for the packets that contain the program map tables for each single program transport stream that has been multiplexed into a given multiple program transport stream. The program clock reference (PCR) contains timing information that enables a decoder to synchronize the program content carried in different packets for the same program, such as matching the audio tracks with the associated video.
[0008] In a typical cable television program distribution system 10 , such as the one depicted in FIG. 1 , the MPEG2 program content is obtained at the system's head end from a plurality of MPEG2 program sources 11 - 12 , such as television networks using earth orbiting satellites, over the air broadcast stations, and other content providers. The MPEG2 program sources 11 - 12 , often include on-demand movies and locally generated programs, such as from a municipal government or a school district. It should be understood that the head end frequently receives a hundred or more programs, each representing a single program transport stream of MPEG2 packets.
[0009] As used herein a “program” includes, but is not limited to, television programs, a sequence of video images, a video game, a video image produced by a computer system, and a video image produced from a storage medium.
[0010] An Internet protocol (IP) network interface 14 at the head end places a group of MPEG2 packets for the same program into an Internet protocol packet that is then inserted into an Ethernet frame for transmission. The Ethernet frames are sent from the head end over a fiber optic cable of an IP network 16 .
[0011] FIG. 3 graphically depicts the format of one Ethernet frame. A group of seven MPEG2 transport stream (TS) packets from one of the program sources 11 - 12 forms the data field of a User Datagram Protocol (UDP) frame. The UDP frame also includes a header that, among other things, contains an identifier denoting the program source from which the UDP data originated and thus the source of the accompanying TS packets. The UDP frame is placed within a standard Internet protocol packet that contains a conventional IP header. In turn, the IP packet is placed within a standard Ethernet frame and is bounded in that frame by a conventional Ethernet header and a conventional Ethernet footer. Each SPTS comprises a sequence of these Ethernet frames carrying the data for the respective program.
[0012] Referring again to FIG. 1 , the fiber optic cable of the IP network 16 terminates at a cluster of end users. For example, a cluster may be a section of a municipality having approximately 500 homes or a large hotel. At the remote terminus of the of the IP network 16 , an IP edge multiplexer 18 (commonly referred to as an “Edge QAM”) extracts the MPEG2 TS packets for each program from the Ethernet frames and uses the TS packets to modulate a radio frequency (RF) carrier for a given television channel that is the carry the associated program. The resultant plurality of modulated RF carriers are combined and fed onto an RF network 20 that usually employs a coaxial cable to distribute the television programs to consumer premises throughout the service area defined by the cluster.
[0013] At a consumer premise, the RF network 20 is connected to a separate decoder 21 , 22 , or 23 which allows the people at that premise to select a particular program by tuning the decoder to the corresponding television channel. The decoder 21 - 23 either translates the RF television signal on the received channel into another predefined common output channel (e.g., channel 3 ) or converts the RF television signal into a composite audio-video signal. In either conversion case, the output from the respective decoder 21 , 22 or 23 is applied to an associated display device 24 , 25 or 26 , respectively, which in this instance is a digital television receiver.
[0014] With reference to FIG. 2 , a conventional IP edge multiplexer 18 comprises an IP network interface 30 to which the fiber optic cable of the IP network 16 connects and which converts the optical signal into an electrical signal carrying the Ethernet frames. The electrical signal is then applied to an IP stack 32 that recovers the MPEG2 transport stream (TS) packets from each Ethernet frame. Those TS packets are then fed to an input buffer 34 in which they are stored temporarily in a manner that identifies their associated program. When data for a particular program is required for further processing one or more of the associated TS packets are read from the input buffer and directed by a router 36 to a channel circuit 38 for the particular television channel that has been designated to carry the respective program. It should be understood that a given television channel can carry several digital television programs at the same time on different sub-channels. Each channel circuit 38 multiplexes the packets of the SPTS's of those individual television programs into a MPTS that then modulates the RF Carrier for the respective television channel.
[0015] To simplify the explanation, the transmission of program data through the IP edge multiplexer 18 will be described in the context of one SPTS, with the understanding that TS packets for a plurality of programs are processed sequentially in the same manner. As each Ethernet frame is received, its group of TS packets is extracted and placed into the input buffer 34 . The conventional input buffer 34 simultaneously stores groups of transport streams packets from a large number of Ethernet frames and thus for a plurality of separate programs. The input buffer 34 is implemented by a very large random access memory so that all the incoming TS packets can be stored until one can be processed by the respective channel circuit 38 . A relatively large amount of buffer memory is required to provide time for the IP edge multiplexer to construct the program specific information, specifically the program association table and the program map table, for the audio-video content being transported. The size of the input buffer varies dynamically based on the amount of incoming data that has to be stored before the channel circuits 38 can process that data.
[0016] The IP stack 32 and the input buffer 34 introduce significant delays in the transmission of the TS packets for each program. Specifically, the IP stack 32 introduces an indeterminate and varying delay, which can be in the microseconds range and thereafter the input buffer 34 introduces another delay that can be up to an additional three to four seconds. Because of the magnitude and uncertainty of these delays at any point in time, a considerable latency in the signal processing occurs.
[0017] When a TS packet for a particular program is finally read out of the input buffer 34 , the router 36 conveys that packet to the appropriate channel circuit 38 for the television channel that has been predefined carry the respective program. Each channel circuit has a similar configuration with one of them being shown in detail in FIG. 2 . Specifically, the channel circuit 38 has a multiplexer 40 that requests data from the input buffer 34 at the proper timing rate needed to produce the television channel output signal. Because the RF signal for a standard television channel is able to carry multiple digital television programs at the same time, the multiplexer's function is to create a transport stream containing the TS packets for those multiple programs. Thus, the multiplexer takes TS packets for a single program transport stream and inserts them into a multiple program transport stream for the respective television channel. In the course of that processing the multiplexer utilizes the PCR timing information embedded in each program's SPTS to determine when to insert the TS packets into the multiplex buffer 42 . Because of the relatively large and often uncertain dynamically varying delays in the IP stack 32 and the input buffer 34 , the internal multiplexer 40 has to restamp the TS packets with a new program clock reference (PCR). The multiplexer 40 also generates a new program map table and a new program association table to ensure proper construction of the MPTS.
[0018] In order to create the proper timing of the MPTS, the multiplexer often outputs null packets between the TS packets as necessary so that the output stage 44 can obtain the data at a constant rate that is higher than the rate at which the SPTS packets were received by the multiplexer 40 . The resultant sequence of packets from the multiplexer 40 is placed into a multiplex buffer 42 to construct the multiple program transport stream in which single TS packets interspersed with groups of multiple null packets, see the data stream depicted at the bottom of the channel circuit in FIG. 2 . The multiplex buffer 42 also enables in order that an output stage 44 can obtain the data at a constant rate that is higher than the rate at which the SPTS packets were received by the multiplexer 40 .
[0019] The output stage 44 clocks the data packets out of the multiplex buffer 42 at a constant rate and then modulates the appropriate RF carrier for the designated television channel with that data. Because such television signal generation utilizes quadrature amplitude modulation, the this type of IP edge multiplexer is often referred to as an “edge QAM.”
[0020] A delay of the magnitude introduced by standard IP edge multiplexers 18 is acceptable for delivery of audio-video content, that is not typically considered to be time sensitive, especially in the case of a standard television program being delivered over a one-way broadcast network.
[0021] More recently, however, most cable television systems have been converted to two-way networks in order to provide interactive applications, such as video game playing, graphical menu systems, and on-demand movies with the ability for the viewer to pause and slow the speed at which the program is delivered. Unfortunately, most previous IP edge multiplexers were not fast enough to deliver that kind of programming from the head end in near real-time. Delays encountered in conventional multiplexers produced an unacceptable lag time between when a viewer's control input was sent upstream until the program produced a visual response on the television set.
[0022] As a consequence, it is desirable to provide an IP edge multiplexer that has a low latency between receiving a program packet from the optical fiber and applying the program data as an radio frequency channel signal onto the coaxial cable leading to the consumer's premises.
SUMMARY OF THE INVENTION
[0023] An apparatus is provided for multiplexing a plurality of single program transport streams into a multiple program transport stream. Each single program transport stream is formed by a series of groups of a predefined number of data packets, in which each data packet contains a packet identifier. Each single program transport stream carries a program map table that identifies packet identifiers associated with that respective single program transport stream. The multiple program transport stream carries a program association table that identifies the program map tables for the plurality of single program transport streams that are multiplexed into the multiple program transport stream.
[0024] The apparatus comprises an input buffer that receives data packets of the plurality of single program transport streams and that is configured to hold only the predefined number of data packets at any point in time. An MPTS table builder receives data packets from the input buffer, reassigns a set of unique packet identifiers to the data packets from each single program transport stream, reconfigures each program map table in the data packets with the set of unique packet identifiers for the respective single program transport stream, and generates a program association table that identifies the program map tables for the plurality of single program transport streams. Nevertheless, the MPTS table builder retains unaltered the program clock reference in the data packets. A first-in, first-out buffer is operably connected to combine data packets received from the MPTS table builder into a multiple program transport stream. For example, the first-in, first-out buffer is a ring type buffer.
[0025] A specific embodiment of the apparatus, further includes an output stage that receives the multiple program transport stream and modulates a carrier signal with the multiple program transport stream. In a particular case, the carrier signal is associated with a television channel.
[0026] One aspect is that the present Internet protocol edge multiplexer, by employing fixed size buffers through which the TS packets are clocked in a first-in, first-out manner, provides a constant and determinate latency in the processing of those packets. Furthermore, the signal processing relies on timing that is derived from the rate at which the TS packets are received from the IP network and processes that TS packets in the identical order in which they were received, thereby maintaining the origination timing among the packets for the same program SPTS. This later feature eliminates the requirement of recalculating the program clock reference for the TS packets, as in prior edge multiplexers. These features significantly reduce the processing delay as comparing to conventional edge multiplexer, thereby enabling faster response times between a user input and a change in the display of an interactive system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a block diagram of a conventional digital television program distribution system;
[0028] FIG. 2 is a block diagram of an Internet protocol edge multiplexer that has been used in previous digital television program distribution systems;
[0029] FIG. 3 is a graphical depiction of an Ethernet frame that carries data for a television program through part of the program distribution system; and
[0030] FIG. 4 is a block diagram of an Internet protocol edge multiplexer according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] With reference to FIG. 4 , a novel Internet protocol edge multiplexer 60 receives each SPTS in the form of a series of Ethernet frames from the IP network 16 . The Ethernet frames are applied an IP network interface 62 which converts the optical network signal into an electric signal. The resultant electrical signal is applied to a packet filter 64 that selects those Ethernet frames that contain program data to be passed to the RF network 20 . Specifically, the packet filter 64 inspects the inbound Ethernet frames discarding those that do not contain a program identifier in the UDP header for which the edge device is configured to process. The IP network can carry other types of data, such as email and other Internet content. The relevant packet identifiers for the IP edge multiplexer 18 are stored within a configuration database 65 . As each incoming Ethernet frame is received, the enclosed program identifier is obtained and the configuration database 65 is inspected to see if that program identifier is listed therein. If that is the case, the Ethernet frame is passed by the packet filter 64 to a TS packet extractor 66 , which removes the seven TS packets from the UPD frame and sends them to an input buffer 68 .
[0032] The input buffer 68 is only seven TS packets wide, i.e., it has a fixed size that can accommodate only the data from the group of seven TS packets contained in a single Ethernet frame. It should be appreciated that the present invention may be used with transport streams that transmit packets in groups having more or less than seven packets. The group of TS packets is held within the input buffer 68 for a period of time on the order of one millisecond until the downstream components of the IP edge multiplexer are ready to process that data. Therefore, unlike the input buffer of the traditional edge multiplexer that has a significantly greater amount of storage capacity and simultaneously holds groups of TS packets from many Ethernet frames and many different programs, the new IP edge multiplexer 60 has an input buffer 68 that can only hold only seven TS packets at a time. Further the input buffer 68 does not hold any one TS packet for more than approximately 1 millisecond which is a significantly shorter period of time (more than three orders of magnitude less) than conventional edge QAM input buffers.
[0033] When a downstream section of the IP edge multiplexer 60 is ready to process new data, the group of seven TS packets is clocked out of the input buffer 68 and fed through a router 70 . The function of the router 70 is to direct the SPTS for a particular program to the appropriate channel circuit 72 for the specific television channel that is designated to carry that program. The configuration database 65 contains a designation of which channel circuit 72 is to receive the TS packets for a particular program. Because TS packets are fed from the packet filter 64 through the TS packet extractor 66 and the input buffer 68 in the same order in which they are received, the program identifier extracted from the Ethernet frame by the packet filter can be used by the configuration database 65 to instruct the router 70 as to which channel circuit 72 to send the TS packet presently being received from the input buffer. Thus, as the seven packets for a given SPTS are clocked out of the input buffer 68 , the router 70 sends those packets as a group to the appropriate channel circuit 72 .
[0034] Each channel circuit 72 has the same circuit configuration with the details for one of them shown in FIG. 4 . The TS packet stream from the router 70 is applied to an MPTS table builder 74 , that performs several functions. Firstly, the MPTS table builder 74 re-stamps the TS packets for from each SPTS with a new and unique set of packet identifiers (PID) to enable proper multiplexing of that program data into the conventional MPTS output. Note that, the set of packet identifiers used by each SPTS was assigned by its particular MPEG2 program source 11 - 12 without the ability to know the packet identifiers being assigned by the other program sources to their SPTS's. As a result, it is possible that, when multiple programs are transmitted on the same MPTS, two of them could use at least one identical PID. This possibility is eliminated by the MPTS table builder 74 reassigning new PID's to the TS packets for each SPTS that is being received. The MPTS table builder 74 also then redefines the associated program map table (PMT) with the newly assigned PID's and generates an new program association table, all in accordance with the MPEG2 system standards.
[0035] Key to the processing by the MPTS table builder 74 is that the program clock reference (PCR) for the TS packets is not altered, as occurred in previous IP edge multiplexers. Instead, the present IP edge multiplexer 60 relies on timing that is derived from the rate at which the TS packets are received from the IP network. In other words, it is assumed that the TS packets are coming in from the IP network 16 with the proper timing and because each group of seven TS packets is fed through the IP edge multiplexer 60 in the identical order in which they were received, and because the latency of the signal between the input and the output has been significantly reduced, the program clock reference does not need to be recalculated. Thus, the fast throughput of the program data and the fact that the TS packets only can be fed out of the IP edge multiplexer 60 in the same order in which they were received, maintains the respective timing among the packets for the same program SPTS.
[0036] The MPTS table builder 74 places the group of seven TS packets into a first-in, first-out (FIFO) buffer 76 . The FIFO buffer 76 may be defined in a relatively small random access memory, in comparison to the multiplex buffers used in previous edge devices, with the buffer instantiated in contiguous memory access (DMA) memory locations implemented as a ring buffer. Should the buffer contents exceed a “high water mark”, non-priority packets are discarded and do not enter that buffer. A priority bit in the transport stream field header distinguishes non-priority and priority packets. Furthermore, if the FIFO buffer 76 becomes full and the router 70 attempts to overrun that buffer, incoming packets will be dropped which is an error state that implies the timing of the input source stream is incorrect.
[0037] Data are clocked out of the FIFO buffer 76 by an output stage 78 at a constant rate. If there is no data in the FIFO buffer, null packets are created and clocked out. This produces an MPTS consisting of groups of seven TS packets from the same SPTS which may be bounded by null packets if necessary to provide a constant data rate for the MPTS. The output stage 78 then modulates an RF carrier with the data in the MPTS according to the modulation protocol for the respective output signal. In the case of an ATSC television signal, the output stage 78 quadrature amplitude modulates a standard RF channel carrier with the MPTS. A combiner 79 combines the resultant RF signal for the associated television channel the channel signals from the other channel circuits 72 to produce the output signal from the IP edge multiplexer 60 that is then fed onto the RF network 20 . Although the output stage uses quadrature amplitude modulation (QAM) in the exemplary program distribution system 10 , other modulation techniques and different output signal format protocols can be employed.
[0038] The multiplexing of multiple incoming SPTS's for different programs occurs by virtue of the order in which the groups of seven TS packets for each SPTS arrive at the input of the FIFO buffer 76 . For instance a group of TS packets arrives from a first SPTS and is followed by a pause during which null packets are produced. Then a group of seven packets from a second SPTS, i.e., a different program, arrives at the same channel circuit 72 and is similarly fed through the FIFO buffer 76 and the output stage 78 .
[0039] The present Internet protocol edge multiplexer 60 , by employing fixed size buffers through which the TS packets are clocked in a first-in, first-out manner, provides a constant and determinate latency in the processing of those packets. Furthermore, the signal processing relies on timing that is derived from the rate at which the TS packets are received from the IP network and processes those TS packets in the identical order in which they were received, thereby maintaining the origination timing among the packets for the same program SPTS. This later feature eliminates the requirement of recalculating the program clock reference for the TS packets, as in prior edge multiplexers. In the exemplary IP edge multiplexer being described the seven TS packets extracted from each Ethernet frame are processed as a group. These features significantly reduce the processing delay as comparing to conventional edge multiplexer, thereby enabling faster response times between a user input and a change in the display of an interactive system.
[0040] The foregoing description was primarily directed to a preferred embodiment of the invention. Although some attention was given to various alternatives within the scope of the invention, it is anticipated that one skilled in the art will likely realize additional alternatives that are now apparent from disclosure of embodiments of the invention. Accordingly, the scope of the invention should be determined from the following claims and not limited by the above disclosure.
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An apparatus for transporting digital multimedia receives signals for a plurality of single program transport streams (SPTS). Each SPTS is transmitted as a series of groups of a predefined number of transport stream packets. An input buffer that receives the packets is configured to hold only the predefined number of packets at any point in time. A table builder receives packets from the input buffer and assigns a set of unique packet identifiers to the packets from each SPTS, reconfigures each program map table in the packets, and generates a program association table for a multiple program transport stream (MPTS). The table builder retains unaltered the program clock reference in the data packets. A first-in, first-out buffer combines packets received from the table builder into a MPTS. An output stage modulates a carrier signal, such as for a television channel, with the MPTS.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a decorative fireplace system and apparatus, having replaceable decorative panels.
[0003] 2. Background of the Invention
[0004] Conventional decorative products produced for fireplaces, address only the outside of the fireplace. For example, there are many decorative mantle pieces produced for fireplaces today, which provide an aesthetic upgrade in appearance of the area surrounding the fireplace. While the decorative mantle pieces are very useful in updating the outer appearance of a fireplace, they do not address the remaining common problems associated with fireplaces. In other words, after many years of use, a fireplace can become damaged and soiled by fires and charred remains of the fireplace's use. While there are cleaning products on the consumer market that are specially designed for cleaning the interior potions of fireplaces, these products do not perform particularly well with older fireplaces or fireplaces that have been extensively used.
[0005] With constant changes in fireplace trends, conventional approaches do not allow the user to achieve a more modern look to their fireplace, other than changing the mantle piece, without performing extensive reconstruction of the fireplace, such as adding marble pieces to the surrounding portions. Accordingly, there is a need for a system and apparatus that allows a homeowner to change the look and appearance of the fireplace without having to do this extensive reconstruction. More specifically, there is a need for a method that allows the homeowner to complement the existing decor within the home while making the interior portions of a fireplace more attractive.
[0006] Additionally, there is a need for such systems to be configurable to fit within various sized and shaped fireplaces.
SUMMARY OF INVENTION
[0007] The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed innovation. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.
[0008] An object of the present invention is to provide a decorative fireplace system that is configurable to present a new and improved look to the interior and exterior portions of the fireplace while hiding the wear and tear from years of use.
[0009] Another object of this invention is to provide a decorative insert for use during the seasons where the fireplace will not be in use, such as summer. This invention is suitable for displaying interchangeable decorative panels to change the visual appearance of the interior and exterior portions of the fireplace. Each decorative panel is positioned so that all viewable regions of the decorative panel cover any imperfections seen from the exterior of the fireplace. The decorative panels comprise a plurality of separate but visually related regions, organized in predefined logical relationships to each other. Thus, when a homeowner desires to change the visual appearance of the fireplace, each decorative panel is removable so that the appearance of the fireplace can be changed and updated to their liking.
[0010] The decorative panels of this invention are made from materials capable of withstanding heat produced by the fireplace without altering the physical characteristics of the panel, due to melting or warping.
[0011] A homeowner can change the visual appearance of the fireplace by removing any of the decorative panels and replacing them with new and/or different panels. Changes in the visual appearance of the decorative panel can be made by resizing the decorative panel, adding a region to the decorative panel, deleting a region from the decorative panel, relocating a region within the decorative panel, resizing a region of the decorative panel, revising a visual characteristic of a region of the decorative panel, and other visually intuitive changes. Also, the decorative panels can be preprinted with visual items, such as logos, pictures, or any other aesthetic appearance characteristics that the homeowner sees fit.
[0012] A further object of the present invention is to provide a wireframe portion that is resizable and reconfigurable to accommodate the appropriate inner dimensions and shape of the fireplace.
[0013] A still further object of the present invention is to provide a means by which the homeowner can attach like decorative panels to the wireframe to change the outer appearance of the fireplace to match the decorative panels placed in the interior portion of the fireplace. Collectively, the means contemplated by the present invention are embodied in certain novel attachment and resizable configurations, which separately and collectively constitute the devices and utilities to accomplish the aforementioned objects of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Various exemplary embodiments of this invention will be described in detail, wherein like reference numerals refer to identical or similar components, with reference to the following figures, wherein:
[0015] FIG. 1 is an exemplary illustration of the fully assembled decorative fireplace system according to this invention.
[0016] FIG. 2 is an exemplary illustration of a novel configuration of the decorative panels being attached to the wireframe structure of this invention.
[0017] FIG. 3 is an exemplary illustration of a second novel wireframe portion of the present invention that is resizable to accommodate various sized decorative panels.
[0018] FIG. 4 is an exemplary illustration of a series of decorative panels attachable to the front portion of the wireframe to change the visual appearance of the exterior portion of a fireplace.
[0019] FIGS. 5A and 5B are exemplary cross sectional views of the shape of the leg portions of the wireframe that is resizable to accommodate the inner dimensions of a fireplace.
[0020] FIG. 6A is a pan view of a second embodiment of the wireframe, according to this invention.
[0021] FIG. 6B is a cross-sectional view of the second embodiment of the wireframe, according to this invention.
[0022] FIG. 7 is an exemplary illustration of a third embodiment of the wireframe, according to this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] The claimed subject matter is now described with reference to the drawings. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the claimed subject matter. It may be evident, however, that the claimed subject matter may be practiced with or without any combination of these specific details.
[0024] FIG. 1 shows the fully assembled decorative fireplace system decorative fireplace system 10 , according to this invention. The decorative fireplace system 10 comprises: decorative inner panels 14 , a cutout 16 and decorative outer panels 12 . Not shown, due to the assembled configuration shown in this figure, is a wireframe in which the decorative outer panels 12 and decorative inner panels 14 are attached. The decorative fireplace system 10 is insertable into an already existing fireplace so that it substantially fits within the inner dimensions of the existing fireplace. In accordance with this invention, the already existing fireplace may be any shape or size as the decorative fireplace system 10 is configurable to accommodate those dimensions.
[0025] The decorative inner panels 14 are configured so that they can be securely attached to the wireframe. Each decorative inner panel 14 can be resized or reshaped to fit the shape and size of the already existing fire place and attached to the wireframe, as described in further detail with respect to FIG. 2 below. The cutout 16 is provided such that where there is built in hardware, such as gas fixtures and/or logs, or the like in the already existing fire place, the decorative inner panels 14 can be cut to accommodate use of those items. It should be appreciated that the cutout 16 can be any size or shape or in any position needed to accomplish the use of the already existing hardware. It should also be appreciated that any of the decorative inner panels 14 can be provided with cutout 16 to accommodate for other hardware items in the already existing fireplace.
[0026] The decorative inner panels 14 and the decorative outer panels 12 are preferably made of any material that is capable of withstanding heat from the use of the fire place unit, such as, but not limited to, ceramic, stone, glass, steel, sheet metal, aluminum, magnesium, titanium, heat resistant plastics, etc. However the decorative inner panels 14 can be made of other traditional materials, such as polyethylene, plastic wood, etc. for use where the fireplace will not be used with a fire or during an off-season, such as the summer months.
[0027] As shown in FIG. 2 , the decorative inner panels 14 and decorative outer panels 12 are attachable to the wireframe 18 . The wireframe 18 can be made of any material capable of supporting the decorative inner panels 14 and decorative outer panels 12 that is capable of receiving an attachment means, such as screws, latches, metal snaps, hooks or tacks. In other words, the wireframe 18 can be made of steel, wood, aluminum, strengthened plastics, polymers, etc. It should be appreciated that the decorative outer panels 12 and decorative inner panels 14 are thick and dense enough to accept conventional methods for attachment purposes, such as screws and other fastening methods. The wireframe 18 is made in such a way to accommodate at least one decorative inner panel 14 so as the decorative inner panel decorative inner panels 14 is viewable from the outside of the existing fireplace. The decorative inner panels 14 may be attached using any conventional fastening method 11 now known or later developed, such as, but not limited to screws, latches, metal snaps, hooks, suction cups or tacks. While the panels shown in FIG. 2 are shown as attachable to the outer edge of the wireframe 18 , it is conceivable that the decorative inner panels 14 can be attached to the inner surfaces of the wireframe 18 without departing from the scope of this invention. As mentioned above with respect to FIG. 1 , the cutout 16 can be placed on the decorative inner panels 14 in any position so as to accommodate for hardware that may be present in the existing fireplace.
[0028] Referring now to FIG. 3 , the wireframe 18 is configured such that each leg portion 13 is adjustable to accommodate any size decorative inner panel 14 . This configuration allows the wireframe 18 to be adjustable on the X, Y and Z axis to accommodate for varying sized fireplaces which the decorative fireplace system according to this invention will be used.
[0029] Referring now for FIG. 4 , the decorative outer panels 12 are attachable to the wireframe 18 in the same manner as the decorative inner panels 14 , as previously shown with respect to FIG. 2 . The decorative outer panels 12 are configurable such that a homeowner can coordinate the outside face of the existing fireplace with the inner surface as defined by the decorative inner panels 14 .
[0030] FIGS. 5A and 5B illustrate a pan view of exemplary embodiments of the leg portions of wireframe 18 . It may be appreciated that the wireframe 18 can be any cross sectional shape that can accommodate the attachment of the decorative inner and outer panels as discussed above. For example the rounded shape, as shown in FIG. 5A is best suitable for use of a strap to attach the decorative panels to the wireframe 18 . However, the squared shape as shown in FIG. 5B may be best suitable for attaching the decorative panels using screw-type attachments. As discussed with respect to FIG. 3 above, FIGS. 5A and 5B also provide a close up view of the slidable leg portions of wireframe 18 .
[0031] FIGS. 6A and 6B depict a second embodiment of the wireframe according to this invention. FIG. 6A shows the c-shaped wireframe 28 in a pan view, wherein it has a substantially c-shaped configuration such that each decorative inner panels 14 can be slidably attached to the c-shaped wireframe 28 . For example, each decorative inner panel 14 is slidable into a c-shaped channel that runs the length of each leg portion of the c-shaped wireframe 28 . FIG. 6B shows the c-shaped wireframe 28 in a cross-sectional view wherein the decorative inner panels 14 substantially fit inside the c-shaped wireframe 28 .
[0032] FIG. 7 illustrates a third embodiment of the wireframe according to this invention. Here, wireframe 38 is shown with detachable leg portions 15 that are connected using elbows 20 . Each detachable leg portion 15 is inserted into the each elbow 20 , such that the wireframe 38 can be easily disassembled for transport, packaging or storage. It should be appreciated that each detachable leg portion 15 can be adjustable as described with respect to FIGS. 5A and 5B above.
[0033] The elbow 20 is configured to provide the maximum range of three dimensional motion for each detachable leg portion 15 . The elbow 20 may be made from a variety of different pivoting joints, such as universal joints, a joint having tacks in which the detachable leg portions 15 can translate or it may be made from rigid materials that do not specifically allow for a range of motion at the connection point. This configuration allows the wireframe 38 to have versatility in motion and configuration, such that the decorative fireplace system, according to this invention may fit within an infinite variety of fireplace sizes and shapes.
[0034] The illustrations and examples provided herein are for explanatory purposes and are not intended to limit the scope of the appended claims. It will be recognized by those skilled in the art that changes or modifications may be made to the above described embodiment without departing from the broad inventive concepts of the invention. It is understood therefore that the invention is not limited to the particular embodiment which is described, but is intended to cover all modifications and changes within the scope and spirit of the invention.
[0035] What has been described above includes examples of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art can recognize that many further combinations and permutations of such matter are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.
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A decorative fireplace system configurable for display interchangeable decorative panels to enhance the visual appearance of the interior and exterior portions of an already existing fireplace. Each decorative panel is positioned so that all viewable regions of the decorative panel cover any imperfections seen from the exterior of the fireplace.
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This application is a continuation, of application Ser. No. 07/315,130, filed Feb. 23, 1989, now abandoned; which is a continuation of application Ser. No. 06/876,689, filed Jun. 20, 1989, now U.S. Pat. No. 4,826,811.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an acellular red blood cell substitute comprising an essentially tetramer-free, cross-linked, polymerized, pyridoxylated hemoglobin solution which is free of stromal contaminants. It further relates to a method of preparing the acellular red blood cell substitute.
2. Description of Related Art
For several years, stroma-free hemoglobin has been known in the art to have oxygen transport and reversible oxygen (or ligand) binding capacities. Since toxicity problems have precluded use as a blood substitute, stroma-free hemoglobin has required further modifications to provide a nontoxic, useful pharmaceutical product. In U.S. Pat. Nos. 4,001,200; 4,001,401 and 4,053,590, a polymerized, cross-linked, stroma-free hemoglobin is disclosed as a blood substitute for carrying oxygen to tissues and organs and as a blood plasma expander. Pyridoxylating the stroma-free hemoglobin has been shown to favorably alter reversible oxygen binding capacities and increase the stability and shelf-life of the biological product. J. Surgical Research 30:14-20 (1981). Pyridoxylated hemoglobin polymerized with glutaraldehyde has been described and characterized in L. R. Sehgal, et al., In Vitro and In Vivo Characteristics of Polymerized, Pyridoxylated Hemoglobin Solution, Fed. Proc. 39:2383 (1980); L. R. Sehgal, et al., Preparation and In Vitro Characteristics of Polymerized, Pyridoxylated Hemoglobin, Transfusion 23(2):158 (March-April 1983). Further, the ability of the polymerized, pyridoxylated hemoglobin to act as an oxygen carrier has been disclosed in L. R. Sehgal, et al., Polymerized, Pyridoxylated Hemoglobin: A Red Cell Substitute with Normal Oxygen Capacity, Surgery 95(4):433-38 (April 1984); L. R. Sehgal, et al., An Appraisal of Polymerized, Pyridoxylated Hemoglobin as an Acellular Oxygen Carrier, Advances in Blood Substitute Research 19-28 (Alan R. Liss, Inc. 1983).
For years investigators have reported that hemoglobin solutions prepared by various techniques, while capable of carrying sufficient quantities of oxygen to support life, have undesirable side effects. The most troubling side effect is a decrease in kidney performance. These changes were thought to be due to the presence of unwanted contaminants such as bacterial endotoxin or fragments of red cell membranes (stroma). While contaminants such as these can indeed produce renal alterations, hemoglobin solutions essentially free of the above contaminants still produce substantial renal dysfunction. Although this dysfunction is temporary and reversible, it can be very alarming in a clinical situation such as hemorrhagic shock, as the kidney is already at risk in this low blood flow state. The cause for the renal dysfunction has been ascribed to physiologically unacceptable amounts of unpolymerized hemoglobin tetramer. Other undesirable side effects of the infusion of tetrameric hemoglobin are renal toxicity, vasoconstriction, hemoglobinurea, depression of heart rate, elevation of mean arterial blood pressure and extravasation of infusate especially into the peritoneal cavity.
In practice, no known hemoglobin-derived blood substitute has been successful in totally avoiding toxicity problems. These products prepared according to the state of the art have been found to contain varying amounts of hemoglobin tetramer. For example, the process of preparation according to U.S. Pat. Nos. 4,001,200; 4,001,401 and 4,053,590 does not provide a therapeutically useful product. First, like other processes, there is an undesirable, high amount of unpolymerized hemoglobin tetramer in the final product. Secondly, too many contaminants such as toxic residual toluene may remain in the solution since they may not be completely removed during preparation. Thirdly, the product, described as having a P 50 of 100-120 mm Hg, would be nonfunctional physiologically in that the hemoglobin solution would not pick up oxygen in the lungs. Lastly, increased proportions of higher molecular weight polymers yield a product of high gelation lability such that subsequent steps of filtration and purification are difficult or impossible to accomplish except in unacceptably dilute solutions.
SUMMARY OF THE INVENTION
It is an important object of the present invention to provide a nontoxic hemoglobin solution therapeutically useful as an acellular red blood cell substitute.
Another object is to provide a nontoxic hemoglobin solution with reversible oxygen binding capacities that will not require compatibility studies with a recipient.
A further object is to provide a pure, polymeric hemoglobin solution essentially devoid of unmodified hemoglobin tetramer with normal oxygen carrying capacity.
A still further object is to provide a temporary oxygen carrier which can be rendered substantially free of microbial and viral antigens and pathogens.
With the foregoing and other objects in view, the invention herein provides an essentially tetramer-free, cross-linked, polymerized, pyridoxylated hemoglobin which is substantially free of stroma and other contaminants.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the accompanying drawings, there are provided fourteen figures, to be hereinafter described in detail, illustrating this invention and its departure from the art wherein:
FIG. 1 is a schematic diagram of the batch method of pyridoxylation;
FIG. 2 is a schematic diagram of the membrane facilitated pyridoxylation and polymerization according to this invention;
FIGS. 3A, 3B and 3C are graphs showing a densitometric scan of essentially tetramer-free, cross-linked, polymerized, pyridoxylated hemoglobin separated by SDS-polyacrylamide gel electrophoresis;
FIG. 4 shows an elution pattern of cross-linked, polymerized, pyridoxylated hemoglobin obtained from a gel filtration column;
FIG. 5 shows an elution pattern of essentially tetramer-free, cross-linked, polymerized, pyridoxylated hemoglobin obtained from a gel filtration column;
FIG. 6A is a graph showing the spectral curve for oxyhemoglobin;
FIG. 6B is a graph showing the spectral curve obtained with oxygenated essentially tetramer-free, cross-linked, polymerized, pyridoxylated hemoglobin;
FIG. 7 is a graph describing the relationship between the hemoglobin concentration of the essentially tetramer-free, cross-linked, polymerized, pyridoxylated hemoglobin and the colloid osmotic pressure (COP);
FIG. 8 is a graph describing the oxy-hemoglobin dissociation curve for an essentially tetramer-free, cross-linked, polymerized, pyridoxylated hemoglobin;
FIG. 9 is a graph describing the elution pattern of essentially tetramer-free, cross-linked, polymerized, pyridoxylated hemoglobin from a High Pressure Liquid Chromatography column;
FIG. 10 is a graph describing the relationship between the hemoglobin concentration of the essentially tetramer-free, cross-linked, polymerized, pyridoxylated hemoglobin and the viscosity of the solution; and
FIG. 11 is a graph describing the plasma disappearance curve for stroma-free hemoglobin (SFH) and essentially tetramer-free, cross-linked, polymerized, pyridoxylated hemoglobin.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention concerns an acellular red blood cell substitute comprising an essentially tetramer-free, cross-linked, polymerized, pyridoxylated hemoglobin which is substantially free of stroma and other contaminants.
For purposes of this invention, the term cross-linked means the chemical emplacement of molecular "bridges" onto or into a molecule, or between molecules with the purpose of altering the shape, size, function or physical characteristics of the molecule. The term essentially tetramer-free denotes the level of purity with respect to tetramer contamination at which certain biological responses to tetramer administered into a mammal are no longer present. A main criterion is the absence of alterations in renal function when pharmaceutically effective amounts are infused, that is, at a level of purity of about 98% or better (less than about 2% of tetramer is present). The "ultrapurified" or "purified" product have the same meaning as being essentially tetramer-free. The term polymerizing solution defines a solution containing a "cross-linking" or polymerizing agent, such as glutaraldehyde, imido esters, diaspirin or others, in a biochemically suitable carrier. The term semipermeable membrane connotes a membrane permeable to some molecular species and not to others and, in particular, a membrane which acts as a selective filter excluding molecular weights of about 30,000 daltons and above.
The product of the process according to the present invention, a polymerized, pyridoxylated hemoglobin solution essentially free of tetrameric (native) hemoglobin and various other contaminants, is physiologically acceptable as well as therapeutically and clinically useful. The product has reversible oxygen binding capacities which is necessary for oxygen transport properties. Most notably, the product demonstrates good loading and unloading characteristics in usage which correlates to having an oxygen-hemoglobin dissociation curve (P 50 ) similar to whole blood. The product shows a high affinity for binding oxygen in the capillaries through the lungs and then adequately releases oxyten to the tissues in the body. The product also does not require compatibility studies with the recipient.
The process of this invention is unique in that it yields a product free of tetramer contamination at a level heretofore unknown in the fractionation and purification of polymeric hemoglobins. The process of this invention provides a further advantage in that it can render the final product substantially free of microbial and viral antigens and pathogens. Such antigens and pathogens include, for example, bacterial, rickettsial, fungal, protozoan, viral and other organisms. Most importantly, the biological product can be rendered substantially free of viruses that cause hepatitis and acquired immune deficiency syndrome (AIDS). A product pure of tetrameric hemoglobin and various other contaminants would have the widest clinical utility, ease of use and safety.
Insofar as the physiological properties are concerned, the biological product of this invention does not cause vasoconstriction, renal toxicity, hemoglobinurea and other problems implicated with intravenous administration of known hemoglobin solutions containing undesirable amounts of tetrameric hemoglobin. Upon intravenous administration of the product described herein, the results have demonstrated no appreciable decrease in urine production, no appreciable decrease in glomerular filtration rate, no appreciable extravasation into the peritoneal cavity and no appreciable change in the color of urine produced.
Therefore, the acellular red blood cell substitute of this invention finds usefulness in the treatment of trauma, myocardial infarction, stroke, acute anemia and oxygen deficiency disorders such as hypoxemia, hypoxia or end stage hypoxia due to impairment or failure of the lung to fully oxygenate blood. The product also finds usefulness in the treatment of any disease or medical condition requiring a resuscitative fluid (e.g., trauma, specifically hemorrhagic shock), intravascular volume expander or exchange transfusion. In addition to medical treatment, the product can be useful in preserving organs for transplants.
The present invention further encompasses methods for using this biological product for medical treatment by administering intravenously to a mammal needing such treatment a pharmaceutically effective amount of the essentially tetramer-free, substantially stroma-free, crosslinked, polymerized, pyridoxylated hemoglobin in conjunction with a nontoxic, pharmaceutically acceptable carrier. An exchange transfusion typically entails replacing the patient's blood with the acellular red blood cell substitute of this invention using conventional techniques in treatment of certain conditions or disorders such as, for example, blood poisoning, autoimmune diseases, etc. The pharmaceutically effective amount varies in relation to the therapy desired for the particular disease or medical condition being treated and typical dosage parameters, such as, for example, the body weight of the patient. Generally, the pharmaceutically effective amount is, of course, the dosage range deemed by physicians and other medical staff to be clinically useful in practice. It would be apparent to one skilled in the medical field how to select a dosage amount in any given situation. The pharmaceutically acceptable carrier is preferably nontoxic, inert and compatible with hemoglobin. Examples of such carriers include, but are not limited to, water, balanced saline solution, physiologic saline solution (e.g., Lactated Ringer's solution, Hartman' s solution, etc.), dextrose solution and the like.
The preferred starting material in the process of the present invention is outdated human blood. Preferably, the blood is not used in this process if it has been in storage for more than eight weeks past the expiration date stamped on the bag. All processes described herein are applicable to other mammalian blood with possible minor modifications within the skill of the art.
The entire process may be carried out at about 2° C. to about 8° C., preferably about 5° C. The outdated blood is washed with about two to about five volumes of an isotonic salt solution such as 0.9% sodium chloride. The wash solution optionally may contain antibiotics, for example, penicillin, streptomycin, gentamycin, polymyxin B sulfate and the like. The addition of antibiotics is not essential to the process but may minimize bacterial contamination if the process is being carried out in a nonpharmaceutical environment.
The red blood cells are washed, packed, pooled and lysed with either an alkali metal phosphate buffer (e.g., sodium phosphate) or pyrogen free water. The next step is to separate the red blood cell stroma from the solution. The removal of the red cell stroma may be accomplished by microporous filtration. A preferred method is the use of cross-flow filtration with hollow fiber cartridges. Examples of cross-flow filtration systems are the Pellicon System (Millipore Corp., Bedford, MA); the HF-Lab 15 ultrafiltration System (Romicon Corp., Woburn, MA); the KF200-100 KROSFLOW (Microgon, Lagona Hills, CA) or the DC-30 System (Amicon, Danvers, Mass). Systems are available for smaller or larger batch sizes than that being described in the example below.
In the next step, the stroma-free hemoglobin solution is pyridoxylated using pyridoxal, 5' phosphate on about a 2:1 to 4:1 molar ratio to hemoglobin. Pyridoxylation desirably takes place in the presence of an acid buffer such as tris-hydrochloride buffer in approximately 0.1M final concentration and about 1 gm/L of glutathione. The solution is completely deoxygenated employing a gas exchanger with helium, nitrogen or other inert gas, desirably with nitrogen gas tanks or liquid nitrogen tanks. Any tubing being used to pump the solution should preferably be impermeable or minimally permeable to oxygen, such as Tygon B-44 tubing (Cole-Palmer Co., Chicago, IL). A reducing agent such as sodium cyanoborohydride or preferably sodium borohydride is added to the deoxygenated solution. Excess reagents may be removed by dialysis against pyrogen free water using a kidney dialysis filter such as C-DAK 1.3 (Cordis Dow Corp., Miami, FL) or TH-15 (Terumo Corp., Tokyo, Japan). Alternatively, ultrafiltration cartridges with a molecular weight cut-off of no greater than 30,000 daltons can be used (cartridges are commercially available from Amicon Corp., Romicon, Millipore).
Subsequently, the stroma-free, pyridoxylated hemoglobin solution is polymerized using 25% glutaraldehyde (E. M. Grade, Polysciences, Warington, PA). The stroma-free, pyridoxylated hemoglobin solution is exposed to the glutaraldehyde across a kidney dialysis filter or other suitable membrane filter. The duration of polymerization and the amount of glutaraldehyde added is dependent on volume of the hemoglobin solution, the desired yield of polymers and the desired molecular weight distribution. In general, the longer the polymerization time, the higher the molecular weight distribution of polymers, the greater their yield and lower the COP of the final solution. Typically, approximately a 70% yield of polymers is obtained in 3.5-4 hours. This is the preferred end point of the polymerization. An 80-90% yield can be obtained in 7 hours but will result in a significantly higher molecular weight distribution of the polymers (FIG. 3C).
The polymerizing process when carried out according to the present invention results in a high yield of polymers. To produce a product with reliable clinical utility, it is very important to control the speed of reaction and surface of interaction during polymerization so as to produce a product of a narrow molecular weight range, the average of which is about 120,000 daltons. The polymerization reaction may be monitored by the decrease in colloid osmotic pressure using an oncometer, such as IL 186 (Instrumentation Laboratories, Danvers, MA) or Wescor Colloid Osmometer (Wescor, Logan, Utah), by High Pressure Liquid Chromatography (HPLC) or by any appropriate technique known in the art. Trace amounts of high molecular weight molecules may be present as determined by sodium dodecyl sulfate polyacrylamide gel electrophoresis (SDS-PAGE).
At the semi-permeable membrane interface in the pyridoxylating and polymerizing steps of the process of this invention, the biochemical carrier (i.e., water, salts, sugars, other small molecules or ions) is very free to move back and forth across the membrane in response to hydrostatic, hydrodynamic, osmotic or oncotic forces. The molecules or ions of the active agent (i.e., polymerizing agents, reducing agents, pyridoxylating agents, etc.) are somewhat less free to move across the membrane owning to their greater size and weight. The hemoglobin molecules cannot cross the intact membrane at all. This set-up results in a controlled exposure of hemoglobin molecules or other starting materials to the active agent. The variables that can be altered are flow rate of the hemoglobin solution, concentration of hemoglobin in solution, concentration of the active agent and flow rate of the active agent. In addition to the above variables, variables such as time, temperature and surface area can be altered to modify this set-up for a wide range of reactants, reactions and efficiencies. The entire reaction can take place in a physiologically acceptable medium. Further, the hemoglobin solution can move through the reaction without experiencing any significant changes in dilution or ionic environment.
Schematically, FIG. 1 shows the batch method of pyridoxylation. A solution of stroma-free hemoglobin and reagents containing pyridoxal, 5', phosphate 6 is added to the mixing vessel or container 5. The pH is adjusted and monitored by a pH electrode 7. The container 5 has a vent or bleed valve 11. A means for stirring such as a toroidal mixer comprising an electric motor 9, universal joint couplers 9a for coupling the motor shaft to the mixing shafts and stirrer 10 provides continual mixing. The solution 6 is pumped out of the container 5 by means for pumping 4 through a membrane gas exchanger 1 and is then returned to container 5. A nitrogen source 8 supplies a constant flow of nitrogen through the membrane gas exchanger 1 to deoxygenate the solution 6. The membrane gas exchanger 1 contains vent 3 for release of gases. A solution containing a reducing agent is added through syringe port 2. Circulation of the solution of deoxygenated hemoglobin continues around this set-up through constant pumping action provided by pumping means 4 until the desired yield of pyridoxylated hemoglobin is obtained.
FIG. 2 illustrates a schematic diagram of pyridoxylation and polymerization respectively using the membrane technique in accordance with this invention. For pyridoxylation, a solution of stroma-free hemoglobin and reagents containing pyridoxal, 5', phosphate 19 is added to the mixing vessel or second reservoir 18. The second reservoir 18 has a vent or bleed valve 17. A means for stirring such as a toroidal mixer comprising an electric motor 16, universal joint couplers 16a and stirrer 20 provides continual mixing. Initially, the solution 19 is continuously pumped through two deoxygenating pathways while ports 31 and 32 are clamped shut. Simultaneously, the solution 19 is pumped out of the second reservoir 18 by means for pumping 15 through a membrane gas exchanger 13 and by means for pumping 21 through a membrane gas exchanger 23 and a renal dialysis membrane filter 27 and then is returned to the second reservoir 18. Nitrogen sources 12 and 24 supply a constant flow of nitrogen through membrane gas exchangers 13 and 23, respectively, to deoxygenate solution 19. The membrane gas exchangers 13 and 23 contain vents 14 and 22 for release of gases. The pH is monitored by pH electrode 25 through an electrical lead 26 attached to a pH meter. After deoxygenation, ports 31 and 32 are opened. A solution containing a reducing agent 30 is pumped by means for pumping 28 from container or first reservoir 29 through the renal dialysis membrane filter 27 and is returned to the first reservoir 29.
After pyridoxylation is completed, the solution containing the reducing agent 30 is replaced by pyrogen-free water. The pyrogen-free water is then pumped by means for pumping 28 through the renal dialysis membrane filter 27 to dialyze excess reagents and is returned to the first reservoir 29. Ports 31 and 32 are closed by clamps and solution 19 is circulated continuously while being deoxygenated.
For polymerization, ports 31 and 32 are opened. The solution of stroma-free, pyridoxylated hemoglobin 19 is constantly circulated through the set-up. The pyrogen-free water in the first reservoir 29 is replaced by a polymerizing solution containing a polymerizing agent 30. The polymerizing solution is then pumped by means for pumping 28 through the renal dialysis membrane filter 27 and is returned to the first reservoir 29. As depleted, the polymerizing agent is added step-wise to the first reservoir.
Basically, the solution containing a reducing agent for pyridoxylation or the polymerizing solution containing a polymerizing agent is pumped from a first reservoir 29 to one side of a semi-permeable membrane in the renal dialysis membrane filter 27 while the deoxygenated hemoglobin solution or pyridoxylated, deoxygenated hemoglobin solution, respectively, is pumped from a second reservoir 18 to the opposite side of the membrane. A portion of the solution containing a reducing agent or polymerizing agent diffuses across the membrane to pyridoxylate or polymerize the hemoglobin on the other side of the membrane. The portion of the solution containing a reducing agent or polymerizing agent which does not diffuse is returned to the first reservoir 29. Likewise, the deoxygenated hemoglobin solution containing either the pyridoxylated or polymerized hemoglobin is returned to the second reservoir 18. This operation works continuously until the desired yield of product has been obtained.
At the termination of the polymerization, the unpolymerized tetrameric hemoglobin concentration in the solution can be decreased significantly by any appropriate filtering and purifying techniques known in the art. Removal of essentially all of the remaining unmodified tetramer may be accomplished by pumping the polymerized solution through hollow fiber ultrafiltration cartridges and then purifying by gel chromatography or, alternatively, by gel chromatography alone.
The remaining traces of unmodified tetrameric hemoglobin can be complexed in accordance with this invention by adding haptoglobin alone, treating with haptoglobin after using hollow fiber ultrafiltration cartridges and/or gel chromatography or removing by affinity chromatography using gel bound haptoglobin. Haptoglobin will bind irreversibly with tetrameric hemoglobin even in the presence of polymerized hemoglobin. Haptoglobin will bind hemoglobin on a 1:1 molar ratio. One would require 1.3-1.5 gm of haptoglobin to bind 1 gm of hemoglobin if the complexing is being conducted in a free solution. Alternatively, haptoglobin can be bound to an activated agarose gel.
The pH of the final solution is adjusted to approximately 9 and balanced with electrolyte concentrations representing that of normal plasma. For clinical use, electrolytes which may be added include, but are not limited to, sodium, potassium, chloride, calcium, magnesium and the like. Conventional anti-oxidants such as glutathione, ascorbate or glucose may also be optionally added. The final solution may be sterilized using any well-known technique appropriate for application to biological products.
The critical properties of the solution of this invention in approximate amounts or ranges are shown along with that of whole blood for purposes of comparison:
______________________________________ Polymerized Hb Whole Blood______________________________________Hb 7-18 gm/dl 12-15 gm/dlO.sub.2 Carrying 9.7-25.0 vol % 16.6-20.9 vol %CapacityBinding Coefficient 1.30 cc/gm Hb 1.32 cc/gm Hb(at 37° C.)P.sub.50 (at pCO.sub.2 14-22 torr 26 torr40 torr, pH 7.4,37° C.)Methemoglobin less than 15% less than 2%Colloid Osmotic 7-30 torr 20-25 torrPressureOsmolarity 290-310 mOsM 290-310 mOsMTotal Phospholipid less than 0.004 mg/mlContentViscosity (at 25° C.) 3.2 cp (8 gm/dl) 3.5 (Hct = 45%)______________________________________
The following examples demonstrate certain aspects of the present invention. However, it is to be understood that these examples are for illustrative purposes only and do not purport to be wholly definitive as to conditions and scope of this invention. All temperatures are expressed in degrees Celsius unless otherwise specified. It also should be appreciated that when typical reaction conditions (e.g., temperature, reaction times) have been given, the conditions which are both above and below these specified ranges can also be used, though generally less conveniently.
A further understanding of the invention may be obtained from the following nonlimiting examples. These examples were conducted at about 5° C. and at atmospheric pressure:
EXAMPLE 1
Preparation of Stroma-Free Tetrameric Hemoglobin Solution
Outdated human blood was washed twice with 0.9% sodium chloride solution containing the following antibiotics per liter of solution:
______________________________________Penicillin 50,000 UStreptomycin 50 mgGentamycin 40 mgPolymixin B Sulfate 2.5 mg______________________________________
The red blood cells (RBC) were washed twice with equal volumes of the above solution and centrifuged at 2,500 g for 15 minutes. Better than 95% of the buffy coat layer was removed with a plasma extractor (Fenwal Laboratories, Morton Grove, IL). The washed and packed RBCs were then pooled and lysed with 3 to 4 volumes of pyrogen free water. One hundred units of washed RBCs resulted in a 15-20 L volume at a hematocrit of 20-24%.
Fifteen to twenty liters of washed RBCs were poured into 40-80 liters of cold pyrogen free water. The lysate thus made, was then pumped through 2 to 4 0.1μ hollow fiber cartridges. An air driven pump was used (LP30, Amicon Corp., Danvers, MA). The 0.1μ cut-off cartridges were commercially available from Romicon Inc., subsidiary of Rohm and Haas Co., Woburn, MA 01801. The hemoglobin, essentially free of RBC stroma, along with the other enzymic contents of the RBC came through the filter as an ultrafiltrate. Aliquots of the filtrate were centrifuged several times during this process. Absence of a pellet reflected good membrane integrity. A 97% recovery of essentially stroma-free hemoglobin was obtained.
During this first separation step, the lysate volume was reduced down to 12-15 liters, and maintained at that volume by addition of pyrogen free water until the necessary recovery of hemoglobin had been effected. Simultaneously with the step, the ultrafiltrate containing the hemoglobin was concentrated, with the aid of 3 to 4 30 k cut-off hollow fiber cartridge filters (H10 P30, Amicon Corp., Danvers, MA) and an LP 30 air pump. The ultrafiltrate was concentrated to a final hemoglobin concentration of about 20-22 gm/dl.
EXAMPLE 2
Preparation of Stroma-Free Tetrameric Hemoglobin Solution An Alternative Method
Individual units of outdated blood were filled with 0.9% sodium chloride solution. The red cells and buffy coat were allowed to settle overnight. The supernatant and buffy coat were then extracted.
The packed cells were then poured into 3-5 volumes of 0.9% sodium chloride solution. The cells were washed and concentrated by use of a 0.2μ hollow fiber cross-flow filter (K205-KROSFLOW, Microgon Corp., Laguna Beach, CA) and an air driven pump (LP30, Amicon Corp., Danvers, MA). The packed cells were then lysed by the addition of 3-5 volumes of pyrogen free water. The cross-flow filtration was then resumed, with the tetrameric hemoglobin along with the enzymic contents of the red cells being collected in the ultrafiltrate, while the stroma was retained by the filter.
Aliquots of the filtrate were centrifuged several times during this process. Absence of a pellet reflected good membrane integrity. A 97% recovery of essentially stroma-free hemoglobin was obtained. Simultaneously with the step, the ultrafiltrate containing the hemoglobin was concentrated, with the aid of 3 to 4 30 k cut-off hollow fiber cartridge filters (H10 P30, Amicon Corp., Danvers, MA) and an LP 30 air pump. The ultrafiltrate was concentrated to a final hemoglobin concentration of about 20-22 gm/dl.
EXAMPLE 3
Pyridoxylation of the Stroma-Free Hemoglobin-Mixed Batch Geometry
A stroma-free hemoglobin solution was prepared according to the process of Example 1 or 2. The following reagents were mixed together:
1. Pyridoxal, 5',phosphate-on a 4:1 molar ratio to hemoglobin;
2. Tris-HCl buffer-0.1M final concentration in the hemoglobin solution;
3. Glutathione-1 gm/L of solution;
4. Ascorbic Acid-0.2 gm/L;
5. Glucose 0.5 gm/L; and
6. Antibiotics-the same antibiotics as described in Example 1.
The above reagents were dissolved in minimal volume of pyrogen free water and the pH adjusted to 7.25-7.45. The above mixture was added to the hemoglobin solution. The pH of the hemoglobin solution was adjusted to 7.35-7.45 at 5° C. with 0.1N NaOH. Finally, the hemoglobin concentration was adjusted to 17.5-18.5 gm/dl.
The solution (18-20 L) was then transferred to a gas tight stainless steel reservoir. Deoxygenation of the solution was accomplished by use of a membrane gas exchanger (William Harvey, Bently Laboratories, Shiley Sales Corp., Irvine, CA). Nitrogen gas was bubbled through the exchanger at a flow rate of about 170 L/min. The hemoglobin solution was pumped through the gas exchanger at a flow rate of 4-6 L/min. Adequate removal of oxygen was defined as an O 2 saturation, of less than 5% and an oxygen content of less than 1 vol % (by the IL 282, Co-oximeter, Instrumentation Laboratories, Lexington, MA). This was accomplished in 4-8 hours (see FIG. 1).
To the deoxygenated hemoglobin solution, 0.02M sodium borohydride (final concentration) per liter of solution was added. The sodium borohydride was dissolved in no less than 300-500 ml of 0.001N NaOH. It was pumped into the hemoglobin solution, through a syringe port of the gas exchanger, at a rate of about 100 ml/hr. A bleed valve in the stainless steel reservoir was kept open to avoid pressure build-up. Following the addition of NaBH 4 , the solution was kept deoxygenated. A maximal yield of about 70-80% of pyridoxylated hemoglobin was obtained in 6-10 hours. The yield was determined by measuring the shift in the oxygen-hemoglobin dissociation curve (P 50 ).
The excess reagents were removed by dialysis against pyrogen free water using a kidney dialysis filter (C-DAK 1.3, Cordis Dow Corp., Miami, FL or TH-15, Terumo, Tokyo, Japan). The solution was kept deoxygenated during dialysis by keeping a membrane oxygenator in line. The N 2 flow rate through the oxygenator was about 100 L/min.
EXAMPLE 4
Pyridoxylation of the Stroma-Free Hemoglobin Membrane Facilitated Geometry
A stroma-free hemoglobin solution was prepared according to the process of Example 1 or 2. The following reagents were mixed together:
1. Pyridoxal, 5',phosphate-on a 2:1 molar ratio to hemoglobin;
2. Tris-HCl buffer-0.1M final concentration in the hemoglobin solution;
3. Glutathione-1 gm/L of solution;
4. Ascorbic Acid-0.2 gm/L;
5. Glucose 0.5 gm/L; and
6. Antibiotics-the same antibiotics as described in Example 1.
The above reagents were dissolved in minimal volume of pyrogen free water and the pH adjusted to 7.35-7.45. The above mixture was added to the hemoglobin solution. The pH of the hemoglobin solution was adjusted to 7.35-7.45 at 5° C. with 0.1N NaOH. The hemoglobin concentration was adjusted to 17.5-18.5 gm/dl.
The solution (18-20 L) was then transferred to a gas tight stainless steel reservoir. Deoxygenation of the solution was accomplished by use of one or more membrane gas exchangers (William Harvey, Bently Laboratories, Shiley Sales Corp., Irvine, CA). Nitrogen gas was bubbled through the exchanger at a flow rate of about 170 L/min. The hemoglobin solution was pumped through the gas exchanger at a flow rate of 4-6 L/min. Adequate removal of oxygen was defined as an O 2 saturation, of less than 5% and an oxygen content of less than 1 vol % (by the IL 282, Co-oximeter, Instrumentation Laboratories, Lexington, MA). This was accomplished in 4-8 hours.
In this process, the membrane oxygenator or gas exchanger 23 was in series with a kidney dialysis filter 27 (Terumo, TH-15) (see FIG. 2). The external parts of the dialysis filter were clamped to prevent loss of water during deoxygenation.
When the end point of the deoxygenation was reached, 3 liters of a 5 gm % sodium borohydride solution was pumped on the outside of the dialysis filter. In this fashion, the pyridoxylation was rapidly accomplished. A 75-80% yield of pyridoxylated hemoglobin was obtained in half an hour, and a maximal yield of 85-90% was obtained in 2-3 hours. The yield was determined by measuring the shift in the oxygen-hemoglobin dissociation curve (P 50 ).
The excess reagents were removed by dialysis against pyrogen free water using the in-line kidney dialysis filter (C-DAK 1.3, Cordis Dow Corp., Miami, FL or TH-15, Terumo, Tokyo, Japan). The solution was kept deoxygenated during dialysis. The N 2 rate through the oxygenator was about 100 L/min.
EXAMPLE 5
Polymerization of Stroma-Free Pyridoxylated Hemoglobin
A stroma-free, pyridoxylated hemoglobin solution was prepared according to the process of Example 3 or 4. To the dialyzed solution was added:
1. 0.1M sodium phosphate buffer (final concentration);
2. Antibiotics as listed above in Example 1; and
3. Glutathione-1 gm/L.
The above chemicals were dissolved in 500 ml of pyrogen free water and added to the hemoglobin solution. The pH of the solution, at 5° C. and using 0.5N NaOH, was adjusted to 8.0. The hemoglobin concentration was adjusted to between 14-15 gm/dl by the addition of 0.1M phosphate buffer. The solution was maintained deoxygenated by keeping the membrane oxygenator in line. An N 2 flow rate of about 170 L/min was maintained.
The hemoglobin solution was pumped from the mixing vessel or second reservoir 18 through the membrane oxygenator or gas exchanger 23 into a kidney dialysis filter 27 (see FIG. 2) at an approximate flow rate of 5-7 L/min. Sampling was done through the syringe port on the oxygenator. Polymerization was not initiated if the percent oxyhemoglobin was greater than 10% as determined by co-oximetry. The solution was polymerized across the kidney dialysis membrane. The polymerizing solution was made up in a 10 L volume and contained:
1. 0.1M sodium phosphate buffer (same final concentration as in the hemoglobin solution);
2. Antibiotics-same concentration as in hemoglobin solution;
3. Glutathione-1 gm/L; and
4. 175-225 ml of 25% Glutaraldehyde solution (about 14.8-18.1 moles glutaraldehyde per mole hemoglobin).
The osmolarity of the polymerizing solution was about the same as that of the hemoglobin solution.
The flow of the deoxygenated hemoglobin solution was first established through the dialysis filter while pyrogen free water was circulating on the outside. Once the required flow rate was set, the polymerizing solution was then circulated on the outside. The solution was pumped (Cole-Palmer pumps, 7018 pump heads) at an approximate flow rate of 0.4-0.6 L/min. The hemoglobin solution in the reservoir was thoroughly mixed throughout the process.
The polymerizing agent (25% Glutaraldehyde) was subsequently added to the polymerizing solution according to the following schedules:
______________________________________Time 1 hour 75 mlTime 2 hours 50 mlTime 3 hours 50 mlTime 4 hours 50 mlTime 5 hours 50 mlTime 6 hours 25 mlTime 7 hours 10 ml______________________________________
The polymerization was monitored by the drop in colloid osmotic pressure (COP). The reaction was stopped when the COP approached about 40 torr. This was accomplished by draining the outside of the dialysis filter of the polymerizing solution, and pumping in pyrogen free water. Dialysis against pyrogen free water was carried out for approximately 2 hours. Approximately 80-90% yield of polymers was obtained.
EXAMPLE 6
Ultrapurification of Stroma-Free, Polymerized, Pyridoxylated Hemoglobin
A stroma-free, polymerized, pyridoxylated hemoglobin solution was prepared according to the procedure of Example 5. The removal of the unmodified tetramer was accomplished in three steps:
Step 1: Ultrafiltration
The polymerized solution was pumped through 3 to 4 hollow fiber ultrafiltration cartridges with a molecular weight cut-off of 100,000 daltons (Amicon). This step was stopped when the hemoglobin concentration in the ultrafiltrate was well below 0.1% and stayed at that level for at least two hours. The polymerized hemoglobin solution at this stage was approximately 90% pure.
Step 2: Gel Filtration
The second purification step resulting in an approximately 95-98% pure polymeric solution was accomplished by gel chromatography as follows:
Two 60 cm×25 cm chromatography bioprocess columns (Pharmacia Fine Chemicals, Piscataway, NJ) were filled with approximately 55 L of ACA-54 Ultrogel (LKB Instruments, Gaithersburg, MD). This gel had a molecular weight exclusion limit of 90,000 daltons. The columns were connected in series with minimal dead space between them, resulting in an effective gel length of approximately 105 cm.
One half to one liter of the polymerized hemoglobin solution from step 1 with a hemoglobin concentration of 6-10 gm/dl was loaded onto the column at a flow rate of approximately 3 L/hr. Subsequent to the loading, the buffer (0.1M sodium phosphate pH 7.40 at 5° C.) was used to elute the hemoglobin at a flow rate of 3.0 L/hr (FIG. 4). The first 2.0 L of the polymerized hemoglobin solution that was eluted from the column was retained. The remaining solution was discarded. The 2 L fraction from the column was concentrated using the Amicon CH-2 ultrafiltration system with 1 to 3 H1P100 cartridges (FIG. 5). The ultrapurified solution was concentrated. Step 2 was repeated as necessary to reduce the tetramer contamination of the polymerized solution.
Step 3: Affinity Chromatography
Haptoglobin (Hp) was bound to an activated agarose gel as follows:
Haptoglobin (greater than 80% pure) was added to CnBr activated Sepharose 4B (Pharmacia Fine Chemicals, Piscataway, NJ), in a ratio of 3 mg Hp/ml sedimented gel. Four volumes of coupling buffer (0.1M sodium bicarbonate, 0.3M NaCl, pH 7.9) was added per volume of sepharose. The mixture was stirred gently overnight at 4° C. The yield of this reaction was 2 mg Hp/ml sedimented gel. An excess of the Hp affinity gel (with respect to the free tetrameric hemoglobin) was added to the polymerized, pyridoxylated hemoglobin solution and stirred gently at 4° C. for 1-4 hours. The solution was then centrifuged gently (4000 g for 2 minutes) and the supernatant recovered. Additional washes and centrifugations were carried out to maximize recovery of the polymerized hemoglobin. The polymerized, pyridoxylated hemoglobin thus obtained was greater than 99.5% free of unmodified tetrameric hemoglobin.
ALTERNATIVE STEP 3: Complexing With Haptoglobin
The final traces of unmodified tetrameric hemoglobin were removed from the polymerized, pyridoxylated hemoglobin solution by complexing it with haptoglobin (Hp). Haptoglobin was added on a 1:1 molar ratio to free tetrameric hemoglobin. The solution was mixed at room temperature for approximately 2 hours.
EXAMPLE 7
Pharmaceutical Composition of Ultrapurified, Stroma-Free, Polymerized, Pyridoxylated Hemoglobin
An ultrapurified stroma-free, polymerized, pyridoxylated hemoglobin solution was prepared according to the procedure of Example 6. The pH of the solution at 5° C. using 0.5 N NaOH was adjusted to about 9.02 and balanced with an electrolyte concentrate to yield the following concentrations in the final solution:
______________________________________Na 140 mEq/LK 4.0 mEq/LCl 100 mEq/LCa.sup.++ 5.0 mEq/LMg 1.5 mEq/LGlutathione 1 gm/L______________________________________
An enzyme cocktail was added to the solution to stabilize it against oxidation. It contained approximately no less than the stated amounts per liter of the final solution:
1. Glucose-6-Phosphate-0.3 gm
2. Glucose-6-Phosphate Dehydrogenase-0.20 mg
3. Ferrodoxin-6 mg
4. Ferrodoxin NADP Reductase-3 mg
5. NADP-40 mg
6. Catalase-0.2 gm
The final hemoglobin concentration was adjusted between 7-18 gm/dl.
EXAMPLE 8
Sterilization Technique
The purified polymerized, pyridoxylated hemoglobin prepared according to the procedure of Example 6 was sterilized using the following filtration scheme with the Pall Profile Filters (Pall Corp., Glen Cove, NY):
______________________________________010 → 007 → 005 → NR7P. (0.2μ absolute).1μ 0.7μ 0.5μ 0.2μ______________________________________
The filter medium was polypropylene. The final 0.22μ sterilizing filter was nylon. All filters were pharmaceutical grade.
The solution thus sterilized showed no growth on blood agar plates (37° C./4 days or 25° C./10 days) or in thioglycollate broth. The solution had trace amounts (0.25 ng/ml) of endotoxin, based on Limulus Amoebacyte Lysate Test, when prepared in a nonpharmaceutical environment.
EXAMPLE 9
Biochemical Characteristics
The tetramer free polymerized, pyridoxylated hemoglobin showed a normal absorption spectrum obtained from a Beckman DU recording spectrophotometer (Beckman Instruments, Lincolnwood, IL) (FIG. 6B). The solution when reconstituted to a normal hemoglobin concentration (12-14 gm/dl) resulted in a solution with acceptable colloid osmotic pressure (COP) (14.5-22.5 torr) (FIG. 7). For purposes of FIG. 7, the hemoglobin concentration was determined on the IL 282 Co-oximeter (Instrumentation Laboratories, Danvers, MA). The COP was measured on the Wescor Colloid Osmometer Model 4400 (Boyce Scientific Inc., Hanover Park, IL). For purposes of comparison, the curve obtained with the unmodified stroma-free hemoglobin (SFH) is also shown. The process of polymerization did not alter the oxygen binding capacity of the hemoglobin (1.30 cc/gm). The product when reconstituted to a normal hemoglobin concentration had a normal oxygen carrying capacity.
The P 50 of the product ranged from 14-22 torr when determined under physiologic conditions of pH, pCO 2 and temperature. A typical oxy-hemoglobin dissociation curve for the product is shown in FIG. 8. The sample was run under standard conditions of pH 7.40, the temperature 37° C. and pCO 2 40 torr. The continuous curve was generated by the Hem-O-Scan oxygen dissociation analyzer (Travenol Laboratories, Deerfield, Ill.).
The molecular weight distribution of the product based on HPLC appeared to range from 120,000 to 600,000 daltons (FIG. 9). The average molecular weight estimated from the data was about 120,000. FIG. 9 describes the elution pattern from an HPLC column (TSK Gel, type G 4000 S.W., Varian Instruments Group, Palo Alto, CA). The elution buffer used was 0.1M sodium phosphate, pH 7.0 (at 25° C.) with 0.1M sodium chloride (osmolarity=353 mOsm). The hemoglobin concentration of the sample is adjusted to approximately 3.0 gm/dl. Sample volume injected was 0.1 ml. Flow rate was 1 ml/min. (the HPLC pump (Model 2150), UV monitor (Model 2238 Uvicord SII) and recording integrator (Model 2220) were manufactured by LKB Instruments, Gaithersburg, MD).
The product characterized by SDS-PAGE showed 4 polymeric bands (FIG. 3A). They represented about 58% at a molecular weight of 120,000, 26% with a molecular weight of 192,000, 11% with a molecular weight of 256,000 and 4% with a molecular weight of 320,000. Trace amounts of higher molecular weight polymers were visible on the gel. FIGS. 3A, 3B and 3C represent densitometric scans of the product of this invention separated by SDS-polyacrylamide gel electrophoresis using the technique described in the LKB note 306 (LKB Instruments, Gaithersburg, MD). The scan was obtained from a Helena Quick Scan, R and D (Helena Laboratories, Beaumont, Tex.) at different stages of polymerization.
The viscosity of the product changed with polymerization. The final product had a viscosity of 3.1 centipoise at a hemoglobin concentration of about 8 gm/dl. This value was comparable to that of whole blood. FIG. 10 describes the relationship between the hemoglobin concentration of the product and the viscosity of the solution. The measurements were made with the Brookfield Model LVT viscometer (Brookfield Engineering Laboratories Inc., Stoughton, MA) at temperature 25° C. and shear rate 450 sec -1 .
The phospholipids that were present in the red cell membrane were not detectable in the final product by thin layer chromatography (TLC). Trace amounts of free fatty acids were visible on the TLC plates on an occasional batch.
The methemoglobin reductase activity in the product was essentially unchanged by the process. The starting lysate as well as the final product had enzyme activities ranging from 1.0-2.0μ. One unit of enzyme activity is defined as 1 μM of ferrocyanide-methemoglobin complex reduced per gram hemoglobin minute.
EXAMPLE 10
Physiological and Biological Assays
A. Renal Alterations
Comparative studies conducted in unanesthetized baboons indicated that infusion of solution contaminated with more than 2-3% tetrameric hemoglobin caused a fall in urine production of approximately 50% and a fall in glomerular filtration rate (creatinine clearance) of approximately 15% as compared to pre-infusion levels. Infusion of pyridoxylated, polymerized hemoglobin solution essentially free of tetramer produced no appreciable effect.
B. Hemodynamic Effects
In baboons a fall of approximately 25% in heart rate and an elevation of approximately 14% in mean arterial pressure was associated with the infusion of a hemoglobin solution contaminated with more than 5-7% tetrameric hemoglobin. This was a primary vasoconstrictor activity of the tetramer and was absent when pyridoxylated, polymerized hemoglobin solution essentially free of tetramer was infused.
C. Extravasation
Up to 2 liters of tetrameric hemoglobin solution was observed in the abdominal cavities of baboons exchange transfused to a hematocrit of 0% with tetrameric hemoglobin. Little if any hemoglobin containing fluid was observed in the peritoneal cavities of animals exchange transfused to a hematocrit of 0% with pyridoxylated, polymerized hemoglobin solution essentially free of tetramer.
D. Destruction of Viral Antigens
A pool of 100 units of human red blood cells, the preferred starting material for the process herein disclosed, tested positive for viral hepatitis B surface antigen. Destruction of this antigen occurred after 1-2 hours of polymerization as described in Example 5.
E. Reduction of Hemoglobin Present in Urine
Infusion of hemoglobin solution containing tetrameric hemoglobin into a baboon resulted in the excretion of tetrameric hemoglobin in urine. This occurred once the mass of infused tetrameric hemoglobin exceeded the baboon's ability to bind hemoglobin tetramer by means of circulating haptoglobin. The resulting urine exhibited a deep red color characteristic of hemoglobin and contained 1-2 gm of hemoglobin per 100 ml of urine. Tetrameric hemoglobin solutions exhibited a 2-4 hour half-life in vivo (mice, baboons were the test animals). Infusion of pyridoxylated, polymerized hemoglobin solution essentially free of tetrameric hemoglobin (less than 2% tetramer present) resulted in little or no appreciable change of the color of the urine (less than 30 mg of hemoglobin per 100 ml of urine). A haptoglobin treated polymerized, pyridoxylated hemoglobin solution (greater than 99.5% free of tetramer) produced no change in the color of the urine, even when infused in very large therapeutic doses in the primate.
The half-life of the product produced by the process herein disclosed was approximately 24 hours (FIG. 11). FIG. 11 describes the plasma disappearance curve (half-life) for the unmodified stroma-free hemoglobin (SFH) and the product of the present invention. One gram per kilogram of body weight of either SFH or essentially tetramer-free, cross-linked, polymerized, pyridoxylated hemoglobin solution in Lactated Ringer's solution, at about 7 to about 14 gm/dl hemoglobin concentration, was administered intravenously to six adult male baboons. Plasma hemoglobin levels were determined by the IL 282, Co-oximeter, at two hour intervals in the case of SFH or at six hour intervals in the case of the product of this invention. The measurements were continued until all hemoglobin disappeared from the test subject's plasma.
In the foregoing, there has been provided a detailed description of preferred embodiments of the present invention for the purpose of illustration and not limitation. It is to be understood that all other modifications, ramifications and equivalents obvious to those having skill in the art based on this disclosure are intended to be within the scope of the invention as claimed.
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An acellular red blood cell substitute which comprises an essentially tetramer-free, substantially stroma-free, cross-linked, polymerized, pyridoxylated hemoglobin and a nontoxic, pharmaceutically acceptable carrier, its uses and a process for preparing said acellular red blood cell substitute.
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FIELD OF THE INVENTION
The present invention relates to a sealing device for sealing between a bearing housing and an axle journal of a roll, the two bearing housings for the axle journal bearings being movable in a direction across the axle.
The present invention also relates to a device for dewatering and/or washing material suspensions (for example pulp suspensions), comprising at least one cylindrical rotary roll, which is surrounded by a casing with an inlet for the material suspension, and which against an element forms an outlet gap for the egress of the material suspension, where the axle journals of the roll are mounted in bearings supported by bearing housings, which are movable for taking up variations in the width of the outlet gap, and sealing devices are provided for sealing between the bearing housing and the axle journals.
BACKGROUND OF THE INVENTION
The prior art, such as Swedish Patent Nos. 504,011; 515,543; and 501,719 show examples of dewatering devices, which comprise liquid permeable press rolls with a nip formed between them for dewatering a material suspension of wood fiber pulp. The pulp suspension is supplied to a portion of the device, which is under pressure and surrounded by a casing, and the dewatered pulp egresses through the nip. The pulp suspension usually is supplied either from above or from below, as can be seen from these references. The width of the outlet gap can vary, depending on the properties of the suspension which can be different along the length of the roll, and thus the roll can be angled in relation to the bearing housing. It may also be necessary to adjust the nip, i.e. to move at least one roll towards or away from the other roll, and during this movement the roll can be slightly angled. The pulp suspension is aggressive, and if it leaks into the bearings, the bearings will be destroyed. The sealing against the bearings, therefore, is of vital importance and an essential risk factor for the accessibility of the device.
Present dewatering devices use as sealing between the bearing housing and the axle stuffing boxes and V-ring sealings (of rubber). They do not withstand, however, the aggressive environment of the pulp suspension and are destroyed and lose their sealing capacity.
One object of the present invention is to provide a sealing device for sealing between a bearing housing and the axle journal of a roll, the two bearing housings of which for the axle journal bearings are movable in the direction across the axle, where this sealing device shall have a long service life even in an aggressive environment, and which allows the axle to be slightly angled in a plane during the movement, and in which the sealing can also take up a certain degree of axial movement. A more specific object of the present invention is, by providing improved sealing devices, to increase the operational reliability of a device for dewatering and/or washing material suspensions, comprising at least one cylindrical rotary roll, which is surrounded by a casing with an inlet for the material suspension, and which against an element forms a gap for the egress of pulp, and the axle journals of the roll are mounted in bearings supported by bearing housings movable in the direction across the axle.
SUMMARY OF THE INVENTION
These and other objects have now been realized by the discovery of apparatus for creating a seal between an axle journal and a bearing housing for the axle journal, the axle journal being angularly displaceable in a plane relative to the bearing housing, the apparatus comprising a stator ring, a pair of diagonally disposed guide pins supporting the stator ring with respect to the bearing housing whereby the stator ring can be angled in a plane with respect to the pair of guide pins, a sealing ring for creating a seal between the stator ring and the axle journal, a bellows for creating a seal between the bearing housing and the stator ring, and at least one resilient member for urging the stator ring in abutment against the sealing ring. Preferably, the bellows is rigidly mounted with respect to the stator ring and with respect to the bearing housing, the bellows comprising a non-resilient material. In another embodiment, the at least one resilient member is disposed to act between the bearing housing and the stator ring. In another embodiment, the sealing ring is mounted for rotation with the axle journal.
In accordance with the present invention, apparatus has also been discovered for dewatering or washing material suspensions comprising at least one cylindrical rotary roll including a pair of axle journals, the at least one cylindrical rotary roll separated by a predetermined gap from a second element, a trough surrounding the at least one cylindrical rotary roll, the trough including an inlet for the material suspension, an outlet for the material suspension comprising the predetermined gap, a pair of bearing housings, a pair of bearings supported by the pair of bearing housings, the pair of axle journals being mounted in the pair of bearings, the pair of bearing housings being individually movable whereby the at least one cylindrical rotary roll can be angularly displaced with respect to the pair of bearing housings, each of the pair of bearing housings including sealing means for creating a seal between the pair of bearing housings and the pair of axle journals, the sealing means comprising a stator ring, a pair of diagonally disposed guide pins supporting the stator ring with respect to the bearing housing, whereby the stator ring can be angled in a plane with respect to the pair of guide pins, a sealing ring for creating a seal between the stator ring and the axle journal, a bellows for creating a seal between the bearing housing and the stator ring, and at least one resilient member for urging the stator ring in abutment against the sealing ring. In a preferred embodiment, at least one of the at least one cylindrical rotary roll and the second element is liquid permeable. In another embodiment, the second element comprises a second cylindrical rotary roll.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be more fully appreciated with reference to the following detailed description, which in turn refers to the Figures, in which:
FIG. 1 is a front, elevational, cross-sectional, partially schematic view illustrating in principle a dewatering device for use in the pulp industry;
FIG. 2 is a top, elevational view of a pair of rolls with an intermediate gap in the device shown in FIG. 1 ;
FIG. 3 is a front, elevational, enlarged sectional view of the rolls shown in FIG. 1 taken along line 3 - 3 thereof;
FIG. 4 is a partial front, enlarged longitudinal view taken through one axle journal bearing of a roll used in accordance with the present invention;
FIG. 5 is a side, elevational, partial, enlarged view of the circled portion shown in FIG. 3 ;
FIG. 6 is a front, elevational, enlarged sectional view of the circle portion shown in FIG. 3 ; and
FIG. 7 is a front, elevational view showing a stator ring for use in the present invention.
DETAILED DESCRIPTION
Turning to the Figures, FIG. 1 shows a roller press intended for liquid treatment, for example, for the washing and dewatering of material suspensions, such as, for example, fiber pulp suspensions. The roller press is described only roughly, because it is already known. Two cylindrical, rotary, liquid permeable rolls, 9 and 10 , are partially located in a trough 11 , which is formed so, that a converging space 12 is formed between the trough 11 and each of the rolls, 9 and 10 . Each space 12 has an inlet 13 for the material suspension. Each space 12 can also have inlets for treatment liquid. Between the rolls, 9 and 10 , a gap 14 is formed, a so-called press nip, through which the dewatered pulp passes. At the inlet 13 a longitudinal seal 19 is provided to seal between the trough 11 and the circumference of the rolls, 9 and 10 , so that the trough 11 forms a tight casing about the lower portions of the rolls.
FIG. 2 shows schematically the two rolls, 9 and 10 , with axle journals, 21 , 22 , 23 and 24 , seen from above. The Figure also shows the end walls, 25 and 26 , of the trough 11 . In the end walls a bearing housing, 30 and 57 and 31 and 58 , is provided for each of the axle journals, 21 , 22 , 23 and 24 . The axle journals, 21 , 22 , 23 and 24 , are mounted in bearings in the bearing housings, 30 and 57 and 31 and 58 , and sealing devices, 27 and 27 ′, and 28 and 28 ′, respectively, seal between the axle journals and the bearing housings. The bearing housings for the axle journals are movable horizontally, so that the gap 14 between the rolls, 9 and 10 , can be changed as will be described with reference to FIG. 3 . The moving of the bearing housings, and thereby of the axle journals of the bearing housings, can take place individually, and during the moving, therefore, the roll can be angled in relation to the bearing housing, as shown in FIG. 2 , and the width of the gap 14 will then temporarily not be equal along the entire roll length, as shown in FIG. 2 . This subjects the sealing devices, 27 , 27 ′, 28 and 28 ′, to large requirements.
FIG. 3 shows the end wall 25 and two bearing housings, 30 and 31 , which are horizontally slidable along guide surfaces, 32 and 33 , in the end wall 25 , as shown in FIG. 4 . When the suspension passes the gap 14 , a line load is obtained on the rolls. The line load can vary along the length of the gap and over time. This is due to the fact that the properties of the suspension vary, such as for example the fiber network. Considerable foreign matter can also enter the process and pass through the gap 14 . Hydraulic cylinders, 34 and 35 , and 36 and 37 , respectively, are provided to prevent a pre-determined level of the line load to be exceeded. If this should happen, the dewatering arrangement can be damaged. The stroke length of the hydraulic cylinders can be, for example, 20 mm. The hydraulic cylinders for one roll, for example the hydraulic cylinders, 34 and 35 , for the roll 9 , can be replaced by stationary stops, if it is desired to guide the gap width (line load) by only one roll.
FIG. 4 shows the bearing housing 31 with one bearing 38 for the axle journal 23 and the sealing device 27 , which seals between the bearing housing and the axle journal. The bearing in the embodiment shown is of a spherical type and, thus, can take up angle changes.
FIGS. 5 and 6 show on an enlarged scale the parts 5 and 6 , respectively, in FIG. 4 , with the sealing device 27 . The sealing device 27 comprises a stator ring 40 , which is supported, for example, by two guide pins 41 , a sealing ring unit 47 , a bellow means 56 and at least one resilient element (in the embodiment shown the resilient element is a spring).
The sealing ring unit 47 is intended to be tight-sealing against the axle journal 23 , to rotate with the axle journal 23 , and to seal against the stator ring 40 . The sealing ring unit 47 in the embodiment shown comprises a holding ring 42 , which is tight-sealing against the axle journal 23 with an O-ring 43 and rotates with the roll by carrying locking pins 44 . The sealing ring unit 47 in the embodiment shown also comprises a sealing ring 55 of solid glide material, for example graphite, which is supported by the holding ring 42 .
FIG. 7 shows an illustration in principle of the stator ring 40 with two first recesses 60 for the guide pins 41 and eight second recesses 61 for the spring 48 . The device shown thus comprises eight springs 48 , but it may, of course, comprise a greater or smaller number of springs 48 . The springs 48 are located in the bearing housing 31 and act against the stator ring 40 . The springs 48 are intended to take up relative movements between the bearing housing 31 and the stator ring 40 , and to ensure that the stator ring abuts against the sealing unit 47 . The sealing can thus take up axial movement and can rise due to wear between rotary and stationary parts, and when different parts of the device are heated unequally rapidly, so that the parts will have a different heat expansion.
The guide pins 41 are arranged diagonally and vertically in relation to each other in the stator ring, and each guide pin 41 has at its front end a top 45 . Each guide pin 41 is slidable in its recess 60 in the stator ring 40 . The top 45 and recess 60 are formed in such a way in relation to each other that the stator ring 40 can be angled slightly in the horizontal plane. The top 45 suitably is spherical.
The bellow means 56 is intended to take up relative movements between the bearing housing 31 and the stator ring 40 . The bellow means 56 is tightly attached to the stator ring and to the bearing housing 31 , in order to seal therebetween, and comprises a bellows 50 . The bellow means 56 in the embodiment shown comprises, for the attachment of the bellows 50 to the bearing housing, a bipartite outer ring 49 with a first ring portion 63 , which is tightly attached to the bearing housing 31 , and a second ring portion 64 , and the bellows 50 , which is ring-shaped, is clamped between the first and second ring portion, 63 and 64 , by external fastening means 65 , for example screws. The bellow means 56 further comprises an inner ring 66 , which by inner fastening means 67 tightly clamps the bellows 50 against the stator ring 40 . As the bellows is rigidly clamped at its outer edges (relative to the stator ring and, respectively, bearing housing), it need not be of resilient material (for example rubber), but can be of a more durable material, for example PTFE, which is not destroyed by the aggressive environment, as for example a pulp suspension. A conventional additional radial sealing 52 is provided in the embodiment shown near the bearing at the axle journal, in order to separate the oil in the bearing from the air-filled closed space 53 . The suspension in the trough is indicated in FIG. 5 by the reference 54 .
The dewatering means shown is only one example, and the dewatering means can thus be of a type other than the one shown. The material flow through the gap 14 , for example, can be downward instead of upward. The sealing device, of course, can be provided for use in means other than dewatering means.
In the embodiment shown the sealing device is arranged so that the axle can be angled slightly in the horizontal plane. The sealing device, of course, can also be arranged so that it allows angling in other planes, depending entirely on the type of means, in which the device shall be used.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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Apparatus for creating a seal between an axle journal and a bearing housing is disclosed, particularly for use in apparatus for dewatering or washing material suspensions. The apparatus includes a stator ring, a pair of diagonally disposed guide pins supporting the stator ring with respect to the bearing housing so that the stator ring can be angled in a plane with respect to the pair of guide pins, a sealing ring for creating a seal between the stator ring and the axle journal, a bellows for creating a seal between the bearing housing and the stator ring, and at least one resilient member for urging the stator ring in abutment against the sealing ring.
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CLAIM OF PRIORITY
[0001] This application is a divisional of U.S. application Ser. No. 10/968,487 filed Oct. 19, 2004, which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] Embodiments of the invention relate to the field of analog and digital copy protection; and more specifically, to the field of copy protection of content stored on digital recordable media.
[0004] 2. Description of the Related Art
[0005] Various well known copy protection schemes for video signals include those disclosed in U.S. Pat. No. 4,631,603, by John O. Ryan, Dec. 23, 1986 and assigned to Macrovision Corporation, directed to modifying an analog video signal to inhibit making of acceptable video recordings therefrom. The '603 patent discloses adding a plurality of pulse pairs to the otherwise unused lines of a video signal vertical blanking interval, each pulse pair being a negative-going pulse followed closely by a positive-going pulse. The effect is to confuse AGC (automatic gain control) circuitry of a VCR (video cassette recorder) recording such a signal, so that the recorded signal is un-viewable due to the presence of an excessively dark picture when the recorded signal is played back.
[0006] Another analog video protection scheme is disclosed in U.S. Pat. No. 4,914,694 issued Apr. 3, 1990, to Leonard, and assigned to Eidak Corporation. The Eidak system (see Eidak Abstract) increases or decreases the length of each video field from the standard length, either by changing the time duration of the respective horizontal line intervals in each field while keeping a constant, standard number of lines per frame, or by changing the number of horizontal line intervals which constitute a frame while maintaining the standard duration of each line interval.
[0007] These video protection systems modify the video signal to be recorded (for example, on tape, magnetic disk, optical disk, or other recordable media) or to be broadcast (for example, protected pay-per-view (PPV) television programs) and to make viewable copying by ordinary VCRs or other recordable media difficult or impossible. When a video tape, or the like, on which is recorded the copy protected video signal is played back for viewing using a VCR or similar playback device, the copy protection process is essentially transparent, i.e., it does not interfere with viewing the originally recorded content. However, any attempt made to copy the video signal from the tape using a second VCR to record the output of the first (playback) VCR yields a picture degraded to some extent, depending on the efficacy of the particular copy protection system. These conventional video copy protection systems protect only analog video signals.
[0008] Also well known are digital video recorders, which both record and play back digitally. The advantage to the user of a digital recorder is that so long as the signals are recorded and played back in the digital domain, each successive generation of copies is without any significant reduction in picture quality, unlike the case with conventional analog recording technology.
[0009] Many consumer products today include both digital and analog inputs and outputs. Some of these systems have the capability to record and playback digital signals, while still having analog output capabilities. Thus, these systems have the capability internally to convert input analog signals into digital signals, and play back the digital signals as an analog video stream from a digital storage device. A digital versatile disk (DVD) player is one example of such a consumer device that retains digital video signals and can output a corresponding analog video stream. During playback, the digital data stream from an optical disk, for example, may be available both as a digital signal for display by a digital television set or converted within the device to a conventional analog video output signal (such as the NTSC signal used in the United States, or PAL or SECAM used elsewhere).
[0010] Because digital video systems are capable of high fidelity reproduction, which in turn facilitates high quality copying, it is important that such devices for consumer use be designed to inhibit or discourage unauthorized recording. For instance, it is important to prevent use of recorders for illegally duplicating copyrighted video material, and also to prevent playing back of such illegally duplicated material.
[0011] U.S. Pat. No. 5,315,448 (the '448 patent), by John O. Ryan, describes a hybrid digital and analog recorder that records digitally and provides copy protection in both the digital and analog domains. For externally supplied analog video, the recorder detects the presence of copy protection and in response disables recording. For externally supplied digital video, both anti-copy bits and serial copy protection bits are detected to respectively (1) disable recording and (2) prevent later copying by a second digital recorder. For playing back of recorded material, the presence of anti-copy bits is detected in the digital playback video, and the digital playback video upon being converted to an analog signal is modified by an analog video copy protection process. In another embodiment of the '448 invention, analog or digital source video material (either prerecorded or from an external source) is provided with a copy protection flag or trigger. Detection of the flag by a playback device results in modification of the played back standard video signal with an analog copy protection process. This embodiment is suitable for playback devices where the source video cannot be copy protected, but a standard (NTSC) video signal is provided from a played-back recording.
[0012] The analog video copy protection process described in the '448 patent includes the use of an ACP (anti-copy process) signal generator, such as an embodiment described in U.S. Pat. No. 4,631,603. This ACP signal generator generates an analog video anti-copy signal. The ACP signal generator then adds this analog anti-copy signal to the output signal of a digital to analog converter, which has converted the digital video output signal from a DVD, for example, to an analog (for example, NTSC) signal. Alternatively, the ACP signal generator can be implemented as shown in above-referenced U.S. Pat. No. 4,914,694 for modifying the “TV signal source”. It will be apparent to those of ordinary skill in the art that other ACP signal generator implementations can be used. Thus, using the '448 invention, the analog (NTSC) video signal presented at an analog output terminal is an analog video signal modified by the analog anti-copy process. This prevents the making of acceptable video recordings on existing analog recording devices from the signal provided from the pre-recorded video signal.
[0013] Although the '448 patent describes an effective analog copy protection system, it would be beneficial to separate out the particular analog anti-copy process from the hardware that actually modifies the analog video signal for output to a rendering or recording device. By separating the anti-copy process from the signal modification hardware, the system would achieve a level of flexibility and configurability not present in systems today.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings, in which
[0015] FIG. 1 is a block diagram of a system in accordance with a first embodiment.
[0016] FIG. 2 is a block diagram of a system in accordance with a second embodiment.
[0017] FIG. 3 is a block diagram of a system in accordance with a third embodiment.
[0018] FIG. 4 is a block diagram of a system in accordance with a fourth embodiment.
[0019] FIG. 5 is a block diagram of a system in accordance with a fifth embodiment.
[0020] FIG. 6 is a block diagram of a system in accordance with a sixth embodiment.
[0021] FIG. 7 is a block diagram of a system in accordance with a sixth embodiment.
[0022] FIG. 8 is a block diagram of a system in accordance with a sixth embodiment.
DETAILED DESCRIPTION
[0023] A copy protection system and method enabling storage of copy protection information separately from protected content is disclosed. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one of ordinary skill in the art that these specific details need not be used to practice the present invention. In other circumstances, well-known structures, circuits, processes and interfaces have not been shown or described in detail in order not to unnecessarily obscure the present invention.
[0024] Referring now to FIG. 1 , a block diagram illustrates one embodiment of the present invention. FIG. 1 shows a mechanism 100 for playing a digital recording medium 105 . One example of such a mechanism is a DVD player or a conventional personal computer. The recording medium 105 (e.g. a DVD disk) has stored thereon a digital content file 107 and a copy protection information file 109 . The digital content file 107 represents a conventional digitized work, such as a video movie. The copy protection information file 109 represents one of several alternative embodiments of a set of information used to implement an analog copy protection process, such as the process described above in relation to the '603, '694, and '448 patents. In one embodiment, the file 109 is a digitized analog copy protection waveform that can be conveniently added to a digital content signal produced from the digital content file 107 . For example, file 109 can represent a horizontal/vertical synch structure for a conventional television set or video monitor. Alternatively, file 109 can represent an entire vertical blanking interval line for a conventional television set or video monitor. Other equivalent implementations of the copy protection information file 109 will be apparent to those of ordinary skill in the art in light of this disclosure. Further, the copy protection information in file 109 can be encoded in a number of conventional ways. In one embodiment, the copy protection information in file 109 can be a raw digitized waveform. In other embodiments, the copy protection information in file 109 can be digitized data in combination with a metadata portion that specifies the particular type of encoding used. In still other embodiments, copy protection information in file 109 can be a mathematical model representation or a programmatic representation that defines the static and dynamic elements of the copy protection waveform.
[0025] The mechanism 100 for playing the recording medium 105 produces a conventional digital content signal from the digital content file 107 . This digital content signal is provided as an input to a digital-to-analog converter (DAC) 130 through a signal modifier 120 . The DAC 130 receives the digital content signal from signal modifier 120 and produces a corresponding analog content signal (e.g. an NTSC video signal).
[0026] Prior to conversion to the analog domain, the digital content signal is also provided as an input to a Copy Protection (CP) detector 110 , as shown in FIG. 1 . CP detector 110 decodes a copy protection trigger encoded into the digital content. The '448 patent summarized above describes an implementation of a CP detector 110 for detecting copy protection trigger bits in a digital content signal. The output of CP detector 110 is connected to signal modifier 120 . Signal modifier 120 is used to modify the digital content signal to add in a copy protection signal for output to DAC 130 , if the CP detector 110 detects the presence of a copy protection trigger in the digital content. If the CP detector 110 does not detect the copy protection trigger, the digital content signal is passed to DAC 130 in an unmodified form. If the copy protection trigger is detected, the signal modifier 120 obtains the copy protection signal from the copy protection file 109 resident on digital media 105 . The signal modifier 120 modifies/augments the digital content signal with the copy protection signal and outputs a modified signal to DAC 130 , which produces a modified analog output signal 150 with an embedded copy protection signal. In a manner similar to the technology described the '603, '694, and '448 patents, the modified analog signal 150 can be used to prevent unauthorized copying of the analog signal, thereby protecting the corresponding content. In one embodiment, the analog output signal is a conventional NTSC video signal with an embedded analog copy protection (ACP) signal.
[0027] Referring now to FIG. 2 , an alternative embodiment is illustrated. As shown in FIG. 2 , the embodiment includes a mechanism 200 for playing a digital recording medium 205 . Similar to the implementation shown in FIG. 1 , one example of such a mechanism is a DVD player or a personal computer. The recording medium 205 has stored thereon a digital content file 207 . In contrast to the embodiment shown in FIG. 1 , the copy protection information file 209 is not embodied on digital media 205 . Rather, the copy protection file 209 is stored separately on either a permanent or removable memory device accessible to mechanism 200 . Various conventional memory devices may be used to retain the copy protection file 209 . For example, a flash memory or other type of semiconductor memory can be inserted into mechanism 200 . A conventional removable card with a magnetic strip or electric interface can also be used. Using any of these various conventional means, the copy protection file 209 can be accessed by the signal modifier 220 and used to modify the digital content signal in the manner described above in relation to FIG. 1 . The copy protection file 209 can take any of the forms described above in relation to FIG. 1 . The embodiment shown in FIG. 2 has the advantage that the digital media 205 does not need to be modified to retain the copy protection file. In all other respects, the embodiment shown in FIG. 2 operates similarly to the embodiment shown in FIG. 1 and produces the modified analog output signal 150 , if CP detector 110 detects the copy protection trigger in the digital content signal.
[0028] Referring now to FIG. 3 , another alternative embodiment is illustrated. As shown in FIG. 3 , the embodiment includes a mechanism 300 for playing a digital recording medium 205 . Similar to the implementation shown in FIG. 1 , one example of such a mechanism is a DVD player or a personal computer. The recording medium 205 has stored thereon a digital content file 207 . In contrast to the embodiments shown in FIGS. 1 and 2 , the copy protection information file 309 is not embodied on digital media 205 nor stored locally on a memory device directly accessible to mechanism 300 . Rather, the copy protection file 309 is stored remotely from the mechanism 300 and made accessible via a conventional network connection 315 . Using conventional techniques, the copy protection file 309 can be obtained via a communication or transmission link with a network connection 315 (e.g. the Internet) and provided as an input to signal modifier 320 . In the manner described above, the copy protection file 309 can be accessed by the signal modifier 320 and used to modify the digital content signal in the manner described above in relation to FIG. 1 . The copy protection file 309 can take any of the forms described above in relation to FIG. 1 . In a typical embodiment, the copy protection trigger bits in the digital content signal detected by CP detector 110 can also be used to trigger the mechanism 300 to require access to the copy protection file 309 via Internet 315 . In this manner, the playback of the content 207 could be inhibited until the file 309 is obtained. The embodiment shown in FIG. 3 has the advantage that the digital media 205 does not need to be modified to retain the copy protection file. Further, the copy protection file 309 can be remotely stored and thus can be updated more readily. In all other respects, the embodiment shown in FIG. 3 operates similarly to the embodiment shown in FIG. 1 and produces the modified analog output signal 150 , if CP detector 110 detects the copy protection trigger in the digital content signal.
[0029] Referring now to FIG. 4 , another alternative embodiment is illustrated. As shown in FIG. 4 , the embodiment includes a mechanism 400 for playing a digital recording medium 205 . Similar to the implementation shown in FIG. 1 , one example of such a mechanism is a DVD player or a personal computer. The recording medium 205 has stored thereon a digital content file 207 . Similar to the embodiment shown in FIG. 3 , the embodiment shown in FIG. 4 includes a copy protection file 409 stored remotely from the mechanism 400 and made accessible via a conventional network connection 315 . In contrast to FIG. 3 , the mechanism 400 includes a copy protection file storage component 417 to locally store a copy of the copy protection file 409 as received via a conventional network connection. In real-time or during a set-up initialization phase, mechanism 400 accesses the copy protection file 409 via a network connection 315 (e.g. the Internet). The obtained copy protection file 409 is stored locally in storage component 417 for later use by signal modifier 420 . In the manner described above, the copy protection file 409 can be accessed from storage component 417 by the signal modifier 420 and used to modify the digital content signal in the manner described above in relation to FIG. 1 . The copy protection file 409 can take any of the forms described above in relation to FIG. 1 . The embodiment shown in FIG. 4 has the advantage that the copy protection file 409 can be remotely stored and thus updated more readily; yet, a copy of the copy protection file 409 can be obtained and stored locally in the mechanism 400 for better efficiency. In all other respects, the embodiment shown in FIG. 4 operates similarly to the embodiment shown in FIG. 1 and produces the modified analog output signal 150 , if CP detector 110 detects the copy protection trigger in the digital content signal.
[0030] Referring now to FIG. 5 , another alternative embodiment is illustrated. As shown in FIG. 5 , the embodiment includes a mechanism 500 for playing a digital recording medium 505 . Similar to the implementation shown in FIG. 1 , one example of such a mechanism is a DVD player or a personal computer. The recording medium 505 has stored thereon a digital content file 507 and a copy protection information file 509 . In contrast to the embodiment shown in FIG. 1 , the mechanism 500 does not include a CP detector 110 . In the embodiment shown in FIG. 5 , the signal modifier 520 always applies the copy protection signal as an input to DAC 130 . In this embodiment, there is no detection of a copy protection trigger in the digital content signal as in the embodiment shown in FIG. 1 . Rather, the mechanism 500 always applies the copy protection process defined in the copy protection file 509 regardless of any trigger in the digital content. Because the particular copy protection process embodied in the copy protection file 509 can be configured for a particular class or type of digital content embodied in the digital content file 507 , the selectable application of the copy protection signal is not required. In another embodiment, the copy protection process defined in the copy protection file 509 can be essentially null. By creating a null copy protection file 509 , the modification of the analog output signal can be prevented in a manner similar to the result obtained when no copy protection trigger is detected in the digital content signal as in the embodiment of FIG. 1 . Using any of various conventional means, the copy protection file 509 can be accessed by the signal modifier 520 and used to modify the digital content signal in the manner described above in relation to FIG. 1 . The copy protection file 509 can take any of the forms described above in relation to FIG. 1 . The embodiment shown in FIG. 5 has the advantage that the mechanism 500 contains fewer parts and thus is less expensive. In all other respects, the embodiment shown in FIG. 5 operates similarly to the embodiment shown in FIG. 1 and produces the modified analog output signal 150 .
[0031] Referring now to FIG. 6 , another alternative embodiment is illustrated. As shown in FIG. 6 , the embodiment includes a mechanism 600 for playing a digital recording medium 605 . Similar to the implementation shown in FIG. 1 , one example of such a mechanism is a DVD player or a personal computer. The recording medium 605 has stored thereon a digital content file 607 . Similar to the embodiments shown in FIGS. 2-4 , the copy protection file 609 is stored separately from digital media 605 . In contrast to the embodiment shown in FIG. 1 , the mechanism 600 does not include a CP detector 110 . In the embodiment shown in FIG. 6 , the signal modifier 620 always applies the copy protection signal as an input to DAC 130 . In this embodiment and similar to the embodiment shown in FIG. 5 , there is no detection of a copy protection trigger in the digital content signal as in the embodiment shown in FIG. 1 . Rather, the mechanism 600 always applies the copy protection process defined in the copy protection file 609 regardless of any trigger in the digital content. Similar to the embodiments of FIGS. 2-4 , the copy protection file 609 can be obtained from a separate memory device or via a network connection and used to modify the digital content signal in the manner described above in relation to FIG. 1 . The copy protection file 609 can take any of the forms described above in relation to FIG. 1 . The embodiment shown in FIG. 6 has the advantage that the mechanism 600 contains fewer parts and thus is less expensive and the digital media 605 does not need to be modified to retain the copy protection file 609 . In all other respects, the embodiment shown in FIG. 6 operates similarly to the embodiment shown in FIG. 1 and produces the modified analog output signal 150 .
[0032] As illustrated in FIGS. 7 and 8 , the various embodiments illustrated in FIGS. 1-6 and described above can be implemented with systems that receive a video feed 705 from various sources, such as broadcast video programming, multicast, webcast, video-teleconferencing, and the like. As shown in FIG. 7 , an alternative embodiment includes a mechanism 700 for receiving and rendering a broadcast digital signal 707 in which a copy protection signal 709 and a copy protection trigger is encoded. Similar to the implementation shown in FIG. 1 , the signal modifier 720 receives both the broadcast digital signal 707 and the copy protection signal 709 . As in the embodiment of FIG. 1 , the broadcast digital signal 707 is also provided as an input to the Copy Protection (CP) detector 110 . CP detector 110 decodes a copy protection trigger encoded into the broadcast digital signal 707 . The '448 patent summarized above describes an implementation of a CP detector 110 for detecting copy protection trigger bits in a digital signal 707 . The output of CP detector 110 is connected to the signal modifier 720 . In this embodiment, signal modifier 720 is used to modify the broadcast digital signal 707 to selectively strip the copy protection signal 709 from the broadcast digital signal 707 prior to outputting the modified signal to DAC 130 , if the CP detector 110 detects the absence of a copy protection trigger in the broadcast digital signal 707 . If the CP detector 110 detects the presence of a copy protection trigger in the broadcast digital signal 707 , the signal modifier 720 leaves the copy protection signal 709 intact and still encoded into the broadcast digital signal 707 . The unmodified broadcast digital signal 707 is then sent to DAC 130 for conversion to the analog domain. This embodiment enables the selective stripping of the copy protection signal 709 from the broadcast digital signal 707 . The embodiment also enables the copy protection signal 709 to be processed separately from the copy protection trigger upstream from the mechanism 700 .
[0033] Referring to FIG. 8 , another embodiment illustrates a system similar to the embodiment shown in FIG. 7 wherein the mechanism 800 receives a video feed 805 from various sources, such as broadcast video programming, multicast, webcast, video-teleconferencing, and the like. In contrast to FIG. 7 , the mechanism 800 receives the broadcast digital signal 807 in which only a copy protection trigger is encoded. Unlike the embodiment of FIG. 7 , the copy protection signal produced from copy protection information file 809 is not encoded into the broadcast digital signal 807 . Rather, the copy protection information file 809 is stored separately on either a permanent or removable memory device accessible to mechanism 800 . As described above, various conventional memory devices may be used to retain the copy protection information file 809 . Similarly, as shown in FIGS. 3-4 , the copy protection information file 809 can be obtained from a network accessible source. Using any of these various means, the copy protection information file 809 can be accessed by the signal modifier 220 and used to produce the copy protection signal and to modify the broadcast digital signal 807 in the manner described above in relation to FIGS. 1-6 . The embodiment shown in FIG. 8 has the advantage that the source of the digital content can be from a broadcast, multicast, or webcast source. This embodiment might be used in a set-top box or a personal video recorder (PVR), for example. In all other respects, the embodiment shown in FIG. 8 operates similarly to the embodiments shown in FIGS. 1-6 and produces the modified analog output signal 150 , if CP detector 110 detects the presence of the copy protection trigger in the broadcast digital signal 807 .
[0034] Thus, a copy protection system and method enabling storage of copy protection information separately from protected content is disclosed. The above description is illustrative and not limiting; further modifications will be apparent to one of ordinary skill in the art in light of this disclosure.
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A copy protection apparatus and method enabling storage of copy protection information separately from protected content is disclosed. One embodiment includes a digital data signal receiver to receive a digital data signal, the digital data signal receiver also to receive a copy protection signal produced from a copy protection information file being storable on a copy protection information storage device, a digital to analog converter operatively connected to the digital data signal receiver for converting the digital data signal to an analog signal, and a signal modifier connected to the digital to analog converter and the digital data signal receiver to produce a viewable copy protected analog signal from the analog signal and the copy protection signal, the copy protection signal specifying a modification to the analog signal to change video lines of the analog signal.
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TECHNICAL FIELD
[0001] The present invention relates to an industrial robot comprising a control system and a manipulator with a tool and a method for such an industrial robot. The invention especially relates to a manipulator with a plurality of arms which are movable relative to each other and which include a tool attachment for attachment of the tool. In particular, the invention relates to a manipulator with a turn disk including the tool attachment.
BACKGROUND ART
[0002] Most industrial robots are intended to work with a tool that is supported by a manipulator. Such a tool is attached to the outer arm of the manipulator and may include a plurality of operating possibilities. These tools often have a considerable weight, which implies that the mounting of the tool to the manipulator entails complicated and heavy work. The mounting work also comprises operations that require very high precision during the mounting. It is a condition for the subsequent work with the manipulator that a correct position for the tool is obtained.
[0003] According to WO 99/50032, a device for attaching a tool to a manipulator is previously known. The task of the known device is to offer simpler mounting which entails a minimum of downtime for a process. Despite the rapid mounting, the method involves an operation when the tool has to be kept in place and at the same time in the correct position while a fixing member is being applied. It is thus desirable to eliminate the need to have to support and guide the tool simultaneously during the mounting.
[0004] In the process industry, a plurality of solutions for automatic tool changing are known. These systems often comprise a device for centring and guiding the tool as well as a system for automatic locking of the tool to the robot. The known systems often provide inferior precision and involve an extensive and costly system for the actual tool-changing operation. The automatic systems must also include functions and magazines for storing and handling tools that are not in operation. When attaching heavier tools, the automatic systems are not suitable since such tools often also require an extensive connection of process media, such as current, control signals, cooling liquids, etc.
[0005] From GB 2 120 634 A, a coupling between a robot and a tool is previously known for automatic tool changing without the intervention of an operator. The task of the known coupling is to provide a simple, light and reliable detachable coupling for this purpose. The coupling comprises a first part that is attached to the robot and a second part that is attached to the tool. The first part comprises a locking device in the form of a pneumatic piston with a transverse pin that is adapted to penetrate an elongated hole provided in the second part. After the piston has penetrated the hole, the first part is oriented in relation to the second part by rotating the first part in relation to the second part. During this rotary movement, also the transverse pin is given such a position that, during a tightening movement of the piston, the pin will rest against the rear side of the first part. The locking operation is then completed by bringing the piston, by the force from the pneumatic arrangement, to pull the second part towards it.
[0006] The known device thus requires process media, in the form of pneumatics, to function. The known method also means that the tool is first oriented and then hooked and locked. The known coupling and method are thus not suited for attaching a heavy tool with great precision.
SUMMARY OF THE INVENTION
[0007] The object of the present invention is to suggest ways and means of providing a method and a device which, when mounting a tool on a manipulator, simplify the work of the operator and relieve the operator of the weight of the tool itself. Another object of the invention is to offer a simple and cost-effective system for manual mounting of a tool.
[0008] These objects are achieved according to the invention by an industrial robot according to the characteristic features described in the characterizing portion of the independent claim 1 and with a method according to the characteristic features described in the characterizing portion of the independent method claim 9 . Advantageous embodiments are described in the characterizing portions of the dependent claims.
[0009] According to the invention, the manipulator comprises a tool attachment including a member for supporting the tool before it is fixed to the manipulator. The supporting member is adapted to carry the weight of the tool such that the manipulator supports the tool during the mounting. The work is carried out in such a way that the tool is lifted by the operator and hooked onto the supporting member. The lifting operation may be carried out completely manually or with a lifting device such as, for example, a crane or a travelling crane. The operation can also be carried out by hooking the robot onto the tool and by lifting the tool to an operator position for fixing. At the same moment that the tool is hooked onto the supporting member, the weight of the tool is transferred to the manipulator. Thus, any lifting devices may then be immediately removed and the tool be completely freely accessible for the mounting work. The continued work comprises centring the tool to a predetermined position and fixing it, in this position, to the tool attachment and hence to the manipulator.
[0010] According to the invention, the supporting member comprises a hook that is fixed to a first structural part and an aperture that is adapted to receive the hook arranged in a second structural part. Here, the first structural part may be the tool attachment and the second structural part the actual tool, or inversely. The designation hook is here to be given a broad meaning of a member adapted to be detachably attached to another member. Thus, a hook may be an elongated object that is partly curved. A hook also comprises a stud with a lower part and a head where the dimension of the head is larger than that of the lower part. The designation aperture for the reception of the hook is also to be given a broad meaning of a hole or a slot that completely or partly surrounds the hook. The function of the aperture is to allow introducing the hook in an unloaded state but to prevent the hook from being pulled out, under loading, through the aperture.
[0011] To assist in the centring of the tool, according to the invention, the tool attachment comprises one or more guide members. In one embodiment, this is implemented by means of a stud, which is adapted to fit into a hole. The stud is thus arranged in a first structural part, which may be the tool, and the hole in a second structural part, which may be the tool attachment. The stud is thus arranged either in the tool or in the tool attachment. The hole corresponding to the stud is arranged in the structural part opposite to the stud. In an advantageous embodiment, the stud is made slightly conical, whereby the structural parts, when being brought together, are allowed to be displaced relative to each other in the lateral direction so as to achieve the correct position when the stud has completely penetrated the hole. The penetration of the stud here means that the structural parts, by the force between the stud and the hole, simultaneously with the threading on, are displaced to the desired position.
[0012] In another embodiment, the guide member is designed to form a so-called dovetail joint, in which case the joint at the same time acts as the supporting member. In a further embodiment, either the tool or the tool attachment includes studs which are provided with heads and which are inserted into corresponding holes comprising a round section and an elongated section, usually referred to as “keyholes”. In this embodiment, the tool is first brought to be supported by the studs provided with heads. The tool is then brought to adopt the correct position through a rotational operation, whereby the studs penetrate into the narrower part of the keyholes. In one preferred embodiment, the elongated part of the holes is arranged wedge-shaped in the direction of rotation.
[0013] The invention also comprises a coupling, by which the tool in its correct position is fixed to the manipulator. According to a preferred embodiment, the coupling comprises a mechanical joint, whereby a surrounding ring comprising two semicircular parts is brought, by tensioning, to fix the tool to the tool attachment. The tool and the tool attachment are adapted to meet each other with a respective disc with the same diameter. Those edges of the discs which are facing away from each other are chamfered. A coupling comprising a clamping ring with a trapezoidal inner groove is brought to surround the two discs. The trapezoidal surfaces of the grooves grip over the chamfered edges of the discs like a key joint and bring the discs to be pressed against each other when the ring applies a surrounding force around the discs. In one embodiment, the ring halves are equipped with flanges at their ends. A coupling brings the flanges of the two halves against each other, whereby the surrounding force arises. In one embodiment, the coupling is a screw joint and in another an eccentric lock in which a small lever arm first clamps the clamping ring and then fixes it.
[0014] In an additional embodiment, the coupling is in the form of a plurality of studs arranged in one of the plates, which studs penetrate into holes in the other plate. The studs are provided with tapering webs limited by accurately adjusted conical portions. When the studs are inserted into the holes, a pin adapted for each stud is brought, in a plane normal to the stud, to penetrate into and make contact with the web. In a further embodiment, the coupling is a screw joint that directly clamps the two plates together.
[0015] In still another embodiment, the tool attachment comprises a locking device that prevents the hook from loosening. Such a locking device comprises, for example, a pin that is arranged in a direction transversely to the extent of the hook and hence blocks the possibility of the hook to move. In another embodiment, the locking device comprises a catch device which, after the hook has reached its supporting position, is folded out and prevents the supported part from moving.
[0016] In case of special tools, such as, for example, a spot welding gun, fault currents, traversing the manipulator, sometimes arise. These fault currents often lead to damage, above all in bearings. The damage arises as recesses in bearing races and leads to extensive and time-consuming repair work. In an additional embodiment, therefore, the tool is galvanically separated from the manipulator. An insulating barrier is then arranged at the section between the tool and the manipulator. In an advantageous embodiment, this barrier is arranged as a disc of insulating material between the tool and the tool attachment. In another advantageous embodiment, the barrier is arranged as an insulating coupling between the turn disc and the tool attachment.
BRIEF DESCRIPTION OF THE DRAWING
[0017] The invention will be explained in greater detail by description of embodiments with reference to the accompanying drawing, wherein
[0018] FIG. 1 is a device according to the invention comprising a tool attachment, belonging to a manipulator (not shown), said tool attachment having a hook for relieving and a guide pin for guiding, and an only partly shown tool,
[0019] FIG. 2 is an advantageous embodiments of the device with a groove,
[0020] FIG. 3 is another embodiment of the device with two supporting and guide pins penetrating two corresponding “keyholes”,
[0021] FIG. 4 is a further embodiment of the device with a centre stud and a guide pin,
[0022] FIG. 5 is an additional embodiment of the device with a dovetail joint,
[0023] FIG. 6 is still another embodiment of the device with a dovetail joint,
[0024] FIG. 7 is yet another embodiment of the device with a screw joint,
[0025] FIG. 8 is a further embodiment of the invention with studs provided with webs with transverse pins for fixing,
[0026] FIG. 9 is an embodiment of the device with a locking device in the form of a pin preventing the hook from loosening,
[0027] FIG. 10 is an embodiment of the device with a locking device in the form of a catch preventing the hook from loosening,
[0028] FIG. 11 is an embodiment of the device with a locking device in the form of a pin preventing the hook from loosening, and
[0029] FIG. 12 is an embodiment of the device with a locking device in the form of a stud penetrating a hole that prevents the hook from loosening
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] The device according to FIG. 1 comprises a tool attachment 1 that is an integrated part of the outermost arm of a manipulator (not shown) that together with a control system constitutes an industrial robot. Further, the device comprises a tool 2 , which in the figure is exemplified by a circular plate. In the example shown, the tool attachment comprises a slot 3 and a guide spindle 4 . The tool comprises, partly concealed, a hook 5 and a hole 6 . In a first step, the hook 5 is adapted to engage with the slot 3 such that the whole weight of the tool is brought to be supported by the tool attachment. In a second step, the guide spindle 4 is adapted to be inserted into the hole 6 , such that the tool is centred into the right position relative to the operating point of the manipulator. In an advantageous embodiment, the hook exhibits a bent outer part which is brought to hook into the rear side of the slot. In the example the slot has parallel sides with a trumpet-shaped opening to facilitate receiving the hook. However, the groove may, of course, also be slightly conical to assist in centring the tool. Similarly, instead of having a bent outer part, the hook may be provided with a head with a larger diameter than the slot so that this head prevents the hook from sliding through the slot.
[0031] The tool attachment 1 and the tool 2 are shown in the example as circular plates of equal size. Each plate has a chamfered edge so that the plates, when being assembled, exhibit a common trapezoidal edge portion. A clamping ring 7 in two halves 7 a and 7 b are adapted to grip over the trapezoidal edge portion. To this end, the inner side of the clamping ring is designed with a trapezoidal groove with a narrower shape such that, like a key joint, it surrounds the edges of the two discs with clamping force. Thus, when the tool is suspended, such that its weight is supported by the manipulator, and centred, such that the operating point of the tool coincides with the operating point of the manipulator, the coupling is fixed by the clamping ring 7 . The two halves 7 a and 7 b of the clamping ring are pressed against each other with a screw joint or the like.
[0032] The device of FIG. 2 includes the same parts as in FIG. 1 but here the tool attachment 1 comprises a recess that forms a first hook line 8 arranged across the disc. In a corresponding way, the tool comprises a second hook line 9 that is adapted to engage with the first hook line. The hook lines are arranged in this example to form a coupling where, in a first step, the weight of the tool is transferred to the manipulator and where, in a second step, the tool is brought, by sliding between the hook lines, to be centred and finally fixed with the clamping ring 7 .
[0033] The device of FIG. 3 also includes the same parts as in FIG. 1 . In this example, the tool attachment comprises two key-shaped holes 10 a and 10 b . Intended to be inserted into these holes, the tool comprises two studs 11 a and 11 b (concealed in the example), each having a head with a larger diameter than the stud itself. When mounting, the studs are thus inserted into the corresponding holes, whereby the weight is transferred. In a second step, the tool is centred by rotating the tool such that the studs slide into the narrower part of the keyhole. Fixing is performed as above.
[0034] The device of FIG. 4 shows a further embodiment of the invention with the same parts as in FIG. 1 . Here, the tool 2 comprises a supporting member in the form of a coarse stud 12 . For receiving this stud, the tool attachment comprises a hole 13 . In this example, the tool also comprises a guide spindle 14 adapted to penetrate into a hole 15 comprised in the tool attachment. The device shown also comprises an insulating barrier in the form of a disc 24 of an insulating material that galvanically separates the tool from the manipulator. Also the guide spindle and the clamping ring must, in this embodiment, be manufactured of insulating material.
[0035] A further example is the device of FIG. 5 in which the supporting member and the guide member consist of a dovetail joint. Here, the tool attachment comprises a dovetail slot 16 in the form of an elongated recess with a wider bottom than the orifice. The tool comprises a dovetail 17 in the form of a projecting portion with two opposing plane sides, diverging outwardly. The mounting is performed such that the dovetail is introduced from the side into the dovetail slot. When the dovetail has been inserted a certain distance, the manipulator assumes the weight of the tool. Then the tool is moved laterally so as to be centred, whereupon it is fixed. An additional variant of the device with a dovetail joint is shown in FIG. 6 . Here, the parts have the same designations as in FIG. 5 . The difference is that the dovetail joint is only arranged along part of the tool and the tool attachment, respectively. This means that the mounting is made from above.
[0036] The device according to FIG. 7 shows a coupling comprising a plurality of screws 18 that are arranged in holes in the tool and that are each engaged with a threaded hole 19 in the tool attachment. Otherwise, the embodiment corresponds to that shown in FIG. 1 . The supporting of the tool is thus attended to by a hook 5 that engages into the slot 3 . The centring is attended to by a hole 6 provided in the tool, the hole being adapted to receive a guide spindle 4 arranged in the tool attachment.
[0037] FIG. 8 shows the device with a different design of a coupling. Two studs 20 with a trapezoidal web 21 are arranged in the tool attachment. Corresponding holes (concealed) are arranged in the tool. In the same way as in FIG. 1 , the device is provided with a hook 5 and a guide spindle 4 for supporting and centring the tool. During mounting, the studs 20 are inserted into the corresponding holes. The tool comprises a pin 22 arranged on either side and running in a normal plane to holes 23 provided for the studs. Each pin is adapted to penetrate from the side into the stud 20 and to make contact with the web 21 of the stud, thus obtaining fixing.
[0038] For safety reasons it is of great interest that the tool be retained in its lifted position, even if the robot, inadvertently or through malfunction, should happen to rotate the turn disc. FIGS. 9 and 12 show a plurality of embodiments of a locking device that prevent the hook from loosening. FIG. 9 shows a hook 5 that, after having penetrated into the groove 3 , is locked by a pin 25 . In FIG. 10 , the locking device is instead shaped as a catch device 26 that, when being unfolded, grasps the lower edge of the first part 1 . An additional example of a locking device is shown in FIG. 11 where a pin provided with a handle is arranged in a groove where it locks the movement of the hook. Finally, FIG. 12 also shows a further solution where the locking operation is achieved in that a stud 28 in the second part 2 , when fastening the hook 5 , penetrates into a hole 29 in the first part.
[0039] Although advantageous, the invention is not limited to the embodiments shown. Thus, the various parts of the device may, for example, be made from a plurality of different materials. The design of the supporting device, the centring device and the locking device may also adopt various embodiments with regard to design and material choice.
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The invention consists of an industrial robot comprising a control system and a manipulator provided with a tool. The manipulator is provided with a number of moveable arms relative to one another, and an attachment of a tool. The attachment of a tool includes a carrying organ, which carries the tool while assembling. A locking ring locks the tool to the manipulator after centring of the tool. A method of doing the same is also included.
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BACKGROUND OF THE INVENTION
1. Field of Invention
This invention uses multiple observers to passively determine range and bearing to an RF emitter. In particular, it employs ambiguous emitter wavefront phase change measured at each of at least two moving aircraft, and pulse time of arrival measurements made between two platforms to perform the geolocation.
2. Description of Related Art
Applicant's copending application entitled, "COMBINED PHASE-CIRCLE AND MULTIPLATFORM TDOA PRECISION EMITTER LOCATION," filed on even date herewith and assigned to present assignee, the entire disclosure of which is hereby incorporated by reference in this specification, discloses a method for reducing the geometrical dilution of precision (GDOP) degradation experienced when using multiplatform circular lines-of-position for precision emitter location. This was accomplished by combining the circles-of-position (COPs) generated by interferometer phase difference measurements made by one moving platform with hyperbolic lines-of-position (HLOPs) generated by pulse time difference of arrival (TDOA) measurements between two observers. This combined technique overcame low-frequency limitations in the phase-circle-only approach and reduced sensitivity to time of arrival (TOA) measurement errors compared with TDOA-only geolocation. The use of measurements made by a fully resolved short baseline interferometer (SBI) on the moving platform was a key element of the method. For example, the SBI angle-of-arrival (AOA) measurements made by two separate platforms were used to provide an initial coarse location of the emitter. This coarse location was accurate enough to verify that TDOA measurements between observers were being made on the same pulse of the emitter signal. The SBI was also used in more fundamental ways to generate the phase circles, or COPs, as discussed briefly below.
The COPs were produced from long-baseline interferometer differential phase measurements by the method described in the applicant's U.S. Pat. No. 5,526,001. Resolving ambiguous LBI phase requires simultaneously measuring fully resolved phase with the SBI, using the technique disclosed by Kaplan in U.S. Pat. No. 4,734,702.
In this approach for generating phase circles, requirements on the system phase measurement's repeatable accuracy were reduced. This reduction occurred because any fixed-phase bias error present during the receiver dwell at the first observation point canceled when forming the phase difference at the second observation point. Thus, the LBI baseline did not require calibration. Also, constant antenna phase mistrack errors and receiver calibration phase-bias errors canceled and had no impact on COP accuracy. But as a consequence of this method, the LBI measured only angle change, and not AOA. The SBI not only predicted angle change to resolve the LBI, but also provided the measure of AOA required to correct for variable bias errors.
Variable bias errors, i.e., those that remain constant during a receiver dwell but vary from one receiver dwell to another, greatly impact COP precision and, hence, location accuracy, and must be reduced. The most significant variable bias error is due to changes in a scanning radar's electromagnetic wave polarization caused by the observer detecting different emitter sidelobes in different receiver dwells. This dwell-to-dwell polarization change affects the LBI antenna phase mistrack, and can cause in the differential phase measurement an error of five electrical degrees or more. Since the error is constant between all signal pulses used to form the phase difference between dwells, it cannot be reduced by averaging, as can thermal noise and quantization errors. The method to reduce this error disclosed in applicant's copending application, entitled, "COMBINED PHASE-CIRCLE AND MULTIPLATFORM TDOA PRECISION EMITTER LOCATION," contemplates producing a table from antenna polarization response measurements on the observing aircraft for different signal angles-of-arrival. The SBI AOA measurements made when LBI phase differences are formed are then used to access this table for calibration data that corrects the LBI measurements.
Hence, for resolving the long-baseline interferometer, correcting the variable phase bias errors, and confirming the TDOA measurement, the SBI forms an intrinsic part of the approach given in applicant's copending application entitled, "COMBINED PHASE-CIRCLE AND MULTIPLATFORM TDOA PRECISION EMITTER LOCATION." However, many aircraft used to passively locate emitters do not currently have an SBI available. Furthermore, because of weight, cost, and airframe limitations, it may not be feasible to add an SBI to the existing electronic surveillance measurement (ESM) system. Therefore, it is desirable to have an alternative approach to implementing a combined COP-HLOP location technique that preserves the method's GDOP reduction, improved low-frequency performance, and reduced need for TDOA accuracy, while requiring only two antenna elements. This requires that alternatives be found to resolve the phase ambiguity and correct the phase polarization error.
One alternative approach to differentially resolving the LBI is disclosed in applicant's U.S. Pat. No. 5,343,212, and discussed in connection with phase-circle generation in U.S. Pat. No. 5,526,001. A set of emitter positions is postulated, and each used to establish a hypothesis test. The hypothesis test generates a set of potential emitter locations, resolves the LBI in a manner consistent with each of these assumed locations, and utilizes a sequential check over a number of measurements to determine the actual emitter location from the set. While robust, this method requires multiple receiver dwells to eliminate the incorrect emitter locations. In many multiplatform geolocation situations that are tactically important, the emitter may transmit for no more than ten seconds and the number of phase difference measurements made in that interval can be severely limited. Such a small number of measurements may not be sufficient for the hypothesis test to generate a single unambiguous phase circle.
This invention overcomes the limitations of using an SBI or hypothesis test to resolve the LBI at the expense of requiring at least two moving observers to separately generate multiple phase circles from the ambiguous LBI differential phase measurements. A phase circle is produced for each possible ambiguity resolution of the differential measurements. This is illustrated in FIG. 3 for the scenario shown in FIG. 2 208. The COPs 300, 301 and 302 are derived from the ambiguous phase measurements made by observer 308, corresponding to aircraft 206 in FIG. 2 208, while COP 304, 305 and 306 are generated from the ambiguous phase measurements made by aircraft 307 (205 in FIG. 2). COP 301 and 305 are the true emitter circles-of-position, and this is determined by the common intersection 309 with the TDOA hyperbola limb 303. In this example the TDOA is measured between platforms 307 and 308, but other observers could be used. Thus the invention does not attempt to correctly resolve the phase difference measurement ambiguities before generating the phase circles, and hence does not have the problem with sparse data that can degrade the hypothesis test method. In fact, the phase difference ambiguity is not resolved before the emitter is located. This creates difficulties in correcting the LBI phase measurements for variable bias error and overcoming this difficulty is a key aspect of the invention.
The use of the TDOA measurement in conjunction with the ambiguous phase measurements to locate the emitter and then the use of emitter location to resolve the differential phase should be compared with methods that use TDOA to directly resolve the LBI. Cusdin et al. in U.S. Pat. No. 4,797,679 provide an approach representative of such direct techniques. The LBI used in Cusdin's method must be phase calibrated, and the TDOA measurement is made on the same platform between the two antennas used to measure LBI phase. Also the TDOA measurement must be nearly simultaneous with the phase measurement. Cusdin's is thus intrinsically a single platform technique that associates resolved LBI phase with emitter signal AOA. For multiplatform geolocation the resolved AOAs on two platforms could be intersected, as shown in FIG. 1a. In this figure 160 and 161 represent the AOA, while 178 and 179 are the wedge shaped AOA errors, and 162 the uncertainty these errors create in the emitter location. This region of uncertainty grows quickly with range, but an advantage the method does have is that the observers 163 and 165 obtain the range estimate in a single observer dwell.
By contrast to the direct ambiguity resolution of calibrated LBI phase measurements by TDOA in a single receiver dwell, the method disclosed here uses uncalibrated LBI baselines that are differentially resolved across receiver dwells. Hence, as noted above, AOA is not measured and at least two separate receiver dwells made seconds apart, indicated by the moving observer at 165-166 and at 167-168, are required. Also the LBI ambiguities for the phase measurements made on at least two aircraft must be simultaneously resolved, in effect, by locating the emitter utilizing TOA measurements made on separate platforms rather than across the LBI baseline. The TOA measurement does not have to be time coincident with the LBI phase measurements, nor, as emphasized above, do the observers making the TOA measurements have to be the same as those making the differential phase measurements. Thus this invention is intrinsically a multiplatform technique.
The association of the LBI differential phase measurements with COP 169 and 170 in 174 FIG. 1a rather than the LBI phase with AOA 160 and 161 (173 FIG. 1a) provides a substantial reduction in GDOP compared with a multiplatform application of Cusdin's method. Although the magnitude of the COP error region does have a range dependence since it is ultimately based on the bearing subtended at the emitter, the excursions caused by one sigma error variations indicated by 175 and 177 are the same at each point on the respective COPs 169 and 170. Further, since the TDOA measurement is made between platforms rather than between two antenna on a single platform, it provides a third LOP 171 (with range independent one sigma error 175) which greatly reduces the GDOP, as indicated by the emitter location error region 172.
FIG. 1b is a top level block diagram of the invention, illustrating how ambiguous LBI and TDOA measurements are used to geolocate the emitter in the manner indicated by 174 FIG. 1a for the FIG. 2 208 scenario, producing the COP and HLOP as shown in FIG. 3. Aircraft 307 in that figure corresponds to observer 100 FIG. 1a. The system on aircraft 308 corresponds to 102 and is identical to 100. Hence only the utilization of system 100 will be described in detail in the following summary. The central computing site 103 could be located on either aircraft, or on both, or on a third platform.
The operation of these particular features and other aspects of the invention, such as the method for reducing the impact of variable bias errors without making SBI measurements, are presented in more detail in the summary that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a contrasts multiplatform emitter location using TDOA to absolutely resolve the LBI and obtain AOA with the approach of the current invention utilizing phase-circles and TDOA.
FIG. 1b is a schematic representation of the current invention. The method is intrinsically a multiplatform approach in which the ambiguous phase measurements made by one observer can only be resolved by both ambiguous phase measurements made by a second observer, and TDOA measurements between observers.
FIG. 2 shows the scenario used in generating performance given in FIG. 6 that contrasts the invention with TDOA-only and phase-circle-only methods.
FIG. 3 illustrates the creation of multiple phase circles from the ambiguous LBI differential phase measurements, and the intersection of the phase-circles with TDOA hyperbola.
FIG. 4 is a flow diagram showing the various steps in applying the method of the current invention.
FIG. 5 is a block diagram of the preferred embodiment of the current invention.
FIG. 6 shows performance for the current invention for the scenario in FIG. 2.
SUMMARY OF INVENTION
One object of the invention is to associate multiple circles with each set of differential phase measurements made by two uncalibrated and unresolved LBIs on two separate aircraft. Each circle is produced by a different permissible ambiguity resolution of the constant phase difference measurements. Two of these circles, e.g., 301 and 305 FIG. 3, in the absence of random measurement error, pass through the emitter's location.
Another object of this invention is to use TDOA measured between these two aircraft, or other platforms, to form a single common intersection, i.e. 309 FIG. 3, with these two phase-circles at the emitter, and hence to locate the emitter.
Yet another object of the invention is to correctly resolve all the ambiguous LBI phase difference measurements collected at the two aircraft by predicting the ambiguity integer from this initial estimated emitter location.
Still another object of this invention is to calibrate these resolved phases to reduce the dwell-to-dwell variable bias error due to emitter polarization changes without requiring direct AOA measurements.
A further object of this invention is to use the initial emitter location to estimate elevation in order to cone correct the LBI differential phase measurements without requiring direct measurements of emitter elevation.
It is also an object of the invention to generate estimates of the initial and final bearings a 1 and a 2 required to obtain the true azimuth difference without measuring azimuth directly.
A final object of this invention is to use these true azimuth differences along with the TDOA measurements and derived elevation to refine the emitter geolocation estimate.
Referring to FIG. 1b, the LBI baseline is formed by antennas 104, 105 on observer 100. Process 106 indicates the ambiguous LBI phase measurement f m , where ##EQU1## with
d=LBI baseline vector
λ=emitter RF signal wavelength
u=signal DOA unit vector
n=ambiguity interger
b=phase bias
is differenced between receiver dwells 1 and 2 to remove the phase bias error b, giving ##EQU2## as the output 107.
The azimuth difference is found by correcting the phase difference as indicated in Equation 3. This equation is the phase-difference to bearing-change association for the simple case of the aircraft heading (with respect to a North-East-Down local coordinate system) making angles q 1 at dwell 1 and q 2 during dwell 2 with no roll or pitch out of the local level plane, i.e. ##EQU3## Here d is the LBI baseline length, while a 1 , a 2 are the emitter azimuths in the local North-East-Down (NED) reference frame at the first and last dwell. The elevation e is assumed to not change significantly between dwells.
In this invention the ambiguity integer n 2 -n 1 in Equation 3 is resolved or found in process 109 after the emitter is initially located. Hence, as noted above, the invention does not separately resolve the LBI differential phase ambiguities for a single platform alone, and then intersect the resulting unique circles associated with each observer to geolocate the emitter, as would be done if the method of applicant's U.S. Pat. No. 5,526,001 were used for multiplatform geolocation. The initial location does require a TDOA measurement between two platforms, but emitter azimuths a 1 , a 2 and elevation e are not measured.
The method this invention uses to estimate these required quantities and also accomplish the other objectives is shown in FIG. 4. It is essential that ambiguous COP be generated by at least two separate observers, hence steps 400, 401 and 402 indicate the iterative (across observers) nature of the ambiguous differential phase measurement process. In order to associate the differential phase with a bearing change Da and hence with a COP it is necessary to determine the set of possible ambiguity integers m=n 2 -n 1 in Equation 3 by 403 and 404, which occurs in 116 FIG. 1b. The minimum and maximum values for m are determined from knowledge of the radar horizon derived from the observer's altitude. Two assumptions are made. These two assumptions are the smallest angle off the aircraft nose the emitter can lie, and the closest range for the emitter. These two assumptions, and the radar horizon, bound the differential phase ambiguity set of possible integer m. In 405 a separate COP, e.g. 300-302 and 304-306 FIG. 3, is generated for the differential phase measurement resolved by each integer in the set. This is done by finding Da utilizing the general relationship of which Equation 3 is a special case. In doing this the emitter elevation e is assumed to be zero. This assumption is corrected later. To set up the ranging solution the same-pulse TOA must be measured 406 between two observers. This is performed in process 115 FIG. 1b. This measurement can be done at any time relative to the phase measurement. That is, absolutely no coordination is required between the two. The TOA measurements are sent, as are the ambiguous COPs, to the central computing site 103, and the TDOA HLOP, e.g. 303 and 310 FIG. 3, formed 407. This site could be each observer, in which case each observer would determine its own emitter geolocation solution, or the site could be a separate nonobserving aircraft or ground station. The COPs and HLOPS are then simultaneously solved 408 for the emitter location. If there were no system errors this solution would result in a single unique position (309 FIG. 3), except in possible cases where COP-HLOP symmetry gives multiple solutions, such as FIG. 3 311. These cases are easily resolved by emitter amplitude AOA measurements, which can be a byproduct of the amplitude and phase measurements made by 111 FIG. 1b to support emitter polarization estimation. Measurement errors can create further multiple solutions, for example 312 FIG. 3. This case is handled 410-414 by reducing the measurement errors in a way that utilizes the multiple candidate positions. The dominant errors are the coning error due to the assumption of zero elevation and emitter polarization induced phase error. Correcting both errors depends on measuring 112 FIG. 1b emitter signal direction of arrival (DOA). Since the LBI measures only AOA change, DOA must be found 410 from the initial emitter location generated 408 from the uncorrected phase, and the observer position when the phase measurement was made. Once DOA is obtained for each candidate emitter location, the resulting elevation estimate is used to cone correct Da, as indicated in Equation 3. The DOA are also used to predict the LBI phase change, and hence resolve the LBI. The resolved LBI phase is adjusted for phase errors induced by variable emitter polarization utilizing calibration data stored in a table, and accessed as a function of signal DOA. New COP are generated 413 using the separate sets of corrected phase data (one set for each possible emitter location). The new COP and HLOP are iteratively solved 414 in 108 FIG. 1b, i.e the solution is obtained by breaking up the differential phase measurement set up into smaller subsets, and choosing the solution producing the most sequentially uncorrelated or "whitest" estimate residual using an algorithm operating on the principals described by Kailath, "An Innovations Approach to Least Squares Estimation-Part 1: Linear Filtering in Additive White Noise," IEEE Transactions on Automatic Control, vol. AC-13, No. 6. The solution with the whitest residual in this problem is equivalent to the one that iteratively correctly resolves the LBI. This solution is chosen in 409 as the emitter location. A final check is done 415 to verify using the estimated emitter location that the same pulse was used to generate the HLOP. If not, new TOAs must be measured and the whole process repeated.
In performing these steps it is advantageous to have a similar system installed on multiple observers, i.e., 100 and 103 in FIG. 1b, each observer measuring both phase and TOA, as well as performing the intersection calculations and doing phase calibration. Such a single system realization of the preferred embodiment of the invention is described below.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 5, which shows the measurement system located on each observing platform required to make both TDOA and LBI differential phase measurements. In making phase difference measurements with the LBI via antennas 500 and 501, the constant bias errors subtract out across dwells, as discussed above and further described by the applicant in U.S. Pat. No. 5,343,212. For instance, the antennas are shown squinted in FIG. 5, that is, with their boresites not parallel. Such squinted antennas are typical of RWR systems, and it is desirable to utilize the existing antenna installations for RWR systems when implementing this invention. This squint induces a phase measurement bias proportional to the emitter's elevation. But since elevation does not change significantly from dwell to dwell, this error cancels in making the differential measurements. The dominant dwell-to-dwell variable phase measurement error, which does not cancel, is caused by the change in emitter signal polarization when the receiver detects mainbeam, side and backlobes on different dwells. Reducing this error requires simultaneously measuring signal phase and amplitude by the collocated antennas 500, which is a right circularly polarized antenna and 502 which is a left circularly polarized antenna. Model 201600-2 dual circular polarization cavity back sinuous types made by Tecom Industries Inc. allow the simultaneous measurements of right hand circular polarization (RHCP) and left hand circular polarization (LHCP) outputs, and is typical of the type antennas that are used for this purpose. Switch 527 allows the RHCP antenna alone to be used with antenna 501 to form the LBI baseline. Switching from dual polarization to single polarization is done during each receiver dwell to allow polarization measurements to be made when LBI phase measurements are made. The amplitude 504 and phase 505 result from these dual polarization measurements, made by a receiver 503 assumed to have the performance of the Litton Industries' Amecom Division's LR-100 ESM Receiver. That is, the receiver has an amplitude measurement capability to 1.5 dB, and phase resolution accuracy to better than 3 electrical degrees. Emitter polarization is extracted from these phase and amplitude measurements in 506 using well established methods such as that described by Lee, Okubo and Ling in "Polarization Determination Using Two Arbitrarily Polarized Antennas," IEEE Transactions on Antennas and Propagation, vol. 36, no. 5. The emitter polarization, and signal AOA 507 obtained from the initial emitter location generated in the Coarse Location Processor 508, are used to determine the phase correction required from calibration data in 509. The adjusted phases 510 are then used to rederive the phase-circle LOP in the Fine Location Processor 522. The required calibration data stored in 509 is obtained using a full-scale mockup of the actual antenna installation, including radomes. The calibration data encompass the entire frequency band and azimuth-elevation field-of-view.
The high-resolution, but ambiguous, phase measurements made between antennas 500 and 501 by receivers 503 and 512 have the ambiguity differentially resolved by intercepting all ambiguous COP and the HLOP in processor 508 as previously described. In contrast to the approach in the applicant's copending patent application entitled, "Combined Phase-Circle and Multiplatform TDOA Precision Emitter Location," the phase ambiguity is resolved only after the emitter is initially located. This resolution is done in process 514, which uses location input 513 to predict the phase change at the LBI baseline for each measurement update. The technique for doing this was described in the applicant's U.S. Pat. No. 5,343,212 when input 513 consist of several possible emitter locations. For instance, in FIG. 3 the true emitter location 309 and incorrect intersection 312 may both be within system error bounds for candidate location positions. Ambiguity Resolution process 514 compares sequential phase measurement resolved by predicted phase for each location for consistency, and chooses the correct location out of the candidate set accordingly. In the FIG. 3 example, only COP-HLOP intersections in the neighborhood of the true location are indicated as possible multiple locations. The other ambiguous locations are deleted by amplitude comparison AOA 515 generated in 518 by measured signal amplitudes 516 and 517. The amplitude AOA can also aid in providing the basis for determining the set of possible ambiguity integers in process 519. Based on observer altitude and attitude 521 from the navigation system 520 the AOA is partitioned to provide means to predict phase and bound the ambiguity integer set. This integer set is then used to generate the candidate phase circles.
Multiplatform TDOA measurement methods are well established, and in this approach are accomplished as described in applicant's copending application entitled, "Combined Phase-Circle and Multiplatform TDOA Precision Emitter Location." Hence receiver 512 measures TOA with a resolution comparable to that of the Litton Industries Applied Technology Division's Advanced Digital Receiver, that is a resolution of 0.625 nsec. The clock 525 used in making the TOA measurement has the capability of the Westinghouse low-power, cesium cell, miniature atomic clock, that is a one-day stability of 10 -11 second. This clock must be synchronized with a similar clock on the second platform using Data Link 526.
The TOA measurements made on the same pulse are differenced in 508, and, after same TOA pulse check, in 522. This same TOA pulse check consist of using the emitter location produced in 508 to predict pulse TOA windows at each observer, and then verifying the observed pulse was in the window.
The Fine Location Processor 522 combines the confirmed TDOA measurement generated HLOP and the calibrated and resolved phase 510 to produce a refined location estimate. In process 522 the location estimate is obtained using an adaptive optimal filter, which modifies the filter gain in a manner that decorrelates the estimator residual. This produces an accurate error variance estimate for fine location.
In contrast to the method described in the applicant's copending application, "Combined Phase-Circle and Multiplatform TDOA Precision Emitter Location," this estimate does not partake the nature of TDOA-only, phase-circle only, or combined depending on the correctly scaled relative weights of the measurement error variances. It is always a phase-circle and TDOA combined estimate. Hence it is of interest to demonstrate the improved performance obtained over a phase-circle only or TDOA only approach for the same system errors. The TDOA errors include time-of-arrival (TOA) variation due to pulse rise time, video bandwidth and signal strength effects, signal propagation length differences, and receiver measurement variation; aircraft location errors due to GPS measurement variation; and time synchronization variation caused by phase error between the reference clock on each aircraft. The TOA system errors assumed produced a TOA error at each observer with a minimum one sigma statistical variation of 34.7 nsec and a maximum one sigma error of 62.1 nsec. This variation is due mostly to multiplatform clock phasing errors. The phase measurement errors include NAV attitude errors in locating the LBI baseline, antenna vibration induced errors, antenna phase mistrack bias, receiver calibration phase bias, and thermal noise and quantization errors. These errors produced a phase measurement error of 9° (used in coarse location) before polarization calibration and 3° after calibration (used in fine location). FIG. 5 contrast the performance for the two aircraft scenario used to produce the ambiguous COP and HLOP in FIG. 2 208 for both 500 phase-circle only and 502 combined methods with the four aircraft scenario shown in FIG. 2 207 required for 501 TDOA. The errors in the TDOA approach cannot be significantly reduced by averaging, and so do not decrease with time. The accuracy in the phase-circle only approach increases with the bearing difference subtended at the emitter, and hence does improve with time and also with increasing emitter frequency. The low frequency 0.7 GHz performance of the COP-HLOP method shown by 502 is comparable to the high frequency performance of the COP-only approach. This improvement is due to the GDOP reduction the addition of the TDOA LOP provides.
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A method and system for determining the geolocation--i.e., the latitude, longitude, and altitude--of a stationary RF signal emitter from two or more moving observer aircraft. The observers receive signals from the emitter and the system measures the phase difference between the signals. The observers then perform pulse time of arrival (TOA) measurements over a predetermined clock interval, and calculate the time difference of arrival (TDOA) of corresponding, same-pulse, emitter signals. Based on geometric relationships, the system creates a series of circular lines of position (LOPs) for each observer, and computes hyperbolic LOPs based on the TDOA calculations. The system determines emitter location from the intersection of the hyperbolic LOPs and the circular LOPs.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. patent application Ser. No.: 10/364,663, filed Feb. 11, 2003, which application is a continuation under 35 U.S.C. 111(a) of PCT/US01/25175, filed Aug. 10, 2001, which claims priority to U.S. patent application Ser. No. 09/637,531, filed Aug. 11, 2000, and U.S. Provisional Patent Application Ser. No. 60/301,340, filed Jun. 26, 2001, all of which are incorporated by reference herein.
[0002] This invention was made with the assistance of the National Institutes of Health under Grant Nos. GM23200 and CA81534. The U.S. Government has certain rights in this invention.
BACKGROUND OF THE INVENTION
[0003] The cytokines IL-4 and IL-13 interact with receptors on target B cells, and stimulate the production of IgE and other mediators of allergy. However, recent data indicate that IL-4/IL-13 signaling also (1) inhibits apoptosis in malignant B cells and other cancer cells, (2) prevents the rejection of tumors by the body, (3) promotes the survival of fibroblasts and therefore increases fibrosis, and (4) stimulates the differentiation of antigen-presenting cells.
[0004] The STAT4 and STAT6 genes encode transcription factors that when phosphorylated by Janus kinases are activated and transported to the nucleus where they regulate cytokine-induced gene expression. See, e.g., J. T. Ihle, Stem Cells Suppl., 1, 105 (1997); M. Heim, J. Recept. Signal. Transduction Res., 19, 75 (1999); K. S. Liu et al., Curr. Opin. Immunol., 10, 271 (1998). For example, STAT-6 is the common transcription factor for IL-4 and IL-1 3.
[0005] STAT4 and STAT6 are essential for the development of CD4 + Th1 and Th2 development, respectively. Tumor immunologists have hypothesized that Th1 cells are critical in tumor immunity because they facilitate differentiation of CD8 + T cells, which are potent anti-tumor effectors. S. Ostrand-Rosenberg et al., J. Immunol., 165, 6015 (2000) used STAT4 −/− and STAT6 −/− mice to test this hypothesis. BALB/c and knockout mice were challenged in the mammary gland with the highly malignant and spontaneously metastatic BALB/c-derived 4T1 mammary carcinoma. Primary tumor growth and metastatic disease were reduced in STAT6 −/− mice relative to BALB/c and STAT4 −/− mice. Ab depletions demonstrated that the effect is mediated by CD8 + T cells, and immunized STAT6 −/− mice had higher levels of 4T1-specific CTL than BALB/c or STAT4 −/− mice. Th1 or Th2 cells were not involved, because CD4 depletion did not diminish the anti-tumor effect. Therefore, deletion of the STAT6 gene facilitates development of potent anti-tumor immunity via a CD4 + -independent pathway.
[0006] Sumitumo Pharmaceutical Co. (published Japanese Patent Application, JP 1997/000288026) discloses certain imidazo [2,1-b]thiazole derivatives that are capable of inhibiting STAT-6. The compounds are disclosed to be useful for the treatment and prevention of allergic diseases and parasitic infectious diseases. However, a continuing need exists for small molecules that can inhibit STAT-6 and thus, inhibit IL-4 and IL-13 signal transduction. Such compounds can be used therapeutically as discussed hereinbelow.
[0007] In addition, there is a need for novel, potent, and selective agents to prevent detrimental effects upon cells due to DNA damage, such as caused by chemotherapy, radiation, ischemic event, including ischemia-reperfusion injury and organ transplantation, and the like. There is also a need for pharmacological tools for the further study of the physiological processes associated with intracellular DNA damage.
[0008] p53, the product of the p53 tumor suppressor gene, is a multifunctional tumor suppressor protein, involved in the negative control of cell growth. In response to a variety of stressors, p53 induces growth arrest or apoptosis, thereby eliminating damaged and potentially dangerous cells. T. M. Gottleib et al., Biochim. Biophys. Acta, 1287, 77 (1996). Mutations in the p53 gene are frequently associated with the metastatic stage of tumor progression, and lack of functional p53 is accompanied by rapid tumor progression, resistance to anti-cancer therapy and increased tumor angiogenesis. See, e.g., A. J. Levine et al., Br. J. Cancer, 69, 409 (1994); R. J. Steele et al., Br. J. Surg., 85, 1460 (1998); C. Cordon-Cardo et al., Surg. Oncol., 13, 319 (1997). p53 deficiency in mice is associated with a high frequency of spontaneous cancers. L. A. Donehower et al., Nature, 356, 215 (1992); T. Jacks et al., Curr. Biol., 4, 1 (1994). On the basis of these reports, the inactivation of p53 was viewed as an unfavorable event, and it has been speculated that cancer can be inhibited by restoration of p53 function.
[0009] A continuing need exists for compounds that can protect mammalian cells from the damaging effects of chemotherapy and irradiation, or in other situations in which it is desirable to protect tissue from the consequences of clinical or environmental stress.
SUMMARY OF THE INVENTION
[0010] The present invention provides compounds that act to inhibit the activity of STAT-6 in mammalian cells, and a method to effectively inhibit signal transduction through the IL-4 and IL-13 pathways, in vitro or in vivo, in the cells of a mammal, such as a human, subject to pathology that is ameliorated by such inhibition. Accordingly, there is provided a method of suppression comprising administering to a mammal in need of said suppression an effective amount of a compound of formula (I):
wherein R 1 , R 2 and R 3 are independently hydrogen, halo, hydroxy, cyano, N(R a )(R b ), S(R a ), NO 2 , (C 1 -C 6 )alkyl, (C 2 -C 6 )alkoxy, (C 2 -C 6 )alkynyl, (C 2 -C 6 )alkenyl, (C 2 -C 7 )alkanoyl, (C 2 -C 7 )alkanoyloxy, or (C 3 -C 7 )cycloalkyl or R 1 and R 2 taken together are benzo, optionally substituted by R 1 , or are (C 3 -C 5 )alkylene or methylenedioxy; wherein R a and R b are each independently hydrogen, (C 2 -C 3 )alkyl, (C 2 -C 4 )alkanoyl, phenyl, benzyl, or phenethyl; or R a and R b together with the nitrogen to which they are attached are a 5-6 membered heterocyclic ring, preferably a pyrrolidino, piperidino or morpholino ring;
[0011] Ar is aryl, heteroaryl, or a 5-6 membered heterocyclic ring, preferably comprising 1-3 N(R a ), non-peroxide O or S atoms, such as a pyrrolidino, piperidino or morpholino ring, optionally substituted with 1-5, preferably 1-2, halo, CF 3 , hydroxy, CN, N(R a )(R b ), (C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, (C 2 -C 7 )alkanoyl, (C 2 -C 7 )alkanoyloxy, (C 3 -C 7 )cycloalkyl, (C 2 -C 6 )alkanoyl, (C 2 -C 6 )alkenyl, or phenyl;
[0012] Y is oxy (—O—), S(O) 0-2 , Se, C(R 1 )(R 3 ), N(R a ), or —P—;
[0013] or a pharmaceutically acceptable salt thereof.
[0014] Preferably, Ar is not substituted with halo or alkoxy. Preferably, Ar is heteroaryl or a heterocyclic ring. Preferably, R 1 and R 2 are not benzo or (C 3 -C 5 )alkylidenyl when Ar is aryl, e.g., is phenyl or napthyl. Novel compounds of formula (I) are also within the scope of the present invention, e.g., preferably Y is —O—, —Se—, C(R 1 )(R 3 ) or P. Preferably, Ar is heteroaryl. Preferably, Ar is substituted with CN, (C 2 -C 7 )alkanoyl), (C 2 -C 7 )alkanoyloxy, (C 3 -C 7 )cycloalkyl, (C 2 -C 6 )alkenyl or combinations thereof. Preferably, R 1 , R 2 and R 3 are independently, OH, CN (N(R a )(R b ), S(R a ), NO 2 , (C 2 -C 7 )alkanoyl, or (C 2 -C 7 )alkanoyloxyl.
[0015] The present method also provides a therapeutic method comprising suppressing STAT-6 or the IL-4/IL- 13 pathways in mammalian cells in vitro or in vivo, and thus treating a pathological condition ameliorated by said suppression, comprising administering to a mammal in need of said suppression an effective amount of a compound of formula (II):
wherein R 1 , R 2 and R 3 as well as Ar are defined as above; R 4 is the same as, but independent from, R 1 , R 2 and R 3 . R 4 in combination with R 1 can also be benzo, C 3 -C 5 alkylidene or methylenedioxy. These compounds are imidazo[1,2-a]-quinazolines.
[0016] Compounds of formula (II) also include (IIa) and (IIb):
wherein R 1 , R 2 , R 3 and R 4 are as defined herein. Novel compounds of formulae II, IIa and IIb are also within the scope of the invention. Preferably, R 4 is not OH in IIa or IIb, e.g., where R 1 and R 2 or R 1 and R 4 are benzo. In compounds of formula II, R 1 and R 2 are preferably not benzo when Ar is phenyl.
[0017] The present invention also includes compounds of formula III:
wherein R 1 , R 2 and R 4 , as well as Ar are defined as herein, for formula (I).
[0018] Also included within the invention are methods of using compounds of formula III in amounts effective to suppress STAT-6 or the IL-4/IL-13 pathways in mammalian cells, and thus to provide treatment for a mammal afflicted by a pathology ameliorated by said suppression.
[0019] Compounds of formula (IV) are also included in the invention:
wherein R 1 , R 2 and R 4 , as well as Ar are defined as above, for formula (II), as well as methods for their use to treat conditions ameliorated by a suppression of STAT-6 or by inhibition of signal transduction through the IL-4/IL-13 pathways in mammalian cells in vitro or in vivo. Preferably, R 1 and R 2 are not benzo when R 4 is H or OH.
[0020] Compounds of formula (V) are also included in the invention:
wherein R 1 , R 2 , R 3 and R 4 as well as Ar are defined as above, for formula (II), as well as methods for their use as discussed above. Preferably, Ar is not 4-methoxyphenyl when R 1 , and R 2 are benzo and R 4 is H.
[0021] Compounds of formulae (I)-(V) are small molecule antagonists of IL-4/IL-13 signal transduction in mammalian cells in vitro and in vivo. These molecules can inhibit the survival of malignant B cells and sensitize them to other chemotherapeutic agents, but are relatively nontoxic to normal lymphocytes. Antibodies to IL-4 and IL-13 receptors and to other receptors are in clinical trials. However, IL-4 and IL-13 have redundant activities, and thus blocking only one of them is insufficient in many instances. Preferred compounds (I)-(IV) can block both IL-4 and IL-13 signaling. They may act by inhibiting expression of the STAT-6 gene, and thus by inhibiting STAT-6, the common transcription factor for IL-4 and IL-13. They can be useful to treat cancer, fibrotic diseases and inflammatory diseases.
[0022] More specifically, compounds (I)-(V) may be useful for:
1. Treatment of leukemia, lymphoma, and other cancers expressing IL-4 and/or IL-13 receptors (e.g., gliomas and head and neck cancers). 2. Sensitization of cancer cells to monoclonal antibodies and chemotherapeutic agents. 3. Use in vaccines against cancer and viral diseases to increase cytotoxic T cell responses. 4. Treatment of proliferative fibrotic diseases, such as rheumatoid arthritis, pulmonary fibrosis, liver cirrhosis, and chronic kidney diseases.
[0027] IL-4 and IL-13 are known to be essential for asthma and allergies. T. Akimoto et al., J. Exp. Med., 182 1537 (1998) report that STAT-6 deficient mice, which cannot respond to IL-4/IL-13, also do not develop allergic asthma.
[0028] M. Dancescu et al., J. Exp. Med., 176, 1319 (1992) and U. Kapp, J. Exp. Med., 189, 1939 (1999) report that IL-4 and IL-13 are survival factors for malignant cells in chronic lymphocytic leukemia and Hodgkin's disease (a form of lymphoma). Thus, the present compounds should be useful for treatment of these diseases.
[0029] K. Kawakami et al., Cancer Res., 60, 2981 (2000) reports the expression of IL-4 receptors in head and neck cancer, melanoma, breast cancer, ovary cancer, neuroblastomas, renal carcinomas. The present compounds thus can be useful for treatment of these cancers.
[0030] M. Terabe et al., Nature/Immunol., 1, 516 (2000) and S. Ostrand-Rosenberg, cited above, report the remarkable finding that lack of STAT-6 signaling promoters immune rejection of cancers. Thus, the claimed compounds can be used in cancer vaccines and/or with monoclonal antibodies to enhance their immunologic effects.
[0031] U. Muller-Ladner et al., J. Immunol., 164, 3894 (2000) reported that the IL-4 pathway is active in the fibroblasts that show unrestrained growth in the joints of patients with rheumatoid arthritis. Similar outgrowth of fibroblasts is seen in pulmonary fibrosis, cirrhosis, renal diseases, scleroderma. The present compounds can be useful in all these conditions.
[0032] The invention also provides pharmaceutical compositions comprising novel compounds of formula (I)-(V), or a pharmaceutically acceptable salt thereof, in combination with a pharmaceutically acceptable diluent or carrier.
[0033] The invention also provides novel compounds of formula (I), or a pharmaceutically acceptable salt thereof, in combination with a pharmaceutically acceptable diluent or carrier. Such compounds can be represented by compounds of formula (I), with the proviso that when Y is S, Ar is not phenyl (C 6 H 5 ).
[0034] Additionally, the invention provides a therapeutic method for preventing or treating a pathological condition or symptom in a mammal, such as a human, wherein the activity of STAT-6 or IL-4/IL-1 3-mediated signal transduction is implicated and antagonism or suppression of their action is desired, comprising administering to a mammal in need of such therapy, an effective amount of one or more compounds of formula (I)-(V), or a pharmaceutically acceptable salt thereof. Such pathological conditions or symptoms include treatment of cancers expressing IL-4 and/or IL-13 receptors, sensitization of cancer cells to chemotherapy or radiation, increasing T c cell responses and the treatment of proliferative fibrotic disease.
[0035] The invention provides a compound of formula (I)-(V) for use in medical therapy as well as the use of a compound of formula (I)-(V) for the manufacture of a medicament for the treatment of a pathological condition or symptom in a mammal, such as a human, which is associated with STAT-6 activation, activation of the IL-4 and/or IL-13 pathways, or p53-induced cellular damage, i.e., with unwanted apoptosis.
[0036] The invention also includes a method for binding a compound of formula (I)-(V) to cells and biomolecules comprising IL-4 and/or IL-13 receptors, in vivo or in vitro, comprising contacting said cells or biomolecules with an amount of a compound of formula (I)-(V) effective to bind to said receptors. Cells or biomolecules comprising ligand-bound IL-4/IL-13 receptor sites can be used to measure the selectivity of test compounds for specific receptor subtypes, or can be used as a tool to identify potential therapeutic agents for the treatment of diseases or conditions associated with IL-4/IL-13 pathway activation, by contacting said agents with said ligand-receptor complexes, and measuring the extent of displacement of the ligand and/or binding of the agent, by methods known to the art.
[0037] In another embodiment, the present invention provides a compound of formula (I)-(V) that act to suppress p53 activity in mammalian cells, and a method to effectively suppress p53 activity in the cells of a mammal subject to a stress or pathology that is ameliorated by such suppression. Accordingly, there is provided a method of p53 suppression comprising administering to a mammal in need of said suppression an effective amount of a compound of formula (I)-(V).
[0038] The invention also provides novel p53 suppressor compounds, as well as pharmaceutical compositions comprising novel compounds of formula (I)-(V), or a pharmaceutically acceptable salt thereof, in combination with a pharmaceutically acceptable diluent or carrier. Such compounds can be represented by compounds of formula (I), with the proviso that when Y is S, Ar is not phenyl (C 6 H 5 ).
[0039] Additionally, the invention provides a therapeutic method for preventing or treating a pathological condition or symptom in a mammal, such as a human, wherein the activity of p53 is implicated and antagonism or suppression of its action is desired, comprising administering to a mammal in need of such therapy, an effective amount of a compound of formula (I)-(V), or a pharmaceutically acceptable salt thereof. Such pathological conditions or symptoms include blocking, moderating or reversing the deleterious effects of chemotherapeutic agents, particularly those which damage DNA; radiation, particularly radiation therapy (gamma-, beta- or UV-radiation), ischemic event, including stroke, infarct, ischemia-reperfusion injury and ischemia due to organ, tissue or cell transplantation; environmental pollution or contamination and the like.
[0040] The invention also includes a method for binding a compound of formula (I) to cells and biomolecules comprising p53 receptors, in vivo or in vitro, comprising contacting said cells or biomolecules with an amount of a compound of formula (I) effective to bind to said receptors. Cells or biomolecules comprising ligand-bound p53 receptor sites can be used to measure the selectivity of test compounds for specific receptor subtypes, or can be used as a tool to identify potential therapeutic agents for the treatment of diseases or conditions associated with p53 activation, by contacting said agents with said ligand-receptor complexes, and measuring the extent of displacement of the ligand and/or binding of the agent, by methods known to the art.
[0041] As used herein, the term “p53” or “p53 activity” refers to p53 protein. The invention is believed to work by temporarily suppressing expression of the p53 gene and/or activity of p53 protein.
BRIEF DESCRIPTION OF THE FIGURES
[0042] FIG. 1 depicts the effects of IBT and PFT-α on B-CLL viability.
[0043] FIG. 2 depicts the protective effect of IBT against spontaneous apoptosis and against fludarabine-induced apoptosis.
[0044] FIG. 3 shows the ability of the various compounds to block the expression of a STAT-6 dependent reporter gene.
[0045] FIG. 4 shows the ability of compounds of the invention to reduce the survival of malignant B cells from a patient with chronic lymphocytic leukemia maintained in tissue culture for 72 hours.
[0046] FIG. 5 shows the structures of compounds numbered in FIGS. 3-4 . Compound 1 is IBT (control).
DETAILED DESCRIPTION
[0047] The following definitions are used, unless otherwise described: halo is fluoro, chloro, bromo, or iodo. Alkyl, alkoxy, alkenyl, alkynyl, etc. denote both straight and branched groups; but reference to an individual radical such as “propyl” embraces only the straight chain radical, a branched chain isomer such as “isopropyl” being specifically referred to. Aryl denotes a phenyl radical or an ortho-fused bicyclic carbocyclic radical having about nine to ten ring atoms in which at least one ring is aromatic. Heteroaryl encompasses a radical attached via a ring nitrogen or carbon of a monocyclic aromatic ring containing five or six ring atoms consisting of carbon and one to four heteroatoms each selected from the group consisting of non-peroxide oxygen, sulfur, and N(X) wherein X is absent or is H, O, (C 1 -C 4 )alkyl, phenyl or benzyl. Heteroaryl also includes a radical of an ortho-fused bicyclic heterocycle of about eight to ten ring atoms, particularly a benzo-derivative or one derived by fusing a propylene, trimethylene, or tetramethylene diradical thereto. Preferred heteroaryls include pyridin-4-yl and thiophen-2-yl. The term “heterocyclic ring” “heterocycle,⇄ or “heterocycyl,” is defined as above for formula (I).
[0048] It will be appreciated by those skilled in the art that compounds of the invention having a chiral center may exist in and be isolated in optically active and racemic forms. Some compounds may also exhibit polymorphism. It is to be understood that the present invention encompasses any racemic, optically active, polymorphic, or steroisomeric form, or mixtures thereof, of a compound of the invention, which possess the useful properties described herein, it being well known in the art how to prepare optically active forms (for example, by resolution of the racemic form by recrystallization techniques, by synthesis from optically active starting materials, by chiral synthesis, or by chromatographic separation using a chiral stationary phase) and how to determine STAT-6 suppression activity using the standard tests described herein, or using other similar tests which are well known in the art. When R 4 is OH, enol or keto forms of compounds (II)-(V) are also within the scope of the invention, wherein the adjacent N may be replaced by N(R a ).
[0049] Specific and preferred values listed below for radicals, substituents, and ranges, are for illustration only; they do not exclude other defined values or other values within defined ranges for the radicals and substituents.
[0050] Specifically, (C 1 -C 6 )alkyl can be methyl, ethyl, propyl, isopropyl, butyl, iso-butyl, sec-butyl, pentyl, 3-pentyl, or hexyl; (C 3 -C 7 )cycloalkyl can be cyclopropyl, cyclobutyl, cyclopentyl, or cyclohexyl; the term cycloalkyl includes (cycloalkyl)alkyl of the designated number of carbon atoms; (C 3 -C 5 )cycloalkyl(C 2 -C 4 )alkyl can be cyclopropylmethyl, cyclobutylmethyl, cyclopentylmethyl, cyclohexylmethyl, 2-cyclopropylethyl, 2-cyclobutylethyl, 2-cyclopentylethyl, or 2-cyclohexylmethyl; (C 1 -C 6 )alkoxy can be methoxy, ethoxy, propoxy, isopropoxy, butoxy, iso-butoxy, sec-butoxy, pentoxy, 3-pentoxy, or hexyloxy; (C 2 -C 6 )alkenyl can be vinyl, allyl, 1-propenyl, 2-propenyl, 1-butenyl, 2-butenyl, 3-butenyl, 1-pentenyl, 2-pentenyl, 3-pentenyl, 4-pentenyl, 1-hexenyl, 2-hexenyl, 3-hexenyl, 4-hexenyl, or 5-hexenyl; (C 2 -C 6 )alkynyl can be ethynyl, 1-propynyl, 2-propynyl, 1-butynyl, 2-butynyl, 3-butynyl, 1-pentynyl, 2-pentynyl, 3-pentynyl, 4-pentynyl, 1-hexynyl, 2-hexynyl, 3-hexynyl, 4-hexynyl, or 5-hexynyl; (C 2 -C 7 )alkanoyl can be acetyl, propanoyl or butanoyl; halo(C 1 -C 6 )alkyl can be iodomethyl, bromomethyl, chloromethyl, fluoromethyl, trifluoromethyl, 2-chloroethyl, 2-fluoroethyl, 2,2,2-trifluoroethyl, or pentafluoroethyl; hydroxy(C 1 -C 6 )alkyl can be hydroxymethyl, 1-hydroxyethyl, 2-hydroxyethyl, 1-hydroxypropyl, 2-hydroxypropyl, 3-hydroxypropyl, 1-hydroxybutyl, 4-hydroxybutyl, 1-hydroxypentyl, 5-hydroxypentyl, 1-hydroxyhexyl, or 6-hydroxyhexyl; (C 1 -C 6 )alkoxycarbonyl can be methoxycarbonyl, ethoxycarbonyl, propoxycarbonyl, isopropoxycarbonyl, butoxycarbonyl, pentoxycarbonyl, or hexyloxycarbonyl; (C 1 -C 6 )alkylthio can be methylthio, ethylthio, propylthio, isopropylthio, butylthio, isobutylthio, pentylthio, or hexylthio; (C 2 -C 6 )alkanoyloxy can be acetoxy, propanoyloxy, butanoyloxy, isobutanoyloxy, pentanoyloxy, or hexanoyloxy; aryl can be phenyl, indenyl, or naphthyl; and heteroaryl can be furyl, imidazolyl, triazolyl, triazinyl, oxazoyl, isoxazoyl, thiazolyl, isothiazoyl, pyrazolyl, pyrrolyl, pyrazinyl, tetrazolyl, pyridyl, (or its N-oxide), thienyl, pyrimidinyl (or its N-oxide), indolyl, isoquinolyl (or its N-oxide) or quinolyl (or its N-oxide).
[0051] A specific value for R 1 and R 2 is hydroxy, cyano, N(R a )(R b ), S(R a ), NO 2 , (C 2 -C 7 )alkanoyl, or (C 2 -C 7 )alkanoyloxy
[0052] A specific value for R 1 and R 2 together is butylene or benzo.
[0053] A specific value for R 1 and R 4 together is butylene or benzo.
[0054] A specific value for R 3 is H.
[0055] A specific value for R 4 is H.
[0056] A specific value for Ar is aryl or heteroaryl, optionally substituted with 1-5, preferably 1-2, halo, CF 3 , hydroxy, CN, N(R a )(R b ), (C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, (C 2 -C 7 )alkanoyl, (C 2 -C 7 )alkanoyloxy, (C 3 -C 7 )cycloalkyl, (C 2 -C 6 )alkanoyl, (C 2 -C 6 )alkenyl, or phenyl.
[0057] A specific value for Ar is heteroaryl or phenyl substituted with CN, (C 2 -C 7 )alkanoyl, (C 2 -C 7 )alkanolyoxy, (C 2 -C 7 )cycloalkyl or (C 2 -C 6 )alkenyl.
[0058] A specific value for Ar is phenyl, 2,3 or 4-pyridyl or 2-thienyl; pyrrolidino, piperidino or morpholino.
[0059] A more specific value for Ar is phenyl, 4-pyridyl or 2-thienyl.
[0060] A specific value for Y is oxy (—O—), S(O) 0-2 , C(R 1 )(R 3 ), N(R a ), or —P—.
[0061] A specific value for Y is S, O, N(R a ), or —P—.
[0062] A specific value for Y is P, Se, SO, SO 2 or C(R 1 )(R 3 ).
[0063] A specific value for Y is P, Se, S(O) or SO 2 .
[0064] A more specific value for Y is S, O, or NH 2 ,
[0065] A specific value for N(R a )(R b ) is amino.
[0066] A specific value for N(R a )(R b ) is pyrrolidino, piperidino or morpholino.
[0067] A specific value for halo is Br or F.
[0068] Processes for preparing compounds of formula (I) are provided as further embodiments of the invention and are illustrated by the procedures disclosed below in which the meanings of the generic radicals are as given above unless otherwise qualified.
[0069] Intermediates useful for preparing compounds of formula (I), are also within the scope of the present invention.
[0070] The present invention is based on the discovery that PFT-α is both cytotoxic to mammalian cells and unstable in aqueous solution under in vivo conditions. PFT-α undergoes spontaneous ring closure in protic solvents, such as alkanols, to form the imidazo[2,1-b]benzothiazole derivative, abbreviated IBT, as shown in Scheme 1.
[0071] Biological evaluation, described below, demonstrated that IBT is actually responsible for the observed p53 inhibition observed by Komarov et al. ( Science, 285, 1733 (1999)). Thus, since IBT and compounds of formula (I) are expected to be both less toxic and more stable than imino compounds such as PFT-α, they are desirable agents for protection of mammalian cells against a wide variety of stressors, including therapeutic agents, and clinical and environmental trauma.
[0072] Compounds of formula (I) can be readily prepared as disclosed by Singh et al., Indian J. Chem., 14B, 997 (1976), as shown in Scheme 2.
[0073] In Scheme 2, a suitable 2-aminobenzothiazole derivative is reacted with an alpha-haloketone in refluxing ethanol resulting in alkylation and ring closure in one single step. An example for the pyridinyl-substituted derivative is given below:
In Scheme 2, the reaction of 1 and 4 can be carried out simply by combining the compounds in a suitable aprotic solvent such as benzene. The conversion of compound 1 to compound 3 can also be accomplished in one step by refluxing 1 and the phenacyl bromide 4 in ethanol.
[0074] Singh et al. used starting materials wherein R 1 and R 2 together are —(CH 2 ) 4 — or —CH(CH 3 )—(CH 2 ) 3 — and Ar is substituted phenyl. Recently, Sumitomo Pharmaceutical Co. Ltd. (Japanese Pat. No. 11-29475) (1999)) disclosed the preparation of certain compounds of formula 2, wherein R 3 is H and Ar is substituted phenyl, and Japanese Pat. No. 11-106340 (1999) disclosed the preparation of certain compounds of formula 3 wherein Ar is substituted phenyl or napthyl and R 1 and R 2 can be, inter alia, H, alkylene or benzo. Compounds of formula 1 were prepared according to Scheme 3.
The compounds of formula (I) are disclosed to be useful for “the treatment and prevention of allergic disease and parasitic infectious diseases, or the like.”
[0075] Certain of the compounds of formula (I) are useful as intermediates to prepare other compounds of formula (I), as would be recognized by the art.
[0076] Compounds of formulae (II)-(V) can be prepared as generally described in PCT/WO97/42192; U.S. Pat. No. 4,020,062, Armianianskii Khim. Zhuv., 43, 245 (1990); Coppola et al., J. Org. Chem., 41, 825 (1976) (II); M. A. Likhale et al., J. Ind. Chem. Soc., 69, 667 (1992); K. T. Potts et al., J. Org. Chem., 35, 3448 (1970); J. E. Francis et al., J. Med. Chem., 34, 281, 2899 (1991) (IV) and A. Guieflier, J. Het. Chem., 27, 421 (1990) (V).
[0077] A general method for preparation of imidazo[1,2-a]quinazolines of formula (II) is found in Coppola, et al., wherein a functionalized isatoic anhydride is first alkylated with the alpha-haloketone and then condensed with a suitable thiopseudourea, as shown below for a pyridinyl derivative:
[0078] A procedure reported by R. Heckendorn et al., Helv. Chim. Acta, 63, 1 (1980) can be used to prepare the 2-aryl-substituted 1,2,4-triazolo[1,5-a]quinazolines wherein a 2-hydrazinobenzoic acid is condensed with an appropriate N-cyanoimidate ester as shown below:
[0079] A suitable procedure by Francis, et al., cited above, is used to obtain aryl substituted 1,2,4-triazolo[1,5-c]quinazolines of formula (IV), wherein an appropriate anthranilonitrile is converted to the corresponding carbamate by reaction of the nitrile with ethyl carbonate in the presence of sodium ethoxide, followed by condensation with a suitable aryl carbohydrazide or heteroaryl carbohydrazide as shown below:
[0080] Imidazo[1,2-c]quinazolines of formula (V) may be prepared according to the procedure outlined by Gueffier, et al., wherein a 4-aminoquinazoline is reacted with a bromomethyl aryl ketone in refluxing ethanol. Heteroaryl ketones may also be used as shown below for a pyridinyl derivative:
[0081] In cases where compounds are sufficiently basic or acidic to form stable nontoxic acid or base salts, administration of the compounds as salts may be appropriate. Examples of pharmaceutically acceptable salts are organic acid addition salts formed with acids which form a physiological acceptable anion, for example, tosylate, methanesulfonate, acetate, citrate, malonate, tartarate, succinate, benzoate, ascorbate, α-ketoglutarate, and α-glycerophosphate. Suitable inorganic salts may also be formed, including hydrochloride, sulfate, nitrate, bicarbonate, and carbonate salts.
[0082] Pharmaceutically acceptable salts may be obtained using standard procedures well known in the art, for example, by reacting a sufficiently basic compound such as an amine with a suitable acid affording a physiologically acceptable anion. Alkali metal (for example, sodium, potassium or lithium) or alkaline earth metal (for example, calcium) salts of carboxylic acids can also be made.
[0083] The compounds of formula (I)-(V) can be formulated as pharmaceutical compositions and administered to a mammalian host, such as a human cancer patient, in a variety of forms adapted to the chosen route of administration, i.e., orally or parenterally, by intravenous, intramuscular, topical or subcutaneous routes.
[0084] Thus, the present compounds may be systemically administered, e.g., orally, in combination with a pharmaceutically acceptable vehicle such as an inert diluent or an assimilable edible carrier. They may be enclosed in hard or soft shell gelatin capsules, may be compressed into tablets, or may be incorporated directly with the food of the patient's diet. For oral therapeutic administration, the active compound may be combined with one or more excipients and used in the form of ingestible tablets, buccal tablets, troches, capsules, elixirs, suspensions, syrups, wafers, and the like. Such compositions and preparations should contain at least 0.1% of active compound. The percentage of the compositions and preparations may, of course, be varied and may conveniently be between about 2 to about 60% of the weight of a given unit dosage form. The amount of active compound in such therapeutically useful compositions is such that an effective dosage level will be obtained.
[0085] The tablets, troches, pills, capsules, and the like may also contain the following: binders such as gum tragacanth, acacia, corn starch or gelatin; excipients such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid and the like; a lubricant such as magnesium stearate; and a sweetening agent such as sucrose, fructose, lactose or aspartame or a flavoring agent such as peppermint, oil of wintergreen, or cherry flavoring may be added. When the unit dosage form is a capsule, it may contain, in addition to materials of the above type, a liquid carrier, such as a vegetable oil or a polyethylene glycol. Various other materials may be present as coatings or to otherwise modify the physical form of the solid unit dosage form. For instance, tablets, pills, or capsules may be coated with gelatin, wax, shellac or sugar and the like. A syrup or elixir may contain the active compound, sucrose or fructose as a sweetening agent, methyl and propylparabens as preservatives, a dye and flavoring such as cherry or orange flavor. Of course, any material used in preparing any unit dosage form should be pharmaceutically acceptable and substantially non-toxic in the amounts employed. In addition, the active compound may be incorporated into sustained-release preparations and devices.
[0086] The active compound may also be administered intravenously or intraperitoneally by infusion or injection. Solutions of the active compound or its salts can be prepared in water, optionally mixed with a nontoxic surfactant. Dispersions can also be prepared in glycerol, liquid polyethylene glycols, triacetin, and mixtures thereof and in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
[0087] The pharmaceutical dosage forms suitable for injection or infusion can include sterile aqueous solutions or dispersions or sterile powders comprising the active ingredient which are adapted for the extemporaneous preparation of sterile injectable or infusible solutions or dispersions, optionally encapsulated in liposomes. In all cases, the ultimate dosage form should be sterile, fluid and stable under the conditions of manufacture and storage. The liquid carrier or vehicle can be a solvent or liquid dispersion medium comprising, for example, water, ethanol, a polyol (for example, glycerol, propylene glycol, liquid polyethylene glycols, and the like), vegetable oils, nontoxic glycerol esters, and suitable mixtures thereof. The proper fluidity can be maintained, for example, by the formation of liposomes, by the maintenance of the required particle size in the case of dispersions or by the use of surfactants. The prevention of the action of microorganisms can be brought about by various antibacterial and antifungal agents, for example, parabens, chlorobutanol, phenol, sorbic acid, thimerosal, and the like. In many cases, it will be preferable to include isotonic agents, for example, sugars, buffers or sodium chloride. Prolonged absorption of the injectable compositions can be brought about by the use in the compositions of agents delaying absorption, for example, aluminum monostearate and gelation.
[0088] Sterile injectable solutions are prepared by incorporating the active compound in the required amount in the appropriate solvent with various of the other ingredients enumerated above, as required, followed by filter sterilization. In the case of sterile powders for the preparation of sterile injectable solutions, the preferred methods of preparation are vacuum drying and the freeze drying techniques, which yield a powder of the active ingredient plus any additional desired ingredient present in the previously sterile-filtered solutions.
[0089] For topical administration, the present compounds may be applied in pure form, i.e., when they are liquids. However, it will generally be desirable to administer them to the skin as compositions or formulations, in combination with a dermatologically acceptable carrier, which may be a solid or a liquid.
[0090] Useful solid carriers include finely divided solids such as talc, clay, microcrystalline cellulose, silica, alumina and the like. Useful liquid carriers include water, alcohols or glycols or water-alcohol/glycol blends, in which the present compounds can be dissolved or dispersed at effective levels, optionally with the aid of non-toxic surfactants. Adjuvants such as fragrances and additional antimicrobial agents can be added to optimize the properties for a given use. The resultant liquid compositions can be applied from absorbent pads, used to impregnate bandages and other dressings, or sprayed onto the affected area using pump-type or aerosol sprayers.
[0091] Thickeners such as synthetic polymers, fatty acids, fatty acid salts and esters, fatty alcohols, modified celluloses or modified mineral materials can also be employed with liquid carriers to form spreadable pastes, gels, ointments, soaps, and the like, for application directly to the skin of the user.
[0092] Examples of useful dermatological compositions which can be used to deliver the compounds of formula (I)-(V) to the skin are known to the art; for example, see Jacquet et al. (U.S. Pat. No. 4,608,392), Geria (U.S. Pat. No. 4,992,478), Smith et al. (U.S. Pat. No. 4,559,157) and Wortzman (U.S. Pat. No. 4,820,508).
[0093] Useful dosages of the compounds of formula (I)-(V) can be determined by comparing their in vitro activity, and in vivo activity in animal models. Methods for the extrapolation of effective dosages in mice, and other animals, to humans are known to the art; for example, see U.S. Pat. No. 4,938,949.
[0094] Generally, the concentration of the compound(s) of formula (I)-(V) in a liquid composition, such as a lotion, will be from about 0.1-25 wt %, preferably from about 0.5-10 wt %. The concentration in a semi-solid or solid composition such as a gel or a powder will be about 0.1-5 wt %, preferably about 0.5-2.5 wt %.
[0095] The amount of the compound, or an active salt or derivative thereof, required for use in treatment will vary not only with the particular salt selected but also with the route of administration, the nature of the condition being treated and the age and condition of the patient and will be ultimately at the discretion of the attendant physician or clinician.
[0096] In general, however, a suitable dose will be in the range of from about 0.5 to about 100 mg/kg, e.g., from about 10 to about 75 mg/kg of body weight per day, such as 3 to about 50 mg per kilogram body weight of the recipient per day, preferably in the range of 6 to 90 mg/kg/day, most preferably in the range of 15 to 60 mg/kg/day.
[0097] The compound is conveniently administered in unit dosage form, for example, containing 5 to 1000 mg, conveniently 10 to 750 mg, most conveniently, 50 to 500 mg of active ingredient per unit dosage form.
[0098] Ideally, the active ingredient should be administered to achieve peak plasma concentrations of the active compound of from about 0.5 to about 75 μM, preferably, about 1 to 50 μM, most preferably, about 2 to about 30 μM. This may be achieved, for example, by the intravenous injection of a 0.05 to 5% solution of the active ingredient, optionally in saline, or orally administered as a bolus containing about 1-100 mg of the active ingredient. Desirable blood levels may be maintained by continuous infusion to provide about 0.01-5.0 mg/kg/hr or by intermittent infusions containing about 0.4-15 mg/kg of the active ingredient(s).
[0099] The desired dose may conveniently be presented in a single dose or as divided doses administered at appropriate intervals, for example, as two, three, four or more sub-doses per day. The sub-dose itself may be further divided, e.g., into a number of discrete loosely spaced administrations, such as multiple inhalations from an insufflator or by application of a plurality of drops into the eye.
[0100] The ability of a compound of the invention to act as a suppressor of p53 activity may be determined using pharmacological models which are well known to the art, e.g., as disclosed below.
[0101] The invention will now be illustrated by the following non-limiting Examples.
EXAMPLE 1
A. Ring-Closure of PFT-α
[0102]
[0103] The preparation of PFT-α was accomplished as shown in Scheme 1 by reacting 4-methyl-2-bromoacetophenone with 2-amino-4,5,6,7-tetrahydrobenzo-thiazole. Upon recrystallization of the PFT-α from isopropyl alcohol, it was noticed that PFT-α readily ring-closed completely to the imidazo[2,1-b]benzothiazole (IBT). Therefore, a subsequent investigation was undertaken to study the propensity of PFT-α to ring-close in protic solvents. Initial results indicated that PFT-α begins cyclizing at room temperature immediately upon dissolution in protic solvents. Thus, PFT-α was dissolved in DMSO and water dilutions were made from this stock. Reversed phase HPLC analysis of the solution at 25° C. over time gave results as shown in Table 1.
TABLE 1 Time (h) % cyclized to IBT 0 5 12 47 24 69 48 92
[0104] In addition, NMR studies were used to confirm the structure of the known IBT and a time course in DMSO-d6 also showed spontaneous conversion of PFT-α to IBT, as judged by the appearance of a new aromatic proton signal at δ8.50 ppm in the proton spectrum corresponding to the C 3 H proton.
B. 2-(Pyridin-4-yl)imidazo[2,1-b]benzothiazole
[0105] A mixture of 2-aminobenzothiazole (0.01 mol) and 4-bromoacetylpyridine (0.01 mol) in anhydrous ethanol (100 mL) is refluxed for 5 hours. The reaction mixture is evaporated to dryness in vacuo and the residue is slurried in ice water. The resulting solid is filtered and dried to provide the title compound as the HBr salt in 60% yield.
C. 2-(Pyridin-4-yl)imidazo[1,2-a]quinazolin-9-one
[0106] Isatoic anhydride (0.01 mol) is treated with sodium hydride (0.012 mol) in dry dimethylacetamide (50 mL) at room temperature for 20 min. and then 4-bromoacetyl-pyridine (0.01 mol) is added and the mixture is stirred at 80 ° C. for 2 hours. The mixture is cooled and poured into cold, aqueous sodium carbonate (500 mL, saturated) and extracted with ethyl acetate (3×200 mL). The organic layer is dried over magnesium sulfate and evaporated to yield the crude alkylated isatoic anhydride which is used directly without further purification for the ring closure procedure. Thus, this ketone intermediate is suspended in acetonitrile (100 mL) containing methyl-2-thiopseudourea (0.012 mol) and sodium carbonate (0.012 mol) and the mixture is refluxed for 30 min. The solvent is then removed in vacuo and replaced with dichloromethane (100 mL). The insoluble salts are filtered off and washed with additional solvent, and the filtrate is evaporated to dryness and diglyme (50 mL) is added to the residue. After addition of one pellet of sodium hydroxide to catalyze the reaction, the mixture is refluxed for 2 hours. Upon cooling, a precipitate forms which is filtered, washed with a small amount of ethyl acetate and recrystallized from methanol or dichloromethane to yield the title compound.
D. 2-(p-Methylphenyl)[1,2,4]-triazolo[1,5-a]quinazolin-5-4H-one
[0107] To a cooled solution (0° C.) of N-cyanoarylethylimidate in absolute alcohol (75 mmol in 100 mL EtOH) is added dropwise triethylamine (225 mmol) over 30 min. and then 75 mmol of 2-hydrazinobenzoic acid hydrochloride is added portionwise keeping the temperature below 3° C. The mixture is then allowed to warm slowly to room temperature and is stirred overnight. The resulting mixture is cooled and neutralized with conc. HCl and warmed for 3 hours at 80° C. with stirring. The reaction mixture is diluted with water and cooled to 5° C. The resulting solid product which separates is filtered off, washed with cold water, then ether and dried to yield the title compound.
E. 2-(Pyridin-4-yl)imidazo[1,2-c]quinazoline
[0108] A mixture of 4-aminoquinazoline (0.01 mol) and 4-bromoacetylpyridine (0.01 mol) in anhydrous ethanol (100 mL) is refluxed for 5 hours. The reaction mixture is evaporated to dryness in vacuo and the residue is slurried in ice water. The resulting solid is filtered and dried to provide the title compound as the HBr salt.
F. 2-(Pyridin-4-yl)1,2,4-triazolo[1,5-c]quinazolin-5(6H)-one
[0109] A mixture of the carbamate of anthranilonitrile (prepared by reacting anthranilonitrile (0.21 mol) with ethyl carbonate (250 mL) in absolute ethanol (500 mL) containing sodium ethoxide, 1.67 mol) is reacted with 4-pyridinecarbohydrazide (one to one equivalence, 55 mmol each) in 2-ethoxyethanol (185 mL) containing tri-n-propylamine (7.4 mL) by heating at reflux for 16 h, cooling, and treating with water gradually to promote crystallization. After overnight refrigeration, the solid product is collected and recrystallized from ethanol.
EXAMPLE 2
Effect of the p53 Inhibitory Compounds on B-CLL Viability
[0110] The malignant lymphocytes from two patients with chronic lymphocytic leukemia (CLL) were isolated by ficoll-hypaque sedimentation and suspended at a density of 1 million cells per milliliter in RPMI 1640 medium supplemented with 10% fetal bovine serum. Two hundred microliter aliquots of cells were dispersed in the wells of culture plates containing the indicated final concentrations of either PFT-α (“PFT-open”) or IBT (PFT-closed). After 3 days culture, viable cells were enumerated by fluorescence-activated cell sorting (FACS) after staining with propidium iodide (PI). Viable cells excluded the dye (open circles). In addition, cell metabolism was assessed by the ability of the cells to exclude the tetrazolium dye MTT (closed squares). As shown in FIG. 1 , the PFT-open dose-dependently reduced CLL survival, whereas PFT-closed (i.e., IBT) was non-toxic at concentrations up to 100 micromolar.
EXAMPLE 3
Protection Against Spontaneous Apoptosis and Apoptosis Induced by the Anti-metabolite Fludarabine
[0111] Chronic lymphocytic leukemia (CLL) cells were cultured for 3 days as described in Example 2. Some of the cultures were supplemented with one micromolar of PFT-open or PFT-closed, as indicated. In the experiment shown in the bottom panel of FIG. 2 , some of the cultures also contained the cytotoxic adenine nucleoside analog fludarabine (abbreviated F-AraA). Fludarabine is the first line treatment for CLL, and the toxicity of the drug is dependent upon the p53 pathway. To assess healthy, viable cells, staining was done with both PI, as indicated in Example 2, and with the mitochondrial dye DiOC6. Cells that were both PI negative and DIOC6 high were enumerated by FACS. While PFT-α and IBT exhibited nearly equivalent effects on untreated CLL cells, IBT exerted less protective effects when combined with CLL cells treated with F-AraA than did PFT-α.
EXAMPLE 4
Screening of Compounds of Formula (I) for Inhibition of IL-4 Transcriptional Activity
[0112] The BEAS-2B human airway epithelial cells were transiently transfected with the human 12/15-lipoxygenase promoter/luciferase reporter gene. Cells were then incubated with the IBT analogs ( FIG. 5 ) at 10 μM for 1 hour, followed by IL-4 (10 ng/ml). After 16 hours, luciferase was measured using a chemiluminometer. The STAT-6 induction was normalized using the B-gal results as “background.” The viability of the treated cells was visually verified at the end of the incubation, and found to be >95%. Results shown in FIG. 3 are the mean of duplicate measurements.
EXAMPLE 5
Sensitization of CLL Cells to Apoptosis by IL-4/IL-13 Antagonists
[0113] Chronic lymphocytic leukemia (CLL) cells were isolated from whole blood of patients, cultured in RPMI-1640 supplemented with 10% FB. CLL cells were pre-incubated for 1 hour with the indicated analogs ( FIG. 5 ) at 1 μM and exposed for 24 hours to the nucleoside analogs Fludarabine (Fludara) and Cladribine (2 CdA) at 1 and 10 μM. Cells were then incubated for 10 minutes in growing medium with 5 μg/ml Propidium iodide and 40 nM DiOC 6 and analyzed by flow cytometry. Viable cells (Y axis) and high DiOC 6 (FL-1) and low PI (FL-3) fluorescence.
EXAMPLE 6
Preparation of Pharmaceutical Dosage Forms
[0114] The following illustrate representative pharmaceutical dosage forms, containing a compound of formula (I)-(V), for therapeutic or prophylactic use in humans.
(i) Table 1 mg/tablet Compound of Formula (I)-(V) 100.0 Lactose 77.5 Povidone 15.0 Croscarmellose sodium 12.0 Microcrystalline cellulose 92.5 Magnesium stearate 3.0 300.0 (ii) Table 2 mg/tablet Compound of Formula (I)-(V) 20.0 Microcrystalline cellulose 410.0 Starch 50.0 Sodium starch glycolate 15.0 Magnesium stearate 5.0 500.0 (iii) Capsule mg/capsule Compound of Formula (I)-(V) 10.0 Colloidal silicon dioxide 1.5 Lactose 465.5 Pregelatinized starch 120.0 Magnesium stearate 10 600.0 (iv) Injection 1 (1 mg/ml) mg/ml Compound of Formula (I)-(V) 1.0 Dibasic sodium phosphate 12.0 Monobasic sodium phosphate 0.7 Sodium chloride 4.5 01 N Sodium hydroxide solution q.s. (pH adjustment to 7.0-7.5) Water for injection q.s. ad 1 mL (v) Injection 2 (10 mg/ml) mg/ml Compound of Formula (I)-(V) 10.0 Monobasic sodium phosphate 0.3 Dibasic sodium phosphate 1.1 Polyethylene glycol 400 200.0 01 N Sodium hydroxide solution q.s. (pH adjustment to 7.0-7.5) Water for injection q.s. ad 1 mL (vi) Aerosol mg/can Compound of Formula (I)-(V) 20.0 Oleic acid 10.0 Trichloromonofluoromethane 5,000.0 Dichlorodifluoromethane 10,000.0 Dichlorotetrafluoroethane 5,000.0
The above formulations may be obtained by conventional procedures well known in the pharmaceutical art.
[0115] All publications, patents, and patent documents are incorporated by reference herein, as though individually incorporated by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention.
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The present invention provides novel indole derivatives useful to inhibit cancer or sensitize cancer cells to chemotherapeutic agents, radiation or other anti-cancer treatments.
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CROSS REFERENCE TO RELATED APPLICATIONS
This is a National Stage of International Application No. PCT/CH2011/000274 filed Nov. 16, 2011, claiming priority based on Swiss Patent Application No. 1623/11 filed Oct. 4, 2011, the contents of all of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
The present invention relates to a double-walled liquid container. This can be in particular a water kettle.
PRIOR ART
Liquid containers are known inter alia in the form of insulated containers in which a hot or cold drink can be kept hot or cold over the longest possible period of time. In order to improve the insulation properties, liquid containers of this type usually have a double-walled configuration.
As is disclosed, for example, in DE 89 08 532, double-walled insulated containers are traditionally configured in such a manner that a glass container with a double-walled form throughout is retained in a surrounding sheath. The problem in the case of these liquid containers, however, is the fracture susceptibility of glass and in particular of double-walled glass vessels.
DE 88 13 591 discloses a liquid container in which a first container in the form of a glass body is inserted into a second container produced from plastic. The two containers are in this case retained in a surrounding sheath container.
Another type of liquid containers concerns water kettles with an integrated heating apparatus and also coffee pots to be supported on hot plates. In the case of these liquid containers, the base is usually configured, in contrast to the insulated containers mentioned above, in such a manner that it allows for the best possible thermal conduction of the heat energy to the liquid for heating. In the case of these liquid containers, the base is therefore preferably formed with a single wall.
These liquid containers, too, often have a double-walled side wall. The reason for this is that a material such as, for example, glass or high-grade steel is preferably chosen for the inner wall, this material having advantageous properties for contact with foodstuffs but not being suitable for the production of the outer structure of the liquid container. By way of example, glass is optimally suitable in particular for contact with foodstuffs, since it is odorless and easy to clean. As already mentioned, glass is however susceptible to fracture and has relatively poor molding properties compared to plastic. For this reason, the inner wall is often retained in an outer, sheathing structure, as in the case of the water kettle disclosed in EP 0 175 231, for example.
A further water kettle, in which an inner container is retained in a surrounding structure and at the same time is protected thereby, is disclosed in CN 200973622.
A liquid container of particularly simple construction having a single-walled base, in which an inner wall is retained in a sheath, is disclosed in CN 201016037. The liquid container is an insulated container. The inner wall in this case is pressed against a top seal element attached to the sheath by means of a bottom part which can be screwed onto the sheath, and is thereby fixed in the sheath.
In the case of these double-walled liquid containers with a single-walled base, the outer structure therefore firstly performs a sheath function for protective or insulation purposes and secondly a retaining function with respect to the inner container. Since the outer structure has to perform these two functions at the same time, conflicting demands are made on the configuration thereof, however, particularly with respect to the material selection. A material which, for example, has good protective or insulation properties but which is only poorly moldable and relatively brittle, and therefore is not suitable for performing a retaining function, can therefore not be used for the outer structure.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to specify a double-walled liquid container with a base of any desired configuration, in which the functions for retaining and sheathing the inner side wall can be individually optimized.
Hereinbelow, directional and location details such as upward, downward, above, below, top, bottom, etc. refer in each case to a liquid container which has been assembled as intended and which stands upright on a surface which is horizontal in relation to the direction of gravity. If the liquid container has a spout, this is arranged at the top, while the base of the liquid container is at the bottom. Details such as inner, inward, outer and outward are in each case to be understood in respect of the inner space of the liquid container.
The present invention thus provides a double-walled liquid container having the following features:
an inner side wall, which has a top edge and delimits an inner space which serves for receiving a liquid; an outer side wall, which is arranged outside the inner side wall and has a top edge and a bottom edge; a retaining structure having an inner retaining element, in which the top edge of the inner side wall is retained, and an outer retaining element, in which the top edge of the outer side wall is retained; and also a fixing element, which is attached to the retaining structure and fixes the bottom edge of the outer side wall in relation to the retaining structure.
The outer and preferably also the inner side wall are therefore fixed in the retaining structure with the aid of the fixing element. Since provision is made of two side walls which are retained with the aid of a fixing element in a retaining structure, a double-walled liquid container which is easy to produce, has a base of any desired configuration and in which the functions of retention and sheathing of the inner side wall are structurally separated is provided. Whereas the outer side wall performs the function of sheathing, the retaining structure serves in particular for retaining the inner side wall. The outer side wall and the retaining structure can be produced from different materials best suited for the respective function. In addition, in particular the retaining structure which is usually best visible from the outside can also have virtually any desired configuration, and in particular can also have openings, windows, etc. Even if the retaining structure does not form a closed sheath around the inner and outer side walls, the inner side wall is nevertheless protected from external influences by the outer side wall.
The shape of the inner side wall defines a longitudinal direction of the liquid container. Preferably, the inner side wall and particularly preferably also the outer side wall have a substantially cylindrical form, as a result of which a radial direction of the liquid container is also defined.
The retaining structure commonly extends along the longitudinal direction of the liquid container both downward and upward beyond the inner and outer side walls. The fixing element is then advantageously attached to the retaining structure below the inner and outer side walls in such a manner that the inner and outer side walls are fixed in position relative to the retaining structure in the longitudinal direction, and are thereby retained firmly in the inner or outer retaining element of the retaining structure. In this respect, the outer side wall can in particular also be clamped in between the outer retaining element of the retaining structure and the fixing element. Similarly, the inner side wall can be clamped in between the inner retaining element of the retaining structure and the fixing element. The fixing element can thus in particular exert a certain contact pressure on the bottom edge of the outer side wall or the outer side wall.
The inner side wall and the outer side wall are preferably each transparent, and the retaining structure is preferably formed in such a manner that the inner space is visible from the outside through the inner side wall and the outer side wall. The retaining structure advantageously has a top base ring, on which the inner and the outer retaining elements are arranged, and a bottom base ring, to which the fixing element can be attached, wherein the two base rings are connected to one another by means of struts. Window openings, through which the inner space of the liquid container is visible, are then present between the base rings and the struts. A handle, which can extend in particular from the top base ring to the bottom base ring, can also be attached to the retaining structure.
It is preferable that the inner side wall is produced from glass and the outer side wall is produced from a plastic such as polycarbonate (PC). It would also be possible, however, to produce the inner side wall from a plastic, for example polycarbonate. Conversely, it would also be conceivable to produce the outer side wall from glass. Glass is very well suited in particular to direct contact with foodstuffs. The production of the outer side wall from a plastic such as polycarbonate is therefore very advantageous, because this material is more resistant, robust and fracture-proof compared to glass. Whereas polycarbonate is a relatively hard and robust material, which is therefore well suited to the sheathing function of the outer side wall, the retaining structure of the liquid container according to the invention can consist of another plastic, which, compared to polycarbonate, is easier to mold and has a higher elasticity and therefore is better suited to performing the retaining function.
In principle, it would be conceivable that the inner side wall is formed so as to be downwardly closed and thereby forms a base which downwardly delimits the inner space. In a preferred embodiment, however, the inner side wall and the outer side wall each substantially have the form of a both upwardly and downwardly open cylinder. As a result, the inner and outer side walls are particularly easy to produce.
Preferably, the inner retaining element is configured as a groove, which in particular can be circumferential. The top edge of the inner side wall is then received in this inner groove. The outer retaining element, too, is preferably configured as a groove, which in particular is circumferential, wherein the top edge of the outer side wall is then received in this outer groove.
The base of the inner space could be formed, for example, by the fixing element. However, the liquid container preferably has a base element, which rests on the fixing element and, together with the inner side wall, delimits the inner space of the liquid container. The base element is in this respect preferably arranged, in particular clamped in, between the fixing element and a bottom edge of the inner side wall. The inner side wall is then arranged between the inner retaining element of the retaining structure and the base element and rests in particular on the base element.
In a particularly preferred embodiment, the liquid container is a water kettle having a heating apparatus. In this case, the base element preferably forms a heating plate, which is connected to the heating apparatus. The base element is then usually produced from a material of good thermal conductivity, preferably a metal, and can in particular have a heating coil attached to the bottom side. However, a thin film heating element can also be involved, for example.
Preferably, the base element has an inner groove, into which the inner side wall extends. This firstly fixes the inner side wall between the inner retaining element of the retaining structure and the base element and secondly fixes the base element between the inner side wall and the fixing element. Moreover, the base element and the inner side wall are each also fixed in the radial direction. The inner groove of the base element advantageously has a circumferential form.
Preferably, a sealing compound is provided in the inner retaining element of the retaining structure and/or in the inner groove of the base element and seals the inner side wall with respect to the retaining structure or with respect to the base element in a liquid-tight manner. This sealing compound can be, in particular, an adhesive, for example Loctite™.
Advantageously, at least one support element produced from a significantly more flexible material compared to the inner side wall and to the fixing element is arranged between the inner side wall and the fixing element, and therefore this support element is suitable for compensating for manufacturing tolerances with respect to the dimensioning of the length of the inner side wall. The support element, which can be produced in particular from silicone, is in this respect preferably attached to the fixing element. It is preferable that the support element is in this case formed as a support plug, which extends in the longitudinal direction of the liquid container through an opening formed on the fixing element and has a support face turned toward the bottom edge of the inner side wall. If a base element is arranged between the inner retaining element of the retaining structure and the fixing element, this base element preferably lies on the at least one support element.
Advantageously, the fixing element and the retaining structure together delimit an outer groove, into which the outer side wall extends. The outer side wall is thereby also fixed in the radial direction. Preferably, this outer groove delimited by the fixing element and the retaining structure together has a lateral inner face which is formed on the fixing element and is inclined relative to the longitudinal direction of the liquid container, such that the outer side wall is pressed radially outward by the fixing element.
In a preferred embodiment, the fixing element is formed as a fixing ring. The latter advantageously has an external diameter which corresponds substantially to that of the outer side wall. It is particularly preferable that the fixing ring has an outer side which bears, in particular circumferentially, against the inner side of the retaining structure. One or more structures having, if the liquid container has support elements, openings for receiving these support elements are preferably attached to the inner side of the fixing ring.
Advantageously, the retaining structure is formed so as to be downwardly open, wherein the fixing element can be introduced into the retaining structure from below during the production of the liquid container. This allows for particularly simple production of the liquid container, in that firstly the inner and outer side walls are inserted into the retaining structure and then are fixed from below with the fixing element.
If the retaining structure is formed so as to be downwardly open, the liquid container preferably has a bottom end plate for closing off the retaining structure in the downward direction. In principle, the fixing element could form this end plate. Advantageously, however, provision is made of a separate end plate, which is preferably fastened to the fixing element. It is particularly preferable for the end plate to be fastened to the fixing element by means of screws. If the fixing element is configured as a fixing ring with structures attached to the inner side, sleeves each with an internal thread can be provided, for example, on these structures, which are then fastening structures. If the liquid container is a water kettle, a plug connection in particular can be provided in the end plate, in order to be able to connect the liquid container to a connection base connected to the electrical mains in a simple manner. The liquid container then has an internal electrical connection, which connects the plug connection of the end plate to the heating apparatus.
Preferably, the fixing element has at least a first latching structure and the retaining structure has at least a second latching structure, these being formed complementarily to one another in such a manner that the fixing element can be latched into the retaining structure. This makes it possible to achieve particularly simple assembly of the fixing element on the retaining structure. The latching structures can here be formed in such a manner that the fixing element, once fastened on the retaining structure for the first time, can only be removed again from the retaining structure by means of destruction. The latching structures can be in particular latching notches and latching lugs.
The liquid container can have a lid in order to close off the inner space to the outside. The lid can be attached in particular pivotably to the retaining structure.
Moreover, the retaining structure can have a spout, in order to pour the liquid out of the inner space. It is preferable that this spout is formed in the region of a top edge of the retaining structure.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention which serve merely for explanation and are not to be interpreted as having a limiting effect will be described hereinbelow on the basis of the drawings, in which:
FIG. 1 shows a perspective view of a double-walled liquid container according to a first embodiment according to the invention;
FIG. 2 shows a central sectional view in plane II-II through the liquid container shown in FIG. 1 ;
FIG. 3 shows an enlarged illustration of the region indicated by dashed lines in FIG. 2 ;
FIG. 4 shows a central sectional view in plane II-II through the liquid container shown in FIG. 1 , without a connection base, an end plate and a fixing ring;
FIG. 5 shows a central sectional view in plane IV-IV through the liquid container shown in FIG. 1 ;
FIG. 6 shows an enlarged illustration of the region indicated by dashed lines in FIG. 5 ;
FIG. 7 shows a perspective view from obliquely below the fixing ring of the liquid container shown in FIG. 1 ;
FIG. 8 shows a central sectional view through a double-walled liquid container according to a second embodiment according to the invention; and
FIG. 9 shows an enlarged illustration of the region indicated by dashed lines in FIG. 8 .
DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 to 7 show a first embodiment according to the invention of a double-walled liquid container, which here is formed as a water kettle. The liquid container has a retaining structure 1 , an outer side wall 3 , an inner side wall 4 and a fixing ring 6 , which serves to fasten the two side walls 3 and 4 to the retaining structure 1 . Here, the two concentrically arranged side walls 3 and 4 are fixed by the fixing ring 6 in top grooves 161 and 162 , which are formed on the retaining structure 1 and thus form retaining elements. Together with a heating plate 5 , the inner side wall 4 delimits an inner space 9 of the water kettle, which serves to receive a liquid or water in this case.
The retaining structure 1 of the water kettle can be readily identified in particular in FIG. 1 . In the present exemplary embodiment, the retaining structure has a bottom base ring 11 and a top base ring 12 , which are connected to one another via connection webs 17 . Window openings are formed between the base rings 11 and 12 and the connection webs 17 . These can be of any desired configuration, but here each have a rectangular shape. The retaining structure 1 has a spout 14 for pouring out the liquid, which here is arranged on the top edge of the top base ring 12 . Moreover, a handle 15 is attached to the retaining structure 1 , on which handle there can be arranged a push-button 151 for switching the water kettle on and off and also a status display 152 for displaying the operating status of the water kettle.
As shown in FIG. 2 , the retaining structure 1 is formed so as to be upwardly and downwardly open. A configuration of this type makes it possible to introduce the side walls 3 and 4 from below into the retaining structure 1 , for example, during the production of the liquid container. Similarly, the heating plate 5 and the fixing ring 6 can be introduced into the retaining structure 1 during the production, before the latter is downwardly closed off by an end plate 13 . As is commonly provided in the case of water kettles, the end plate 13 has a central plug connection, in order to be able to establish an electrical connection with a connection base 7 that can be connected to the electrical mains for heating the water. Plug connections of this type are well known in the prior art.
The retaining structure 1 has in particular a fastening structure 16 , which is arranged directly below the spout 14 on the top base ring 12 and protrudes radially into the interior of the retaining structure 1 . The downwardly open, inner groove 162 , which serves to receive the top edge 41 of the inner side wall 4 , is formed on the fastening structure 16 . The inner groove 162 in this case has a circumferential form. In addition, together with the inner face of the top base ring 12 , the fastening structure 16 forms a likewise downwardly open, outer groove 161 , which here likewise has a circumferential form and which serves to receive the top edge 31 of the outer side wall 3 .
It is apparent from FIG. 4 that the bottom base ring 11 of the retaining structure 1 has latching notches 111 on its inner side. In the case of the water kettle shown in FIGS. 1 to 7 , five latching notches 111 are present. It goes without saying that more or fewer than five latching notches 111 can also be provided. The latching notches 111 serve to fasten the fixing ring 6 on the retaining structure 1 .
A pivotable lid 2 having a lid face 22 for closing off the inner space 9 is attached to the retaining structure 1 . A push-button 23 is provided on the lid 2 . The lid 2 is connected to the retaining structure 1 via a spring in such a manner that it automatically pivots upward when the push-button 23 is operated. A screen insert 8 is provided in the region of the spout 14 and holds back solid constituents such as, for example, detached limescale when pouring out the liquid.
The retaining structure 1 is preferably produced in one piece from a plastic in an injection molding process.
The outer side wall 3 , which can be identified in FIGS. 2 to 6 , has a substantially hollow cylindrical configuration and is formed so as to be upwardly and also downwardly open. In the present exemplary embodiment, as is apparent from FIG. 3 , the bottom end region of the side wall 3 is provided with a circumferential, beveled inner face 33 , which is accompanied by tapering of the wall thickness of the outer side wall 3 downward toward the bottom edge 32 . A circumferential, radially inwardly projecting shoulder is formed directly above this beveled inner face 33 and serves for centering the heating plate 5 .
In order that the inner space 9 is visible to the user from the outside, the outer side wall 3 is preferably produced from a transparent material. In order to increase the fracture resistance, this is preferably a plastic, such as in particular polycarbonate (PC).
The inner side wall 4 , which can be identified in FIGS. 2 to 6 , has a substantially hollow cylindrical configuration and is formed so as to be both upwardly and downwardly open. It has a top edge 41 and a bottom edge 42 , which both form a circumferential bead.
The inner side wall 4 preferably has a transparent form. As a result, the inner space 9 is visible from the outside. Since the inner side wall 4 comes into contact with the water received in the inner space 9 , it is particularly preferably produced from glass. Alternatively, however, it could also be produced from high-grade steel, for example.
The heating plate 5 , which has a base face 51 , forms a base element in relation to the inner space 9 . A heating coil 53 is attached to the bottom side of the heating plate 5 and serves for heating the liquid received in the inner space 9 . The base face 51 is surrounded by a circumferential, upwardly open groove 52 . The groove 52 serves for receiving the bottom edge 42 of the inner side wall 4 . In the present exemplary embodiment, the groove 52 is arranged offset slightly underneath the base face 51 .
The heating plate 5 is conventionally produced from a material of good thermal conductivity, such as in particular a metal.
The configuration of the fixing ring 6 is readily apparent in particular from FIG. 7 . The fixing ring 6 has an annular shape and is in this case dimensioned in such a manner that it bears by way of its outer face, as shown in FIG. 2 , against the inner face of the bottom base ring 11 of the retaining structure 1 . In order to fasten the fixing ring 6 in this position on the retaining structure 1 , the outer side of the fixing ring is provided with latching lugs 64 , which are formed complementarily in terms of their number, arrangement and configuration to the latching notches 111 of the retaining structure 1 . The fixing ring 6 is thereby designed to enter into a latching connection with the retaining structure 1 . Here, the latching lugs 64 each have a bottom side which extends in the radial direction perpendicular to the adjoining inner wall of the base ring 11 . The top side of the latching lugs 64 is, by contrast, formed inclined relative to the longitudinal direction and to the radial direction, such that the fixing ring 6 easily latches in upon insertion into the retaining structure 1 . Preferably, after latching in for the first time, this latching connection can only be separated again by means of destruction. The interior of the water kettle between the heating plate 5 and the end plate 13 can thereby be made inaccessible to the user.
The fixing ring 6 extends in each case slightly further downward into the regions of the latching lugs 64 than into the interlying regions. Whereas the top edge of the fixing ring 6 runs in a single plane, the bottom edge thereby describes a wavelike form.
Toward the top, the fixing ring 6 has a circumferential pressure element 65 , which is readily apparent in cross section in particular in FIGS. 2 and 3 . The pressure element 65 is attached to the inner wall of the fixing ring 6 in the region of the top edge thereof and extends from there beyond the top edge upward. The outer face of the pressure element 65 , which extends from the top edge of the fixing ring, has such an inclination in cross section that it moves upward away from the inner wall of the bottom base ring 11 of the retaining structure 1 . Together with the inner wall of the bottom base ring 11 , the pressure element 65 of the fixing ring 6 thus forms a bottom groove, which has a complementary configuration compared to the bottom end region of the outer side wall 3 . This bottom groove therefore serves for receiving the bottom edge 32 of the outer side wall 3 . The angular faces of the pressure element 65 and of the bottom end region of the outer side wall 3 in this case have the effect that the outer side wall is pressed both upward and radially outward. The top edge of the fixing ring 6 serves to support the bottom edge 32 of the outer side wall 3 .
Inwardly protruding fastening structures 61 are attached to the inner side of the fixing ring 6 at regular intervals. In the present exemplary embodiment, provision is made of four fastening structures 61 , but of course more or fewer can also be present. The fastening structures 61 each have a connection plate 62 , which extends inward perpendicular to the inner face of the fixing ring 6 and on the bottom side of which there is attached a downwardly extending sleeve with an internal thread. The sleeve 63 can be connected to the inner face of the fixing ring 6 via a radially running reinforcement strut. The sleeves 63 serve to connect the fixing ring 6 to the end plate 13 by means of screws. It is preferable that the fixing ring 6 is produced in one piece from a plastic in an injection molding process.
Two openings 66 are formed in each case in the connection plate 62 of the fastening structures 61 and are arranged in each case in front of and behind the sleeve 63 in the circumferential direction. The openings 66 serve to receive support plugs 10 . These support plugs 10 are produced from a flexible material compared to the fixing ring 6 . This is preferably silicone. As can be seen in FIGS. 5 and 6 , the support plugs 10 serve to support the heating plate 5 . It goes without saying that it would also be possible, in an alternative embodiment, that the inner side wall would lie with its bottom edge 42 directly on the support plugs 10 . Owing to their flexible configuration, the support plugs 10 in this case serve in particular for compensating for certain manufacturing tolerances with respect to the dimensioning of the inner side wall 4 , so that the fixing ring 6 nevertheless exerts a certain contact pressure on the bottom edge 42 of the inner side wall 4 .
During the production of the liquid container, the inner side wall 4 and the outer side wall 3 are inserted into the inner groove 162 and respectively the outer groove 161 of the retaining structure 1 . The heating plate 5 is then introduced into the retaining structure 1 from below in such a manner that the circumferential groove 52 of the heating plate 5 receives the bottom edge 42 of the inner side wall 4 . Then, the fixing ring 6 is latched or snapped into the latching notches 111 by way of its latching lugs 64 . The outer side wall 3 and the inner side wall 4 are thereby fixed between the fastening structure 16 of the retaining structure 1 and the fixing ring 6 . In addition, in this exemplary embodiment, the heating plate 5 is also fixed between the fixing ring 6 and the fastening structure 16 or the inner side wall 4 . Finally, the retaining structure 1 is closed off at the bottom by means of the end plate 13 , by screwing the end plate 13 onto the fixing ring 6 . Alternatively, it would also be possible to screw the end plate 13 onto the fixing ring 6 even before the fixing ring 6 is inserted into the retaining structure, or to connect the end plate to the fixing ring in another way, for example by adhesive bonding, welding, etc.
Sealing compounds are preferably provided in the inner groove 162 of the retaining structure 1 and in the groove 52 of the heating plate 5 and seal the inner side wall 4 with respect to the retaining structure 1 or the heating plate 5 in a liquid-tight manner. These sealing compounds are preferably an adhesive, for example Loctite™. Similarly, a sealing compound, preferably in the form of an adhesive, for example Loctite™, can be provided in each case in the outer groove 161 of the retaining structure 1 and in the bottom groove formed by the fixing ring 6 and the retaining structure 1 together.
FIGS. 8 and 9 show a further embodiment of a liquid container according to the invention. In contrast to the embodiment shown in FIGS. 1 to 7 , here the fixing ring 6 alone, and not together with the inner face of the retaining structure 1 , forms the bottom groove for the bottom edge 32 of the outer side wall 3 . Just like the inner side wall 4 , the outer side wall 3 additionally has a circumferential bead in each case in the region of its top edge 31 and its bottom edge 32 .
The invention is of course not limited to the above exemplary embodiments, and a multiplicity of modifications are possible. Thus, by way of example, the heating plate does not necessarily have to be fixed between the inner side wall 4 and the fixing ring 6 , but rather could also be attached to the retaining structure or to the inner side wall in any other desired way. The liquid container does not necessarily have to be formed as a water kettle. The inner and outer side walls could each also lie with their bottom edges on the end plate, which would then form the fixing element. The roles of the latching notches and latching lugs on the retaining structure and on the fixing element can of course also be interchanged. A multiplicity of further modifications is possible.
LIST OF REFERENCE SIGNS
1
Retaining structure
11
Bottom base ring
4
Inner side wall
111
Latching notch
41
Top edge
12
Top base ring
42
Bottom edge
13
End plate
14
Spout
5
Heating plate
15
Handle
51
Base face
151
Push-button
52
Groove
152
Status display
53
Heating coil
16
Fastening structure
161
Outer groove
6
Fixing ring
162
Inner groove
61
Fastening structure
17
Connection web
62
Connection plate
63
Sleeve
2
Lid
64
Latching lug
22
Lid face
65
Pressure element
23
Push-button
66
Opening
3
Outer side wall
7
Connection base
31
Top edge
8
Screen insert
32
Bottom edge
9
Inner space
33
Beveled inner face
10
Support plug
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The invention specifies a double-walled liquid container having an inner side wall ( 4 ), an outer side wall ( 3 ), which is arranged outside the inner side wall ( 4 ), a retaining structure ( 1 ) and a fixing element ( 6 ), which is fitted on the retaining structure ( 1 ). The inner side wall ( 4 ) has an upper edge ( 41 ) and delimits an interior ( 9 ), which serves for accommodating a liquid. The outer side wall ( 3 ) has an upper edge ( 31 ) and a lower edge ( 32 ). The retaining structure ( 1 ) has an inner retaining element ( 162 ), in which the upper edge ( 41 ) of the inner side wall ( 4 ) is retained, and an outer retaining element ( 161 ), in which the upper edge ( 31 ) of the outer side wall ( 3 ) is retained. The fixing element ( 6 ) here fixes the lower edge ( 32 ) of the outer side wall ( 3 ) in relation to the retaining structure ( 1 ).
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FIELD OF THE INVENTION
The present invention has for its subject a method and an apparatus for laying sleepers, or ties, at predetermined intervals and in prescribed alignment, on the bed of ballast of a railway track.
DESCRIPTION OF THE PRIOR ART
There are already known processes of this type which consist in laying the sleepers, also known as ties at predetermined intervals as a function of the distance travelled by a works vehicle over the laying positions. In this vehicle, one supplies the sleepers from a stock-pile up to a laying point where one brings and retains successively each sleeper to be laid a little above the level of the bed of ballast at the prescribed alignment and where it is freed at the desired moment so that it falls at the prescribed interval.
These processes are satisfactory in the situation where accuracy is not required in the respect of prescribed intervals. In fact, the sleepers in falling do not stabilize themselves immediately at the moment of the arrival on the bed of ballast. This emerges from the fact that the impact is produced in accordance with an oblique trajectory, - resultant from the combination of the speed of the vertical fall of the sleeper and of the speed of advance of the laying vehicle, - on a bed of ballast the state of the surface of which does not necessarily present the same characteristics of flatness and resistance from one sleeper to another. This phenomenon causes irregularities in the intervals between the laid sleepers and it is necessary to correct them manually when these irregularities exceed tolerable limits.
Moreover, at the moment of impact, it is very rare that the sleeper encounters the bed of ballast at the same time over the whole of its length, which has the effect that it stops slightly obliquely, the end which enters into contact with the ballast first becoming settled more quickly than the other. Here likewise, it can become necessary to correct their position manually.
The process and the device of laying of the present invention have for their object to remedy these inconveniences in ensuring the laying of the sleepers with a precision which is sufficient to avoid all further need for manual correction of the position of the laid sleepers.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided a method of continuously laying sleepers at permanent positions at predetermined intervals on a bed of ballast for a railway track, by means of a vehicle travelling along the track, which method comprises feeding each sleeper in turn from a stock of sleepers to a laying mechanism where the sleeper is held a little above the level of the bed of ballast, removing vertical support from beneath the sleeper at a position in advance of the intended permanent position of the sleeper so that the sleeper falls onto the bed of ballast in advance of its intended permanent position, drawing the sleeper along the bed of ballast until it reaches its intended permanent position and then completely releasing the sleeper in its intended permanent position.
According to a further aspect of the invention there is provided apparatus for continuously laying sleepers at permanent positions at predetermined intervals on a bed of ballast for a railway track, which apparatus comprises a vehicle provided with a laying mechanism for holding a sleeper a little above the level of the bed of ballast, the laying mechanism including a retractable vertical support which when retracted permits the sleeper to fall onto the bed of ballast, a displaceable stop which in operation draws the sleeper along the bed of ballast until the stop is displaced to release the sleeper in the intended permanent position of the sleeper, a conveyor for conveying sleeper in turn from a stock of sleepers to the laying mechanism and a control circuit responsive to the distance travelled by the vehicle for controlling the sequence of operations of the retractable vertical support and the displaceable stop to lay the sleeper at the predetermined intervals.
Thanks to this process, the sleepers are laid with great precision by the fact that these are no longer freed in an unstable bouncing condition due to their fall, the effects of which are uncontrollable, but are released after stabilization of this phenomenon at the precise moment when they arrive at the prescribed position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
It is advantageous to complete the action of releasing the sleeper in its prescribed position by the application of a vertical pressure on the sleeper, which has the effect of securing it in position by slight anchoring in the ballast.
This complementary operation presents the advantage of not risking leaving the sleeper posed on several pebbles above the level of the bed of ballast, thus in an unstable position.
The control circuit preferably includes a sequential regulating member controlled according to the distance travelled.
For the application of a vertical pressure onto the sleeper to be laid, this device preferably comprises, in addition to the support and stop members, at least one vertically acting ram disposed at the fulcrum of the said sleeper to be laid and actuated by a motor member controlled by the control circuit; the sequential regulating member of the said circuit being adjusted so that the said ram operates after the withdrawal of the support member.
Preferably the control circuit also controls the operation of the conveyor to supply the sleepers from the stock to the laying mechanism.
In a preferred form of the apparatus, the retractable support member for the sleeper in which the retractable support member for the sleeper to be laid comprises two retractable tongues extending from the end of the laying mechanism and disposed one on each side of the axis of symmetry of the sleepers. It is also preferred that the displaceable stop for the sleeper to be laid comprises two pivotable stops one disposed on each side of the axis of symmetry of the sleeper the pivotal axis of which is parallel to the longitudinal axis of the sleeper and is situated above the sleeper, and the end of the stops is in contact, in the retaining position, with the back face of the sleeper with respect to the direction of advance of the laying apparatus.
There may also be a retaining system for the feed of sleepers to the laying mechanism controlled by the control circuit, and the displaceable stop for the sleeper to be laid includes a contact on its contact face and connected with the said control circuit to control the supply of sleepers during the laying operation.
DESCRIPTION WITH REFERENCE TO THE DRAWINGS
The present invention will be described further, with reference to the accompanying drawings showing by way of example one embodiment of the invention, in which:
FIG. 1 shows a simplified representation of a renewal train for railway tracks provided with a laying device in accordance with the invention;
FIG. 2 is a detailed view of part of the laying device;
FIG. 3 is a diagram of the feed and control circuit of the laying device; and
FIGS. 4, 5, 6 and 7 show the steps of the operation of laying of a sleeper.
The renewal train shown in its basic features in FIG. 1 is similar to that described in Swiss Pat. No. 511,332.
This train includes a beam 1 pivoted at one end 2 on a bracket 3 of a locomotive 4 partially shown, and supported at the other end 5 on a bracket 6 of a sleeper stock wagon 7.
This train travels from right to left as shown, in accordance with the arrow F, the stock wagon 7 riding on the rails 8 of an old track and the sleepers 9 to be changed and the locomotive 4 riding on the rails 10 of the new track and the new sleepers 11.
On the beam 1, mounted on a framework 12, is a pick-up device 13 for the old sleepers 9, a regulating device 14 for levelling the ballast 15 and a laying device 16 for new sleepers 11. A system of conveyors 17 and 18 connect the laying and pick-up devices 16 and 13 to the stock wagon 7.
As the train moves forward, the old rails 8 are lifted and swung clear by a guiding device 19, the old sleepers 9 are picked up and replaced by the new sleepers 11 which are laid on a flattened and levelled bed of ballast 15 and the new rails 10, previously laid on each side of the old track are lifted and brought towards each other and then laid at the normal distance apart on the new sleepers 11 by a guiding device 20.
The laying device 16, shown in detail in FIG. 2, comprises a hollow structure formed by two concave metal sheets 21 and 22 and having two outer vertical flanges parallel to the direction of the track, only one of which, the flange 23, is visible in the drawing. The upper concave metal sheet 22, for the final guiding of the sleepers 11 to be laid, is an extension of the rolling plane of the conveyor 18, of which the rollers 24, the motor 25 and reducer 26 traction assembly are shown. This hollow structure, on which is mounted the laying mechanism proper, is connected at the end of the conveyor 18 by a pivot 27 and to the framework 12 (FIG. 1) by suspension jacks, not shown in FIG. 2, permitting the adjustment of its height with respect to the bed of ballast 15 and for lifting the apparatus for light running.
The laying mechanism comprises two sets of laying equipment disposed on both sides of the centre axis of the sleepers between the two vertical flanges. The mechanism includes a retractable support tongue 29 for the new sleepers 11 to be laid, such as the sleeper 28, which tongue can be withdrawn into the space beneath the concave metal sheet 22, by a hydraulic jack 30.
A first retractable retaining member in the form of a pivotal stop 31 is provided, the pivotal axis 32 of which is situated above the sleeper 28 to be laid. The end of the stop 31 is provided with a contact 33, and in the retaining position, is in contact with the rear face of the sleeper 28. This stop 31 is actuated by a hydraulic jack 34.
A pressure part consituted by a vertically acting hydraulic ram 35 is disposed above the fulcrum of the sleeper 28 to be laid, actuated by a hydraulic jack 36. A second retractable retaining part is provided which is constituted by a retaining member 37 the pivotal axis 38 of which is situated above the next sleeper 39 to be laid, and actuated by a hydraulic jack 40. Slides 41 and 42 for guiding the sleepers during their journey on the conveyor 18 are provided.
The hydraulic control jacks of these parts of the sleeper laying mechanism, as well as the hydraulic motor of the conveyor 18, are connected to a feed and control circuit shown in FIG. 3.
A motor 43, for example an electric motor, drives a hydraulic pump 44. This pump 44 feeds, by a first branch circuit 45, the three control jacks 34, 36 and 30 of the stop 31, the ram 35 and the tongue 29 respectively by mechanically controlled four way valves 46, 47 and 48. This pump 44 likewise feeds by a second branch circuit 49 the hydraulic control jack 40 of the retaining member 37 by a four way electromechanical valve 50 and the hydraulic motor 25 of the conveyor 18 by a two way electromechanical valve 51. The hydraulic circuit comprises in usual manner a filter 52, a discharge valve 53, a choke 54 and non-return valves.
The valves 50 and 51 are controlled by the contact 33 on the stop 31 (FIG. 2) and the valves 46, 47 and 48 by pusher rods 55, 56 and 57 respectively actuated by cams 58, 59 and 60 respectively mounted on a shaft 61. This cam shaft 61 is connected to a wheel 62 maintained in permanent contact, during the laying operation, with a rail of the track, for example the rail 8. This wheel 62 is selected to be of a circumferential length equal to the length of sleeper spacing. A differential 63 is mounted on the shaft 61 on which a motor 64 operates to permit the return-to-zero of the cams whenever necessary.
This mechanical control of the distributors 46, 47 and 48 permits the laying of the sleepers at regular intervals corresponding to the length of the track as a function of the path traversed by the laying train.
The laying operation of each sleeper unfolds by successive stages shown by the progress of FIGS. 2, 4, 5, 6 and 7.
So as not to unnecessarily complicate the description of these stages, they will only be described for one of the two sets of laying equipment of the laying mechanism.
In FIG. 2, the retaining member 37 and the ram 35 are lifted, the stop 31 is lowered into the retaining position and the tongue 29 extends to support position the sleeper 28 to be laid. The conveyor 18 operates and feeds the laying mechanism. At a precise moment of this first stage, the first sleeper 28 comes into contact with the contact 33. The feed and control circuit is at this time in the state shown in FIG. 3.
In FIG. 4, the sleeper 28 having operated the contact 33 is in abutment with the stop 31. The contact 33 directly controls the changeover of the position of the valves 50 and 51, thus stopping the motor 25 of the conveyor 18 and lowering the retaining member 37 on to the next sleeper 39.
At this moment, the sleeper 28, supported on the tongue 29 and retained by the stop 31, is ready for the laying operation proper.
This laying operation is shown in FIG. 5, wherein just before the sleeper 28 arrives in the desired position determined by the wheel 62 (FIG. 3), the cam 60 operates the pusher 57 and switches the valve 48 to cause the retraction of the support tongue 29. The sleeper 28 then settles on the bed of ballast 15 whilst continuing to be drawn along with the forward movement of the train in accordance with the arrow F, by the stop 31.
When the sleeper 28 arrives in the desired position determined by the wheel 62 (FIG. 3), the cam 58 operates the pusher 55 and changes the position of the valve 46, thus causing the raising of the stop 31. Simultaneously, pressure is applied by the ram 35 to the upper face of the sleeper 28, the ram 35 being controlled by the action of the cam 59 (FIG. 3) and its pusher 56 on the changeover valve 47.
At this moment the sleeper 28 is exactly in the prescribed position after stabilization of the rebounding phenomenon which tends to accompany the drop of the sleeper and is fixed in this position regardless of irregularities in the surface of the bed of ballast 15.
Finally, the contact 33 is freed of the pressure of the sleeper 28 at the moment of the raising of the stop 31, which has the effect of exciting a delay relay mounted in the circuit connecting the contact 33 with the electromechanical valves 50 and 51 which control the conveyor motor 25 and the retaining member 37 so as to actuate them after the subsequent stage shown in FIG. 6.
In FIG. 6, the stop 31 is relowered. The pusher 35 is raised and the tongue 29 is extended by the simultaneous actions of the cams 58, 59 and 60 on the valves 46, 47 and 48 as soon as the stop 31 disengages the laid sleeper 28 and all these valves return to the position shown in FIG. 3. The retaining member 37 and the motor 25 of the conveyor 18 are operated in the last stage shown in FIG. 7, immediately after the closure of the contacts of the delay relay previously excited by the contact 33.
At this moment, the laying mechanism and its control circuit are in the state shown in FIGS. 2 and 3 with the only difference that the sleeper 28 has been replaced by the subsequent sleeper 39, and the same cycle of operations restarts for this sleeper and similarly for each of the subsequent sleepers on the stock wagon 7.
The time intervals separating each operation from the subsequent one are determined as a function of the distance between each of them in taking account the travel and the transverse gauge of the sleepers on the right of the parts which operate on them, so as to ensure the free functioning of these parts. These time intervals would be also adpated to the length of time of the rebounding of the sleepers after their drop, which depends in turn on their weight, their elasticity, and their height of drop, so as to ensure the maximum precision which one can attain of the laying process in accordance with the invention.
The application of the laying process for the sleepers in accordance with the invention is not limited to the renewal of permanent ways given by way of example, but on the contrary extends to all operations necessitating the laying of sleepers at regular intervals on a bed of ballast of permanent ways.
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The invention is a method of and apparatus for continuously laying sleepers at permanent positions at predetermined intervals on a bed of ballast for a railway track, by means of a vehicle travelling along the track, which method comprises feeding each sleeper in turn from a stock of sleepers to a laying mechanism where the sleeper is held a little above the level of the bed of ballast, removing vertical support from beneath the sleeper at a position in advance of the intended permanent position of the sleeper so that the sleeper falls onto the bed of ballast in advance of its intended permanent position, drawing the sleeper along the bed of ballast until it reaches its intended permanent position and then completely releasing the sleeper in its intended permanent position. The invention permits the sleepers to be laid with greater accuracy than when using prior apparatus.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an image sensor driving unit that orders an image sensor to rapidly discharge an unnecessary electrical charge generated by a charge-transfer channel, such as a CCD, before a photographing operation.
[0003] 2. Description of the Related Art
[0004] Various kinds of image sensors that generate an image signal corresponding to an optical image of a subject are known. Among the various kinds of image sensors, a CCD image sensor is commonly used owing to its adjustable size, relatively high S/N ratio, sensitivity, and various other desirable attributes.
[0005] A CCD image sensor outputs pixel signals according to the amount of light received by the pixels by ordering a vertical CCD to receive signal charges generated by a plurality of pixels separately, by ordering the vertical CCD to transfer the signal charges to a horizontal CCD, and by ordering the horizontal CCD to transfer the signal charges to an output amplifier.
[0006] The vertical CCD happens to store the electrical charge which the vertical CCD generates itself when light is leaked to the vertical CCD, and from an electrical charge left upon transferring an electrical charge exceeding the transferring capacity, from an electrical charge leaked from a pixel, and so on. Such an electrical charge becomes noise in a signal charge, and should be discharged to display an accurate image.
[0007] Japanese Unexamined Patent Publication No. H04-356879 discloses the rapid discharge of electrical charges that remain in the vertical CCD before the vertical CCD receives and transfers signal charges from pixels.
[0008] The influence of noise can be reduced by the rapid discharge. However, the time required to discharge electrical charges from the vertical CCD is added to the time to complete a photographing operation from depressing a release button. Accordingly, the entire time to complete the photographing operation is undesirably prolonged. Especially in the case of continuous photographing, it is desirable to increase the amount of photographing per a certain time by completing the photographing operation rapidly.
SUMMARY OF THE INVENTION
[0009] Therefore, an object of the present invention is to provide an image sensor driving unit that shortens the time it takes to complete a photographing operation by discharging an electrical charge stored in a charge-transfer channel, such as a CCD.
[0010] According to the present invention, an image sensor driving unit, comprising a first controller, a second controller, and a third controller, is provided. The image sensor driving unit drives an image sensor to carry out a capture of an image. The image sensor has a plurality of pixels and a charge-transfer channel. The pixels generate signal charges according to amounts of received light. The charge-transfer channel reads out the signal charges from the pixels and transfers the signal charges. The capture is carried out by ordering the pixels to generate the signal charges and the charge-transfer channel to transfer the signal charges. The first controller orders the image sensor to carry out a rapid discharge operation before the charge-transfer channel reads out and transfers the signal charges. An electrical charge remaining in the charge-transfer channel is discharged in the rapid discharge operation. The second controller controls the first controller to order the image sensor to carry out the rapid discharge operation when light is made incident on the pixels for the capture after the first capture with the image sensor operating in continuous photographing mode. The third controller varies a discharge number. The discharge number is the number of the rapid discharge operations to be carried out. The third controller decreases the discharge number for the capture after the first capture from the discharge number for the first capture.
[0011] According to the present invention, an imaging apparatus, comprising an image sensor, a first controller, a second controller, and a third controller, is provided. The image sensor has a plurality of pixels and a charge-transfer channel. The pixels generate signal charges according to amounts of received light. The charge-transfer channel reads out the signal charges from the pixels and transfers the signal charges. The image sensor carries out a capture of an image. The capture is carried out by ordering the pixels to generate the signal charges and the charge-transfer channel to transfer the signal charges. The first controller orders the image sensor to carry out a rapid discharge operation before the charge-transfer channel reads out and transfers the signal charges. An electrical charge remaining in the charge-transfer channel is discharged in the rapid discharge operation. The second controller controls the first controller to order the image sensor to carry out the rapid discharge operation when light is made incident on the pixels for the capture after the first capture with the image sensor operating in continuous photographing mode. The third controller varies a discharge number. The discharge number is the number of the rapid discharge operations to be carried out. The third controller decreases the discharge number for the capture after the first capture from the discharge number for the first capture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The objects and advantages of the present invention will be better understood from the following description, with reference to the accompanying drawings in which:
[0013] FIG. 1 is a block diagram showing the internal structure of a single-lens reflex camera having the image sensor driving unit of the embodiments of the present invention;
[0014] FIG. 2 is a schematic diagram showing the structure of the image sensor;
[0015] FIG. 3 is a deployment diagram showing the first-fourth electrodes;
[0016] FIG. 4 is a timing chart illustrating the release operation in the single photographing mode;
[0017] FIG. 5 is a timing chart illustrating the release operation in the continuous photographing mode;
[0018] FIG. 6 is a flowchart illustrating the process for the single release control carried out by the CPU; and
[0019] FIG. 7 is a flowchart illustrating the process for the continuous release control carried out by the CPU.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The present invention is described below with reference to the embodiment shown in the drawings.
[0021] In FIG. 1 , the single-lens reflex camera 10 comprises a photographic optical system 11 , an image sensor 30 , a timing generator (TG) 12 (signal generator), a digital signal processor (DSP) 13 , a CPU 14 , and other components.
[0022] The photographic optical system 11 comprises a plurality of lenses, including a focus lens (not depicted) and a zoom lens (not depicted). The image sensor 30 is arranged on the optical axis of the photographic optical system 11 so that the light-receiving surface of the image sensor 30 is perpendicular to the optical axis. The photographic optical system 11 enables an optical image of a subject to be in focus on the light-receiving surface.
[0023] A diaphragm 16 , a mirror 17 , and a shutter 18 are positioned between the photographic optical system 11 and the image sensor 30 . By varying the size of the aperture of the diaphragm 16 , the amount of light incident on the image sensor 30 may be adjusted. In ready mode for photographing, the mirror 17 intersects the optical axis, and an optical image is reflected by the mirror 17 to a pentaprism 19 and transmitted to a viewfinder (not depicted). Upon a release operation, the mirror 17 is turned upward, and the optical image arrives at the shutter 18 . By opening and closing the shutter, light arriving at the image sensor 30 may be controlled.
[0024] The diaphragm 16 , the mirror 17 , and the shutter 18 are driven by the optical system driver 20 . The optical system driver 20 drives each of the components on the basis of the control of the CPU 14 .
[0025] The TG 12 drives the image sensor 30 to generate an image signal corresponding to the optical image reaching the light-receiving surface. The TG 12 is controlled by the DSP 13 . The generated image signal is transmitted to the DSP 13 via an AFE 21 .
[0026] The AFE 21 carries out correlated double sampling processing, auto gain control processing, and analog-to-digital conversion processing on the received image signal. The DSP 13 carries out predetermined signal processing on the received image signal. The image signal, having undergone predetermined signal processing, is stored in a memory 22 or transmitted to an LCD 23 , where a captured image is displayed.
[0027] The DSP 13 is connected to the CPU 14 . The DSP 13 drives the TG 12 , carries out predetermined signal processing on the image signal, stores the image signal in the memory 22 , and conducts other operations on the basis of orders from the CPU 14 .
[0028] Furthermore, the CPU 14 controls the operations of each component of the single-lens reflex camera 10 . The CPU 14 is connected to an input block 24 that comprises a release button (not depicted), a power button (not depicted), a multifunctional cross key (not depicted), and so on. The CPU 14 controls the components according to various commands input by a user to the input block 24 .
[0029] Next, the operation of the image sensor 30 upon the release operation, and the structure of the image sensor 30 are explained.
[0030] The image sensor 30 is a CCD image sensor. As shown in FIG. 2 , the image sensor 30 comprises pixels 31 , vertical CCDs 32 , a horizontal CCD 33 , an output amplifier 34 , and other components.
[0031] A plurality of pixels 31 are arranged on the light-receiving surface in two dimensions. The vertical CCDs 32 are arranged in each column of the arranged pixels 31 . All the pixels 31 are connected to their respective adjacent vertical CCD 32 . The horizontal CCD 33 is arranged at the lower end of the vertical CCDs 32 . All the vertical CCDs 32 are connected to the horizontal CCD 33 . One end of the horizontal CCD 33 is connected to the output amplifier 34 .
[0032] Each pixel 31 generates and accumulates a signal charge corresponding to the amount of light received. A substrate (not depicted) where the pixels 31 are arranged is connected to an electronic shutter terminal 35 sub. When an electronic shutter pulse, hereinafter referred to as ΦSUB, is input to the electronic shutter terminal 35 sub, an accumulated electrical charge is discharged from all the pixels 31 . In addition, a sensor gate (not depicted) is arranged between the pixels 31 and the vertical CCDs 32 . The sensor gate comprises a sensor gate terminal 35 sg, hereinafter referred to as SG terminal. When an SG pulse, hereinafter referred to as ΦSG, is input to the SG terminal 35 sg, the accumulated signal charge in each pixel is output to the vertical CCDs 32 .
[0033] As shown in FIG. 3 , first, second, third, and fourth electrodes 36 a, 36 b, 36 c, and 36 d are arranged repeatedly in order along the column direction of the vertical CCDs 32 . In addition, the first, second, third, and fourth electrodes 36 a, 36 b, 36 c, and 36 d are connected to first, second, third, and fourth vertical transfer terminals 35 v 1 , 35 v 2 , 35 v 3 , and 35 v 4 (see FIG. 2 ), respectively. By inputting vertical transfer pulses, hereinafter referred to as ΦV, to the first through fourth electrodes 36 a - 36 d while shifting their phases, the electrical charge stored in the vertical CCDs 32 is transferred to the horizontal CCD 33 .
[0034] The speed at which the vertical CCDs 32 transfer an electrical charge varies in proportion to the frequency of ΦV. The frequency of ΦV is adjusted to the first frequency that is predetermined so that the signal charges can be transferred when the signal charges should be transferred, without the transfer error. The frequency of ΦV is adjusted to the second frequency, which is predetermined to be greater than the first frequency, when a rapid discharge is to be carried out.
[0035] The fifth and sixth electrodes (not depicted) are arranged repeatedly in order along the row direction of the horizontal CCD 33 . In addition, the fifth and sixth electrodes are connected to first and second horizontal transfer terminals 35 h 1 and 35 h 2 (see FIG. 2 ), respectively. By inputting horizontal transfer pulses, hereinafter referred to as ΦH, to the fifth and sixth electrodes while shifting their phase, the electronic charge received by the horizontal CCD 33 is transferred to the output amplifier 34 .
[0036] ΦSUB, ΦSG, ΦV, and ΦH are generated by the TG 12 and input to their respective terminals.
[0037] The output amplifier 34 comprises a capacitor (not depicted), that converts a received signal charge into a signal voltage, and outputs the converted signal voltage.
[0038] The single-lens reflex camera 10 has single and continuous photographing modes. Release operations in the single and continuous photographing modes are explained using FIGS. 4 and 5 .
[0039] In the single photographing mode, a single photograph is taken by fully depressing the release button, and one frame of an image signal is generated. In the continuous photographing mode, a plurality of sequential photographs is taken automatically upon fully-depressing the release button, and a plurality of frames of image signals is generated.
[0040] The CPU 14 commences the single release control, which is a sequential control, when the fully depressed release button is detected.
[0041] At time t 1 after detection of full depression of the release button, the mirror 17 is turned upward.
[0042] At time t 2 following time t 1 , the input of ΦV of the first frequency to the first to fourth vertical transfer terminals 35 v 1 - 35 v 4 , the input of ΦH to the first and second horizontal transfer terminals 35 h 1 and 35 h 2 , and the input of ΦSUB to the electrical shutter terminal 35 sub commence. Then, electrical charges remaining in the vertical CCDs 32 , the horizontal CCD 33 , and the pixels 31 are discharged.
[0043] At time t 3 , the input of ΦSUB is suspended and all the pixels 31 become capable of accumulating signal charges. In addition, at time t 3 , the shutter 18 is opened and the exposure of an optical image to the image sensor 30 commences. At time t 4 , after a set exposure time has elapsed since time t 3 , the shutter 18 is closed and the exposure is completed.
[0044] As described later, the image sensor 30 is driven with an interlace scan. And the signal charges generated in one exposure are read out in two separate field periods, which are an even field period and an odd field period. During the even field period, the signal charges generated by the pixels 31 arranged in the even rows are read out from the image sensor 30 . During the odd field period which follows the even field period, the signal charges generated by the pixels 31 arranged in the odd rows are read out from the image sensor 30 .
[0045] Before reading out the signal charges during the even field period, the rapid discharge from the vertical CCDs 32 is carried out. At time t 3 , the frequency of ΦV is changed to the second frequency, and then electrical charges stored in the vertical CCDs 32 are rapidly discharged.
[0046] An electrical charge can be stored in any location of the vertical CCDs 32 . A single rapid discharge operation is carried out by transferring the electrical charges stored in each location to the horizontal CCD 33 , in order from the nearest to the farthest locations from the horizontal CCD 33 .
[0047] Before reading out the signal charges during the odd field period, two rapid discharge operations are carried out. At time t 5 when the second rapid discharge is completed, the frequency of ΦV is changed to the first frequency.
[0048] The time it takes to carry out two rapid discharge operations from the vertical CCDs 32 (i.e. time t 3 -time t 5 ) is constant because the second frequency is predetermined. On the other hand, the period for opening the shutter 18 varies. Accordingly, the period for two rapid discharge operations happens to be shorter than that for opening the shutter 18 . If the period required to carry out two rapid discharge operations is shorter than that for opening the shutter 18 , the rapid discharge continues until the shutter 18 is closed, even if two rapid discharge operations have been completed.
[0049] If the exposure time is long, two rapid discharge operations can be carried out after the exposure. It is preferable to carry out the rapid discharge from the vertical CCDs 32 until just before starting the transfer of the signal charges. However, the continuous rapid discharge carried out during a long exposure causes power consumption to increase. In addition, in a long exposure a high speed is generally not required for a release operation. Accordingly, the rapid discharge operation during the exposure time can be suspended on the basis of the Tv value, and the rapid discharge operation can be carried out after exposure, as described above.
[0050] After completion of the rapid discharge operation from the vertical CCDs 32 , ΦSG is input to the sensor gate terminal 35 sg (see time t 6 ). In addition, ΦV, which is adjusted so that the vertical CCDs 32 read out the signal charges accumulated in the pixels arranged in the even rows, is input to the first through fourth vertical transfer terminals 35 v 1 - 35 v 4 . By inputting ΦSG and ΦV described above, the signal charges generated by and accumulated in the pixels 31 of the even rows during the period from time t 3 to time t 4 are read out by the vertical CCDs 32 .
[0051] The frequency of ΦV is changed again to the first frequency after reading out the signal charges. By changing the frequency of ΦV to the first frequency, signal charges can be transferred to the horizontal CCD 33 without transfer error.
[0052] When the transfer of the signal charges in all the pixels 31 in the even rows by the vertical CCDs 32 and the horizontal CCD 33 is completed, reading out from the even field finishes (see time t 7 ). After finishing the reading out from the even field, the frequency of ΦV is changed again to the second frequency, and electrical charges stored in the vertical CCDs 32 are rapidly discharged (see the period from time t 7 to time t 8 ).
[0053] Unlike reading the signal charges from the even field, only a single rapid discharge operation is carried out before reading out the signal charges from the odd field. At time t 8 , when the single rapid discharge operation is completed, the frequency of ΦV is changed to the first frequency.
[0054] After completion of the rapid discharge from the vertical CCDs 32 , ΦSG is input to the sensor gate terminal 35 sg (see time t 9 ). In addition, ΦV, which is adjusted so that the vertical CCDs 32 read out the signal charges accumulated in the pixels arranged in the odd rows, is input to the first-fourth vertical transfer terminals 35 v 1 through 35 v 4 . By inputting ΦSG and ΦV described above, the signal charges generated by and accumulated in the pixels 31 of the odd rows during the period from time t 3 to time t 4 are read out by the vertical CCDs 32 .
[0055] When the transfer of the signal charges in all the pixels 31 in the odd rows by the vertical CCDs 32 and the horizontal CCD 33 is completed, reading out from the odd field finishes (see time t 10 ). Then, by generating and reading out one frame of an image signal, one capture of an image is completed. After completing the capture of an image, electrical charges accumulated by the pixels 31 are discharged until the next single release control is started by inputting ΦSUB to the electrical shutter terminal 35 sub again.
[0056] Next, the release operation in the continuous photographing mode is explained. As in the single photographing mode, the CPU 14 commences the continuous release control, which is also a sequential control, when the fully depressed release button is detected.
[0057] In the continuous release control, the same operations as in the single photographing mode are carried out at the same time for the first capture of an image (i.e. generating and reading out the first frame of an image signal) (see time t 1 -time t 10 in FIG. 5 ).
[0058] After the first capture of an image (time t 10 ), by inputting ΦSUB to the electrical shutter terminal 35 sub, electrical charges accumulated by the pixels 31 are discharged.
[0059] After a predetermined discharge period elapses from the beginning of the electrical charges, a second capture of an image can be started. At time t 11 , the input of ΦSUB is suspended, and all the pixels 31 become capable of accumulating signal charges.
[0060] In addition, at time t 11 , the shutter 18 is opened and the second exposure of an optical image to the image sensor 30 commences. At time t 12 , after a set exposure time passes from time t 11 , the shutter 18 is closed and the exposure is completed.
[0061] In addition, at time t 11 , the frequency of ΦV is changed to the second frequency, and electrical charges stored in the vertical CCDs 32 are rapidly discharged. Unlike the first exposure, a rapid discharge operation is carried out one time, as a rule, for the second capture of an image before reading out the signal charges during the even field period. If the exposure is not completed after one rapid discharge operation, the rapid discharge continues until the exposure is completed.
[0062] At time t 12 , when the exposure and the rapid discharge are completed, the frequency of ΦV is changed to the first frequency. After completion of the rapid discharge, ΦSG is input to the sensor gate terminal 35 sg (see time t 13 ).
[0063] Thereafter, by carrying out the same operations that were conducted during the period from time t 6 to time t 10 for the first capture of an image, the second frame of an image signal is generated and read out. In addition, while the release button remains fully depressed the subsequent frames of image signals are generated and read out, similar to the generating and reading out the second frame of an image signal.
[0064] Next, the single release control carried out by the CPU 14 is explained below using the flowchart of FIG. 6 . The single release control commences when the CPU 14 detects the fully depressed release button.
[0065] At step S 100 , the CPU 14 sets the number of the rapid discharge operation from the vertical CCDs 32 to two. After the number has been set, the process proceeds to step S 101 .
[0066] At step S 101 , exposure of the light-receiving surface commences. The CPU 14 orders the optical system driver 20 to turn the mirror 17 upward and to open the shutter 18 for the duration of the set exposure time. After completion of the exposure, the process proceeds to step S 102 .
[0067] At step S 102 , the CPU 14 orders the TG 12 to set the frequency of ΦV to the second frequency. The CPU 14 also orders the TG 12 to carry out the rapid discharge operations from the vertical CCDs 32 for the number of times that was set at step S 100 . After completion of the rapid discharge operation, the process proceeds to step S 103 .
[0068] At step S 103 , the signal charges generated and accumulated by the pixels 31 in step S 101 are transferred to the output amplifier 34 . As described above, the CPU 14 controls the TG 12 so that the vertical CCDs 32 read out the signal charges, the vertical CCDs 32 transfer the signal charges to the horizontal CCD 33 by changing the frequency of ΦV to the first frequency, and the horizontal CCD 33 transfers the signal charges to the output amplifier 34 . After completion of the transfer of the signal charges to the output amplifier 34 , the process proceeds to step S 104 .
[0069] At step S 104 , the CPU 14 determines whether or not the reading of the signal charges from the odd field has been completed. If the reading from the odd field has not been completed, the process proceeds to step S 105 . (0064)
[0070] At step S 105 , the CPU sets the number of the rapid discharge operation from the vertical CCDs 32 to one. After the number has been set, the process returns to step S 102 .
[0071] If the reading from the odd field is completed, the single release control terminates.
[0072] Next, the continuous release control carried out by the CPU 14 is explained below using the flowchart of FIG. 7 . The continuous release control commences when the CPU 14 detects the fully depressed release button.
[0073] At step S 200 , the CPU 14 determines whether or not it is the first time the capture of an image is to be carried out. If it is the first time for the capture of an image, the process proceeds to step S 201 . If it is not the first time for the capture of an image, the process proceeds to step S 202 .
[0074] At step S 201 , the CPU 14 sets the number of the rapid discharge operation from the vertical CCDs 32 to two. At step S 202 , the CPU 14 sets the number of the rapid discharge operation from the vertical CCDs 32 to the number of rapid discharge operations that can be carried out during the determined exposure time. After the number has been set at step S 201 or S 202 , the process proceeds to step S 203 .
[0075] At step S 203 , the exposure of the light-receiving surface commences. The CPU 14 orders the optical system driver 20 to turn the mirror 17 upward and to open the shutter 18 for the duration of the set exposure time. After the completion of the exposure, the process proceeds to step S 204 .
[0076] At step S 204 , the CPU 14 changes the frequency of ΦV to the second frequency, and then the rapid discharge operation is carried out for the number of times that was set at step S 201 or S 202 . In addition, at step S 204 the signal charges generated and accumulated by the pixels 31 in step S 203 are transferred to the output amplifier 34 . Namely, the CPU 14 controls the TG 12 so that the vertical CCDs 32 read out the signal charges, the vertical CCDs 32 transfer the signal charges to the horizontal CCD 33 by changing the frequency of ΦV to the first frequency, and the horizontal CCD 33 transfers the signal charges to the output amplifier 34 . After completion of the rapid discharge and transfer of the signal charges to the output amplifier 34 , the process proceeds to step S 205 .
[0077] At step S 205 , the CPU 14 sets the number of the rapid discharge operation from the vertical CCDs 32 to one. After the number has been set, the process proceeds to step S 206 .
[0078] At step S 206 , the CPU 14 orders the TG 12 to carry out the rapid discharge operation for the number of times that was set at step S 205 , and to transfer the signal charges to the output amplifier 34 . After completion of the rapid discharge operation and transfer of the signal charges to the output amplifier 34 , the process proceeds to step S 207 .
[0079] At step S 207 , the CPU 14 determines whether or not the release button is still fully depressed. If the release button remains fully depressed, the process returns to step S 200 and steps S 200 -S 207 are repeated. If the release button does not remain fully depressed, the continuous release control terminates.
[0080] In the above embodiment, the period of the release operation is shorter than it was for the prior camera, as explained below.
[0081] In a general camera, the rapid discharge from the vertical CCDs does not commence until the exposure has been completed. After the rapid discharge operation, the signal charges are then read out from the pixels and transferred. On the other hand, in the above embodiment, the rapid discharge from the vertical CCDs is carried out at the same time as the exposure, and the period for the release operation is shortened accordingly.
[0082] In addition, in the above embodiment, the amount of photographing per a determined period can be increased because the period of the time required for one capture of an image can be shortened in the continuous photographing mode.
[0083] In the single photographing mode, the rapid discharge operation is carried out twice before transferring the signal charges from the even field. On the other hand, in the continuous photographing mode the number of the rapid discharge operation is decreased upon the capture of an image after the first capture of an image. Accordingly, the period for one capture of an image after the first capture of an image is shortened by the period for one rapid discharge operation per one capture of an image.
[0084] If the captures of an image are repeated in the single photographing operation mode, the interval between the successive captures may be long enough to allow a large amount of electrical charges to accumulate in the vertical CCDs. In order to remove a sufficient amount noise, many rapid discharge operations are necessary. On the other hand, the interval between the successive captures in the continuous photographing mode is shorter than that in the single photographing operation mode. Accordingly, electrical charges accumulated in the vertical CCDs can be sufficiently discharged even if the number of rapid discharge operations is low.
[0085] The exposure of an optical image to the image sensor and the rapid discharge are simultaneously carried out for the first capture of an image in the continuous photographing mode, in the above embodiment. However, the exposure and rapid discharge do not have to be simultaneously carried out for the first capture as long as the exposure and rapid discharge are simultaneously carried out for the captures after the first capture.
[0086] Of course, in order to increase the amount of photographing it is preferable to carry out the exposure and the rapid discharge for the first capture simultaneously. However, the period for the capture of an image can be shortened through removing the electrical charge accumulated in the vertical CCDs by partially or entirely overlapping the periods in which the exposure and the rapid discharge operations are carried out, as long as the overlap occurs by the capture after the first capture at the latest.
[0087] All the signal charges are transferred to the output amplifier 34 by twice interlace scanning, in the above embodiment. However, the number for transferring the signal charges is not limited to two, the transfer of the signal charges may be divided by three or more times. Or all the signal charges can be transferred to the output amplifier 34 at once, according to progressive scanning. If the signal charges are transferred according to progressive scanning, the same effect as the above embodiment can be achieved as long as the number of the rapid discharge operation for the first capture of an image is more than that for the captures after the first capture in the continuous photographing mode.
[0088] The rapid discharge operation is carried out twice before transferring the signal charges in the first field period for the first capture, but the rapid discharge operation is carried out once per each subsequent transfer in the above embodiment. However, the same effect as the above embodiment can be achieved as long as the number of rapid discharge operations carried out before transferring the signal charges in the first field period for the first capture is greater than that per required time in subsequent captures.
[0089] Four electrodes 36 a - 36 d are arranged for the vertical CCDs 32 in the above embodiment. However, the number of electrodes for the vertical CCDs 32 is not limited to four. In addition, two electrodes are arranged for the horizontal CCD 33 in the above embodiment. However, the number of electrodes for the horizontal CCD 33 is not limited to two.
[0090] The image sensor 30 is a CCD image sensor in the above embodiment. However, other kinds of charge-transfer image sensors can be used.
[0091] Although the embodiments of the present invention have been described herein with reference to the accompanying drawings, obviously many modifications and changes may be made by those skilled in this art without departing from the scope of the invention.
[0092] The present disclosure relates to subject matter contained in Japanese Patent Application No. 2008-239856 (filed on Sep. 18, 2008), which is expressly incorporated herein, by reference, in its entirety.
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An image sensor driving unit, comprising a first controller, a second controller and a third controller, is provided. The image sensor driving unit drives an image sensor to carry out the capture of an image. The capture is carried out by ordering pixels to generate signal charges and the charge-transfer channel to transfer the signal charges. The first controller orders the image sensor to carry out a rapid discharge operation before the charge-transfer channel transfers the signal charges. The second controller controls the first controller to order the image sensor to carry out the rapid discharge operation when light is made incident for capture after the first capture with the image sensor operating in continuous photographing mode. The third controller decreases the discharge number for capture after the first capture.
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