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BACKGROUND OF THE INVENTION
[0001] Kayaking has become considerably more popular over the last decade and is in fact one of the world's fastest growing sports in terms of the increase in the number of Kayaks sold. It is estimated that there are 5 million Kayakers in the United States alone. This burgeoning popularity is due in part to the adventurous nature of Kayaking, particularly in rough and rapid moving water, but also is due in part to the technological development of the Kayak itself, including molded seating systems, improved foot rests, and improved interior floatation arrangements.
[0002] The Kayak system usually includes a skirt that is sealed to the Kayak deck opening and wraps around the torso and vest of the Kayaker to prevent the ingress of water into the interior of the Kayak.
[0003] This system is particularly useful when the Kayak capsizes and the Kayaker is “turtled” under the water. In this mode, the skirt prevents water from entering the hull and enables the Kayaker to execute a maneuver called an “eskimo roll” whereby the Kayaker rights the Kayak without wet exiting the Kayak.
[0004] However, because of inexperience, fear, and an inability to breathe underwater, many Kayakers, even ones with substantial experience, must wet exit the boat when capsized and drag it to shore, empty it, and reboard. This is a laborious and time-consuming task. There are many Kayak classes where the students attempt to learn the “eskimo roll” but are hindered by the inability to breathe underwater.
[0005] Thus, there is a need in Kayaking to provide a breathing system for the Kayaker, particularly when the Kayak capsizes.
[0006] In the Dusenbery, U.S. Pat. No. 5,887,585, a Water Rafting Canoeing and Kayaking Safety Vest is disclosed having front rear panels that incorporate sections of a floatation material, wherein the floatation material receives and stores miniature scuba-compressed air tanks.
[0007] This system has not proved commercially viable because the vest is too bulky and interferes with the Kayak skirt. Moreover, it is uncomfortable and heavy making oar manipulation by the Kayaker more difficult.
[0008] A somewhat different system is shown in the Schoettle, U.S. Pat. No. 5,671,694 , wherein an Air System for a Kayak is provided that includes a pair of similar air bags having an input valve for filling the bags and an outlet orifice for providing air to the Kayaker.
[0009] The principal disadvantage in this system is that the air bags are small and are not pressurized, and hence, do not provide the Kayaker with sufficient breathing time to execute the “eskimo roll”. Furthermore, in this system the Kayaker exhales into the air bags, filling them with carbon dioxide and thus decreasing breathing quality. Also, the Schoettle system provides no means for purging the mouth piece of air.
[0010] It is a primary object of the present invention to ameliorate the problems noted above in Kayak air breathing systems.
SUMMARY OF THE PRESENT INVENTION
[0011] In accordance with the present invention, a Kayak breathing system and method are provided particularly designed for breathing in difficult situations such as when the Kayak is turtled and the Kayaker's head submerged.
[0012] Toward these ends a mouth piece is held near the Kayaker's mouth with a vest mounted holding device, a tube having a flexible portion is connected to the mouth piece and runs through the vest, and held by the vest downwardly (when upright) into the Kayak interior. The open end of the tube freely connects with the hull interior air and a floatation device on the end of the tube keeps the tube exposed to air and not water when the interior partly fills with water.
[0013] A first check valve in the tube permits the expulsion of water from the tube by exhaling. A second check valve in the tube prevents water in the tube from traveling to the Kayak interior.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a longitudinal section of a Kayak showing the present Kayak breathing system;
[0015] [0015]FIG. 2 is a cross section approximately midway through the Kayak with the Kayak inverted or capsized and the Kayaker submerged;
[0016] [0016]FIG. 3 is an exploded view of the Kayak breathing system according to the present invention;
[0017] [0017]FIG. 4 is an assembled view of the Kayak breathing system illustrated in FIG. 3;
[0018] [0018]FIG. 5 is an end view of one of the check valves illustrated in FIG. 3;
[0019] [0019]FIG. 6 is a side view of one of the check valves illustrated in FIG. 3;
[0020] [0020]FIG. 7 is an end view of the check valve sub-assembly;
[0021] [0021]FIG. 8 is a side view of the check valve sub-assembly, and;
[0022] [0022]FIG. 9 is a longitudinal section through the check valve illustrated in FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Referring to the drawings and particularly FIGS. 1 and 2, it should be understood that the Kayak 10 illustrated in both of these views is schematically illustrated in longitudinal section in FIG. 1, and an approximate mid-ship cross section is shown in FIG. 2, where the Kayak is “turtled” or inverted when capsized.
[0024] Kayak 10 is seen to include a hull portion 11 , a gunnel 12 , and a top deck 13 . The top deck has a plurality of hand loops 14 thereon for manually handling the Kayak. A Kayaker 16 is also illustrated in FIGS. 1 and 2, although without arms in FIG. 1 simply for clarity. The Kayaker is positioned in the Kayak in the rowing position within a central generally oval opening 18 therein. Opening 18 is covered by a skirt, which has a flared portion 19 sealed to the opening 18 and an integral tube portion 20 that laces or is otherwise tied around the Kayaker's torso partly covering vest 22 . The Kayaker sits on a molded plastic seat 24 having a back rest of a seat portion, and rests his feet on an adjustable foot rack 13 . A bow floatation device 28 is positioned within the hull in the bow and rear floatation device 29 is positioned in the stern behind the Kayaker 16 .
[0025] A breathing system 30 , according to the present invention, is shown generally in schematic form in FIGS. 1 and 2, and as seen in FIG. 4, includes a rigid mouth piece assembly 32 having an integral short straight tubular section 33 communicating with mouth piece opening 35 . A first check valve 37 permits exhaled air to purge water in tube 33 and mouth piece assembly 32 and opens only in the direction of arrow 38 . Also when breathing, check valve 37 discharges exhaled air into the surrounding water. A second check valve assembly 40 prevents water from entering flexible tube section 42 when the mouth piece is not in the Kayaker's mouth and opens only in the direction of arrow 43 . Both of the check valves 37 and 40 are similar in construction and the check valve 40 is illustrated in detail in FIGS. 5 to 9 . As seen in these views, check valve 40 includes a stepped annular outer section 44 having a male end 45 and a female end 46 adapted to mate respectively with tubular portion 50 on tube 42 and tubular portion 47 on tube 33 . The outer section 44 has a seat 52 defined by four struts separated by a screen section against which a movable check valve 55 seats as shown in the cross section of FIG. 9. When a vacuum is applied to valve side 56 , valve 55 moves away from seat 52 permitting air to flow into the mouth piece 35 . However, when water is applied to side 56 , seat 53 closes and prevents the entry of water into the canoe hull through flexible tube 42 .
[0026] Instead of check valve 40 , a manually operated On/Off valve can be provided at the location of check valve 40 . In some situations this On/Off valve can provide easier breathing than the check valve 40 .
[0027] While not shown clearly in FIGS. 1 and 2, the flexible tube 42 threads inside the vest 22 and is held in position by the vest and it has an open end 60 that freely communicates with the interior of the Kayak so that the Kayaker, when breathing through the mouth piece 32 , breathes atmospheric air within the Kayak hull. The check valve 40 prevents exhaled air and carbon dioxide from entering the hull and it passes freely out the check valve 37 into the water when in the turtled position illustrated in FIG. 2. A styrofoam sphere 66 , or other types of floatation devices, is bonded to the end 60 of the tube 42 and prevents the open end of the tube 60 from becoming submerged in the event there is water in the Kayak when in the inverted position illustrated in FIG. 2. The vest 22 is shown more clearly in FIG. 10 and is seen to include a first “Velcro” type strap 68 for holding the mouth piece 32 around the shoulder strap portion of the vest 12 near the Kayaker's face so that it can be easily inserted into the mouth. A second Velcro strap 70 encompasses the mouth piece and an upper portion 42 a of tube 42 to keep the flexible tube 42 in a bent position in the event that the check valve 40 is desired to be eliminated. That is, the bend in the tube 42 in FIG. 10 prevents water from entering the Kayak through the tube 42 , and thus, is an alternative to the check valve 40 . It should be understood, however, that the check valve 40 has a dual purpose of preventing the entry of water into the Kayak and also preventing the entry of exhaled carbon dioxide into the Kayak.
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A method and apparatus for breathing in a Kayak with a mouth piece and a flexible tube including positioning the mouth piece adjacent the Kayaker's head, positioning the tube so that it extends downwardly into the Kayak interior and freely communicates with hull interior air, inserting the mouth piece when necessary into the mouth and breathing Kayak interior air.
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GRANT REFERENCE
This invention was developed in part under Grant HD 05863 by the National Institutes of Health.
BACKGROUND AND PRIOR ART
Mammalian spermatozoa have been known to be antigenic for many years. More recently, it has been demonstrated that mammalian sperm contain an antigenic enzyme, which is known as the C 4 isozyme of lactate dehydrogenase, (LDH-C 4 ) LDH-C 4 has been isolated in pure crystalline form from mouse testes. Goldberg (1972) J. Biol. Chem. 247:2044-2048. The enzyme has a molecular weight of 140,000 and is composed of four identical C subunits. The amino acid sequence and three-dimensional structure of LDH-C 4 has been described by several investigators: Musick et al (1976) J. Mol. Biol. 104:659-668; Wheat et al (1977) Biochem & Biophys. Res. Comm. 74:1066-1077; Li et al (1983) J. Biol. Chem. 258:7017-7028; and Pan et al (1983) 258:7005-7016 J. Biol. Chem.
In 1974, Dr. Erwin Goldberg reviewed the effects of immunization with LDH-C 4 on fertility, and advanced the possibility that "by using a defined macromolecular constituent of sperm it becomes possible to elucidate its primary structure in terms of amino acid sequence, to map specifically the antigenic determinant(s) responsible for inducing infertility, and then to construct synthetic peptides containing these determinants. Possessing the capability for synthesizing a molecule with such properties, making the immunological approach to fertility control feasible. Karolinska Symposia on Research Methods in Reproductive Endrocrinology, 7th Symposia: Immunological Approaches to Fertility Control, Geneva, 1974 202-222.
Subsequent investigations by Dr. Goldberg and his research associates have identified several amino acid sequences of mouse LDH-C 4 which in isolated form (e.g., as short chain peptides) bind to LDH-C 4 antiserum. Wheat et al (1981), in Rich et al, Peptides: Synthesis-Structure-Function, Proc. 7th Amer. Peptide Symp., pp. 557-560; and Gonzales-Prevatt et al (1982) Mol. Immunol. 19:1579-1585. Antigenic peptide compounds based on the Goldberg sequences have been patented. See U.S. Pat. Nos. 4,290,944; 4,310,456; 4,353,822; 4,377,516; and 4,392,997.
These antigenic peptides are useful in preparing vaccines to reduce female fertility. Immunization of female mammals results in the development of circulating antibodies specific to LDH-C 4 . These immunoglobins reach the female reproductive tract as a transudate of serum. Kille et al (1977), Biol. Reprod. 20:863-871. Antibody in cervical mucus, uterine fluids and oviducal fluids combines with LDH-C 4 on the sperm surface and impedes the progress of the male gamete, presumably by agglutination. Systemic immunization with LDH-C 4 markedly interferes with sperm transport in the female reproductive tract. Kille et al (1980) J. Reprod. Immunol. 2:15-21.
The current status of research on LDH-C 4 and antigenic peptides for use in female contraceptive vaccines are summarized in two recent publications by the Goldberg group: Goldberg et al (1983), In Immunology of Reproduction, Chapt. 22, pp. 493-504; and Wheat et al (1983), In Isozymes: Current Topics in Biological and Medical Research, Vol. 7, pp. 113-140.
The search for additional antigenic peptides containing antibody binding sequences of mouse LDH-C 4 has continued. While it is known that this isozyme contains multiple antigenic domains, there is no recognized basis for locating such domains nor for predicting their effectiveness for binding antibodies to LDH-C 4 or for generating antibodies in female mammals capable of interfering with sperm transport. The effectiveness of immunocontraception by this route probably depends upon sufficiently high concentrations of antibodies in the reproductive tract. To date, laboratory trial and error experimentation has been the only available approach.
SUMMARY OF INVENTION
A new antigenic peptide compound binding to LDH-C 4 antisera has now been discovered. The 13 amino acid peptide comprises the linear sequence Val-Asn-Met-Thr-Ala-Gly-Glu-Glu-Gly-Leu-Leu-Lys-Lys. This sequence is believed to correspond to amino acids MC 304-316 in mouse LDH-C 4 , as sequenced by Li et al (1983) J. Biol. Chem. 258:7017-7028. The peptide compound of this invention may include other amino acids of LDH-C 4 connecting with and including the above sequence, or shorter segments thereof including the antigenic domain, which are believed to be multiple. This compound can be used to prepare vaccines for reducing the fertility of female mammals including woman, since mouse LDH-C 4 is homologous with human LDH-C 4 .
DETAILED DESCRIPTION
Standard abbreviations and symbols will be used herein to designate the amino acid present in the peptide compound of this invention. These are:
______________________________________Amino Acids Abbreviations Symbols______________________________________L-alanine Ala AL-asparagine Asn NL-aspartic acid Asp DL-glutamic acid Glu Eglycine Gly GL-leucine Leu LL-lysine Lys KL-methionine Met ML-threonine Thr TL-valine Val V______________________________________
The antigenic peptide compound of this invention comprises the compound corresponding to the amino acid sequence MC 304 to 316 of mouse LDH-C 4 or segments thereof including the antigenic domain or domains thereof. More specifically the compound is represented by the sequence: V-N-M-T-A-G-E-E-G-L-L-K-K. The above formula represents a linear peptide shown in left to right representation, the N-terminal amino acid being on the left side and the C-terminal amino acids being on the right side. All of the amino acids represented are L-amino acid with the exception of glycine (G) which has only one form.
The peptide compound of the present invention can be synthesized from its constituent amino acids. For example, the synthesis can be carried out by the Merrifield solid phase method, as described in J.A.C.S. 85:2149-2154 (1963). This solid phase method for synthesizing sequences of amino acids is also described in Stewart and Young, Solid Phase Peptide Synthesis (W. H. Freeman and Co., San Francisco, 1969), pages 1-4. In this procedure, the C-terminal amino acid is attached to chloromethylated polystyrene-divinylbenzene co-polymer beads. Each subsequent amino acid, with suitable protecting group, is then added sequentially to the growing chain. For example, as described in the Merrifield article, the protective group may be a carbobenzoxy group. By the procedure of coupling, deprotection, and coupling of the next amino acid, the desired amino acid sequence and chain length can be produced. As a final step, the protective group is removed from the N-terminal amino acid (viz., lysine) and the C-terminal amino acid is cleaved from the resin, using a suitable reagent, such as trifluoroacetic acid and hydrogen bromide. Since this synthesis procedure is well known, it is not believed that it will be necessary to further describe it herein.
To utilize the antigenic peptide of this invention in the form of a fertility reducing vaccine, the peptide is conjugated to a carrier molecule, which is preferably a protein which itself elicits an antigenic response and which can be safely administered. For example, the peptide can be coupled to tetanus toxoid for administration by intramuscular injection. For example, a mixture of 1, uMole tetanus toxoid, 60, uMoles antigenic peptide, and 18 millimoles 1-ethyl-ε-(3 dimethyl aminopropyl) carbodiimide hydrochloride reacted in water (pH6) for 12 hours at room temperature and 24 hours at 4° gives a product containing 3.5 moles of peptide/mole tetanus toxoid. Excess reactants can be removed by dialysis or gel filtration. See Pique et al, Immunochemistry, 15:55-60 (1978). Alternatively, the peptide may be coupled using bisdiazotized benzidine (Bassiri et al, Endocrinology, 90:722 (1972) or glutaraldehyde. To facilitate coupling to a protein an additional amino acid such as cysteine may be attached to the N-terminal valine. For example, the compound prepared in a form for coupling would be: N-Cys-Val-Asn-Met-Thr-Ala-Gly-Glu-Glu-Gly-Leu-Leu-Lys-Lys.
For intramuscular injection, the coupled peptide may be suspended in a sterile isotonic saline solution, or other conventional vehicle, and, if desired, an adjuvant may be included. A preferred use of such a vaccine is for administration to human females. Antibodies will be formed, which will appear in the oviduct fluids and thereby achieve a significant reduction in fertility. For this purpose, the amount to be administered will range from about 1 to 10 milligrams (mg) of the antigenic peptide.
The compounds of this invention and their antigenic properties are further illustrated by the following examples.
EXAMPLE I
The purification of peptides by reverse phase high performance liquid chromatography has been described by Wheat et al (1981), cited above. Pure mouse LDH-C 4 is reduced and carboxymethylated with iodoacetic acid. Digestion with trypsin (4% w/w) proceeds for 4 hours in the presence of 2 M urea. After desalting on Sephadex G-10, the digest is fractionated on a ,uBondapak C 18 column (3.9 mm×30 cm; Waters Associates) with a gradient of increasing acetonitrile. Trifluoracetic acid (0.04%) is present throughout the gradient. The column effluent is monitored at 214 nm, and fractions are collected manually based on peak absorbance. Fractions are dried under a stream of nitrogen and lyophilized from water. Purity is assessed isocratically in the same chromatographic system, and peptides are repurified as necessary. Following hydrolysis (6 N HCl, 107°, 40 hrs.), amino acid compositions are determined with reverse phase chromatography of o-pthalaldehyde derivatives. See Hill, et al. (1979) Anal Chem. 51:1338-1341. Amino acid sequences were established by the manual Edman degradation. See Tarr (1977) in Methods in Enzymology, Vol. 47, pp. 335-357; and Tarr (1981) Anal. Biochem. 111:27-32.
Following this procedure a segment was obtained which was later determined to be the sequence Val-Asn-Met-Thr-Ala-Gly-Glu-Glu-Gly-Leu-Leu-Lys-Lys. The peptide was tested for antibody binding activity as follows:
Antibody binding by the purified peptide was assessed with a solid matrix radioimmunoassay. The peptide was coated on the walls of a polyvinyl chloride microtiter plate by incubating, overnight at 4° C., a solution containing 5 nmoles of peptide in 100, ul of 0.05 M NaPO 4 , 0.14 M Na Cl (PBS) in each well. Each well was washed with 200 Ml/well 10% horse serum in PBS and incubated for 1 hour in the same solution. After washing, the plate was incubated with 50, ul of the gamma-globulin fraction of pooled rabbit antimouse LDH-C 4 sera. After 4-hours incubation, the plate was washed and then incubated with 100, ul/well of 125 I-goat antirabbit gamma-globulin for 16 hours at 4° C. After exhaustive washing, bound radioactivity was determined using a gamma counter.
EXAMPLE II
Synthesis of the peptide Val-Asn-Met-Thr-Gly-Glu-Glu-Gly-Leu-Leu-Lys-Lys can be carried out employing solid phase techniques now well known in the art. In a preferred procedure amino protected lysine, representing the -COOH terminal group of the above peptide, is coupled to a conventional solid phase peptide synthesis resin such as chloromethyl polystyrene crosslinked with 1 to 2% divinyl benzene. The amino protecting group is then selectively removed utilizing a suitable reagent whose nature will depend on the protecting group used. In the preferred embodiment the t-butyloxycarbonyl (Boc) group is utilized for amino group protection and 40% trifluoracetic acid in methylene chloride is the selective deprotecting agent.
After deprotection, the lysine is treated with protected lysine, preferably αBoc- εcarbobenzoxy-L-lysine, and dicyclohexycarbodiimide in a manner known per se as to form a peptide bond between the free amino group of the lysine residue and the carboxyl group of protected lysine.
The cycle of deprotection and coupling with amino acid derivatives and dicyclohexylcarbodiimide is then repeated with the remaining amino acids in the sequence order of the above peptide. Some of the amino acids required side-chain blocking groups besides the alpha-amino protection. Such amino acids and the blocking groups are as follows:
Thr(oBzl) Lys(Z) Glu(oBzl) (oNP)
where Bzl is benzyl and N is nitrophenyl and Z is ε-carbobenzoxy.
Completion of the synthesis provided the following tridecapeptide coupled to the styrenedivinylbenzene copolymer resin:
Val-Asn(oNP)-Met-Thr(Bzl)-Ala-Gly-Glu(oBzl)-Glu(oBzl)-Gly-Leu-Leu-Lys(Z)-Lys(Z).
Decoupling of the peptide from the resin is accomplished by treatment with liquid hydrogen flouride with concomitant cleavage of all protecting groups to produce the desired peptide.
The antibody binding activity of the peptide, prepared as described, can be determined as described in Example I.
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The novel antigenic linear peptide of this invention comprise a linear peptide of 13 amino acids, comprising the sequence Val-Asn-Met-Thr-Ala-Gly-Glu-Glu-Gly-Leu-Leu-Lys-Lys. This compound corresponds with the amino acids 304 to 316 of mouse LDH-C 4 . The compound has utility in vaccines for reducing the fertility of female mammals.
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FIELD OF THE INVENTION
This invention relates to a soybean cereal containing a nutritionally valuable amount of soy protein and exhibiting excellent nutritional, taste and texture properties. This invention also relates to method from preparing said soybean cereal from full fat, enzyme active soybean flakes made from mechanically dehulled soybeans. Hilum soybean variety is preferred in boiling water technique; and triple null soybean variety are preferred in the microwave method.
BACKGROUND OF THE INVENTION AND RELATED ART
Soybeans have long been a staple of the Asian diet in multiple food forms including tofu and soymilk, among many other soy based and fermented foods. Soybeans are excellent sources of protein. Enzyme active soy protein, i.e., soy protein which has not been denatured, has a desirable amino acid profile for nutritional purposes, and includes other health promoting elements such as phytoestrogens. In recent years, demand for soy foods has grown dramatically in the United States and other western countries, principally in the form of meat analogs, nutrition bars and powdered nutrition beverages prepared from soy protein isolates and concentrates. Chemically fractionated soy ingredients and soymilk are prepared by modernized methods to reduce much of the traditional “beany” flavor favored in the East, but severely objected to in the West.
Demand for natural and organic foods has grown at extraordinary rates. Natural and organic foods generally cannot utilize chemically processed materials. The soy ingredients commonly used are not full fat/oil and have been treated with solvents such as hexane to remove the fat/oil fraction, and would not thus qualify as natural or organic food materials. Such isolates and concentrates are commonly further processed with water and alcohol to remove both soluble and insoluble carbohydrates to produce soy protein isolates (minimum 90% protein, dry basis). Or, just the soluble carbohydrate fraction is removed to produce soy protein concentrates (about 70% protein). The terms fats and oils are used interchangeably with respect to soybeans in the prior art and in this application. The soybean flakes used in the present invention are full fat and enzyme active made from mechanically dehulled and processed full fat, enzyme active soybeans. Hilum varieties soybeans are useful in making the soybean flakes used in the boiling water method of the present invention. Triple null soybean variety is preferred and critical in the microwave method of the present invention. Where the soybeans used in making the flakes are full fat, enzyme active, and mechanically dehulled and processed, the flakes and cereal prepared therefrom would qualify as natural food. Where prepared from organically grown soybeans, the flakes and cereal would also qualify as organic. The defatted concentrates and isolates commonly used do not qualify as natural or organic, as has become increasingly popular in today's market. U.S. Pat. Nos. 6,495,140 and 6,426,111, for example, illustrate preparation of soy fractionates and/or isolates using solvent extraction.
While the soybean flakes used in the present invention may be made by other methods, they are preferably made according to the method recited in U.S. Pat. No. 4,895,730, which patent is incorporated herein by reference.
Soybeans are excellent sources of elements necessary for good health, and supply outstanding nutritional and nutraceutical benefits. Products containing soy are excellent sources of protein, iron, vitamin-B, calcium, lecithin and isoflavones. In particular, its lecithin content is from 2.7 to 3.1 percent. Soybeans also contain essential minerals including phosphorus, which is an essential element used by the body for building bones. Soy isoflavones are now considered helpful in reducing risks for cancer, heart disease, and osteoporosis. Pure soya contains about 38–42%, 18–22% fat or oil (of this lecithin is 2.7–3.1%), 25–35% carbohydrate, 1.5–2.5% minerals, 3–5% fiber, and 5–6% water. Full soya flour furnishes about 89 grams of protein per 1000 calories, i.e., about 132 grams of protein and 44 grams oil per 1000 grams. By contrast potatoes contain only about 21 grams of protein per 1,000 calories. Full soya flour contains about three times the grams of protein per 1000 grams as lean beef. A “typical analysis of soy flour and grits appears in “ The Soybean Digest ”, Vol. 19, No. 8, Jun. 1959, pages 8 to 9, as follows:
Full High Low fat fat fat Defatted Protein, % 40.0 45.0 48.0 52.0 Fat, % 20.0 15.0 5.0 0.5 Fiber, % 2.5 2.5 3.0 3.0 Ash, % 5.0 5.0 5.5 6.5 Moisture, % 8.0 8.0 8.0 8.0
MicroSoy full fat, enzyme active soybean flakes contain about 40.48% protein, 19.0% crude fat, 2.1% fiber, 4.79% ash, 8.08% moisture, and 27.59% carbohydrate. In addition, since soybeans do not contain particular glutens, products made from soy offer an alternative for people suffering from celiac disease and/or gluten allergies.
There exists in the prior art the need for soy-containing products made from natural unchemically processed soybean material; and having the highest possible soy content, while maintaining good taste and texture. Applicants and the prior art faced the problem that unfortunately products containing soybeans, especially in substantial amounts, tend to exhibit undesirable taste and/or texture properties. For Example, products containing soy materials, may exhibit unpleasant characteristics including chalkiness and/or mouth dryness, grittiness, grassy flavor, bitter flavor, salty flavor, and astringency. Primarily as a result of said flavor and texture problems, soybeans have been used in the hot and cold cereal market almost exclusively as additives to grain cereals in the form of soy concentrates and isolates. Limited quantities of soy materials have been added as a protein supplement to cereals made from other grains such as corn, wheat and rice. Soy isolates and concentrates are expensive forms of protein, prone to flavor problems, available mainly in powder form, and do not qualify as natural or organic food stuffs.
Additionally, a normal serving of applicants' inventive cereal, which is prepared from full fat, enzyme active, dehulled soybean flakes, meets the FDA cardiovascular health claim minimum of 6.25 grams of soy protein. According to the FDA, 25 grams of soy protein per day, when consumed as part of a diet low in saturated fat and cholesterol may reduce risk of heart disease. Moreover, the presently inventive cereal should be able to deliver the full 25 grams of soy protein in a single serving of a good tasting quality hot cereal.
Furthermore, the use of soybeans as flakes, provides significant advantages over use of soybean materials which have been further processed into granules or powder. The milling of the flakes into granules or powder increases the surface area of the soybean material, and adversely subjects the soybean material to denaturing additional heat and exposure to oxygen and moisture. Soy flours and powders have significant texture and processing problems (too powdery) and potential flavor problems as a result of milling.
Soy flakes and soy protein isolates or concentrates have been used, as illustrated in U.S. Pat. No. 6,372,782, to make soy-protein-based, liquid nutritional products, wherein the protein source is chosen from soy flakes, soy protein isolate or concentrate, hydrolyzed soy protein, soy flour, soy protein flour, soy whey, and mixtures thereof (note claims 1 and 4 , for example). U.S. Pat. No. 4,895,730 discloses using soybean flakes for making soybean milk. The method for making soybean flakes shown in the '730 patent is the preferred method for making soybean flakes used in the present invention.
U.S. Pat. No. 6,303,177 shows a breakfast cereal containing at least one cereal grain selected from corn, wheat, rye, rice, oats, barley, and mixtures thereof; and, a soy material selected from soy flour, soy grits, soy flakes, a comminuted whole soybean material, or combinations thereof. The cereal grain and soy materials are taught to be blended, cooked to form a cereal dough, and the dough further processed to form a flaked, puffed or shredded ready-to-eat cereal.
U.S. Pat. No. 5,866,192 discloses an edible soy material containing soybean cell walls. The soy material is produced by providing dehulled and hypocotyl-removed soybeans without substantial swelling by water absorption; soaking and heating the soybeans in hot water to which an alkali has been added; and then crushing the soybeans. The edible soy material produced is disclosed to be used similarly to bean jam, mashed potato, hard-boiled egg yolk and the like, and also for gelation (5th paragraph in “Description of the Related Art”). The soaking temperature is taught to be 80° C. or higher, preferably, 85° C. or higher (6th paragraph of “Detailed Description of the Invention). U.S. Pat. No. 4,810,513 discloses producing a full fat, flaked soybean product to be used as cattle feed. The soybeans are not dehulled. The raw soybeans with hulls intact are subjected to steaming at temperatures greater than 100° C., followed by flaking in a roller mill. The flaked soybeans are dried in a forced air dryer by the application of superheated air at temperatures in excess of 300° F. (149° C.), and cooled to ambient temperature. U.S. Pat. No. 4,748,038 discloses a method of producing a bland tasting full fat soy flour meal or grits, wherein the soybeans either whole or split are treated with live steam or water under atmospheric pressure at temperatures ranging between 85 to 100° C. apparently 21 times for 2 to 20 minutes, or for an equal or shorter time under steam pressure in excess of atmospheric pressure. The patent indicates (6th paragraph in “Description”), “If whole soybeans are simply ground to a meal or flour, the flavour is objectionable being described as ‘green’, ‘painty’ and ‘raw’(;) such flavours being a consequence of the enzymatic activity in the full-fat soy flour so prepared.” U.S. Pat. No. 3,290,155 describes a process for producing a full-fat soy flour using dehulled full fat soybean flakes or grits as raw material. The flakes or grits are subjected to screw-type extrusion in which the soy material is heated to 115 to 145° C. under a dynamic pressure of 375 to 400 psi, so as to expel from the soybean flakes as much soybean oil as can be reabsorbed by the flakes upon release from the pressure zone.
U.S. Pat. No. 4,097,613 discloses a protein fortified (above about 20%), natural cereal product which comprises a mixture of whole farinaceous grains (rich in or consisting of starch), such as whole wheat, whole oats rolled oats and flaked wheat; flavorants; sweeteners; and a textured vegetable protein material derived at least in part from peanuts. Peanuts are taught to provide a “nutty” taste “generally more recognized and acceptable to humans than is the more ‘beany’ flavor of soybeans” (2nd paragraph of “SUMMARY OF THE INVENTION”). Also discussed (paragraph 7 of “SUMMARY OF THE INVENTION”) is the inclusion in many breakfast cereal products of protein sources including defatted soybean flakes, or soybean isolates. Canadian patent 972,276 relates to debittering soy products and eliminating the undesirable bitter or beany flavor of soy. This patent indicates it is known in the art to incorporate soy flour, soy protein isolates, soy grits, soy flakes, soy meal and the like, into foods such as ready-to-eat and other breakfast cereals, but which also include cereal grains such as corn, rice, wheat, barley and the like, etc. (paragraph bridging pages 1 and 2). Also, disclosed is use of soy materials in bread formulations, cake flour, soup and gravy mixes, cookie, pancake, doughnut and waffle mixes and meat loaf. The patent notes, however, that the amount of soy that can be incorporated in a given food is limited by the natural soybean flavor that may be characterized as bitter or beany. The patent teaches reducing these flavors by incorporating as flavor controller, caramelized malt, Munich malt, or other high flavor malt. The patent teaches adding the soy material at a level of 0.5 to 30%; preferably adding 15 to 25% concentrated soy for breakfast cereal formulations.
The Soybean Digest , June 1959, pp. 8–9, broadly indicates edible soy products are useful additives in a variety of food products including bread and other bakery products of all types, hot and cold breakfast cereals, macaroni and spaghetti, doughnuts and doughnut mixes, cookies and crackers, and snake items. U.S. Pat. No. 6,242,033 shows preparation of an expanded cereal product from starch from a tuber such as potatoes and protein from soybeans. U.S. Pat. No. 3,852,491 shows high temperature and high pressure extrusion formation of an expanded cereal from up to 55% soy protein.
Applicants have discovered, totally unexpectedly and contrary to the teachings of the prior art, a hot cereal having good taste and texture characteristics prepared from substantially 100% full fat, enzyme active, soybean flakes made from dehulled soybeans. Hereinafter the soybean flakes made from dehulled soybeans will, for convenience, often be referred to as “full fat, enzyme active, dehulled soybean flakes”. Applicants have also discovered unexpected boiling water method and microwave method for making said cereal from soybean flakes.
SUMMARY OF THE INVENTION
An object of applicants' invention is to provide a substantially 100% soybean cereal having unexpectedly good taste and texture. Another object to provide such as cereal made from full fat, enzyme active, dehulled soybean flakes. An additional object is to provide boiling water method and microwave method for making a substantially 100% soybean cereal from full fat, enzyme active, dehulled soybean flakes.
Applicants have discovered a substantially 100% soybean cereal having unexpectedly good taste and texture qualities. Applicant have also discovered unexpected boiling water method and microwave method for making said soybean cereal. Applicants' inventive soybean cereal has excellent nutritional properties, including protein content; and exhibits excellent flavor and texture characteristics. An outstanding feature of the applicants' soybean cereal is the high content of balanced proteins, containing in readily available form all of the so-called essential amino acids in proportions that insure or promote efficient utilization within the body. The boiling water method both hydrates the soybean flakes and deactivates enzymes that cause undesirable flavors typically referred to as “beany.”
Unlike the cited prior art, which tend to use hulled (hull not removed), de-fatted soy materials, concentrates or isolates, applicants' invention utilizes full fat, enzyme active soybean flakes made from mechanically dehulled and processed soybeans. Conventional clear hilum soybean variety is preferred for best flavor and texture in the boiling water method of preparation of the cereal. For microwave preparation of the inventive cereal, use of triple null soybeans is critical and preferred. The dehulled, full fat, enzyme active soybean flakes used in applicants' invention provide significant advantages over soybean materials that have been processed by grinding or extruding to form granules and particularly powders. The forming into small granules and especially powders dramatically increases the surface area of the soybean material exposed to oxygen and moisture, and adversely subjects the soybean material to denaturing heat and exposure to oxygen and moisture during processing. The exposure and additional heating lead to degradation of the soybean material, especially denaturing of the proteins, and off-flavors. Soy flours and powders have significant texture and handling problems, and potential flavor problems as the result of milling.
The full fat, enzyme active, dehulled soybean flakes useful in applicants' invention can be prepared by methods known in the prior art. Especially preferred are soybean flakes made substantially in accordance with the method set forth in U.S. Pat. No. 4,895,730, which patent is incorporated herein by reference. As disclosed in this patent, the soybean flakes are prepared by (1) brushing the soybeans to remove earth matter and earth born germs; (2) adjusting the water content to facilitate separation of the skin portion; (3) separating the skin portion from the flesh portion, while simultaneously dividing the flesh portion of each soybean into four to eight parts; and, (4) passing the soybean granules thus obtained through flat-pressing rollers, whereby a product in the form of a mass of uniformly distributed, dehulled, full fat, enzyme active soybean flakes is obtained. The soybean flakes have a thickness of about 0.2 mm., or less, and long storage capability. The heat resistant earth-born germs and sporal germs are completely removed during the brushing and dehulling or skinning of the soybeans, which germs are not removed by conventional steps of washing. The soybean flakes prepared in accordance with the method set forth in the '730 patent, and foodstuffs prepared therefrom, are thus rendered less perishable and highly wholesome. Soybean flakes prepared according to '730 patent are especially useful in the present invention. While numerous varieties of soybeans are available, the clear hilum soybean variety is preferred for the boiling water method of preparing applicants' inventive cereal. Triple null soybean variety is especially preferred and critical for use in the cereal preparation method using microwave. Null refers to soybeans wherein the lipoxygenase enzymes has been bred out of the soybean. Triple-null refers to soybeans which are essentially free of the native lipoxygenase enzyme that causes an unpleasant and generally undesired flavor in soy foods.
DETAILED DESCRIPTION OF THE INVENTION
Applicants have invented a substantially 100% soybean cereal made from full fat, enzyme active soybean flakes made from mechanically dehulled and processed soybeans. The soybean flakes used in the boiling water method of making applicants' cereal are made preferably from clear hilum soybean variety. Soybean flakes made from triple null variety soybean are preferred and critical in the inventive microwave method of making applicants' cereal. Applicants have invented a boiling water method and a microwave method for making the soybean cereal from said soybean flakes.
The full fat, enzyme active soybean flakes used in the present invention are made from full fat, enzyme active (undenatured), dehulled soybeans. While the soybean flakes may be made by a variety of processes known in the prior art, it is advantageous that the soybeans be mechanically dehulled and processed. The temperature of the soybeans material during processing to flakes should be maintained no higher than 55° C., and more preferably no higher than 50° C. Higher temperatures lead to denaturing of the soybean material, and off flavors. Especially preferred soybean flakes for use in the present invention are made by the method disclosed in U.S. Pat. No. 4,895,730, which patent has incorporated herein by reference.
Full fat, enzyme active soybean flakes prepared from mechanically dehulled and processed soybeans by the method disclosed in the '730 patent are available from MicroSoy Corporation in Jefferson, Iowa, marketed under the trademark MicroSoy Flakes. MicroSoy Corporation has a main office and plant in Jefferson, Iowa. According to the method disclosed in the '730 patent, full fat, enzyme active soybean flakes are prepared by subjecting soybeans to brushing and dehulling or skinning, such that earth-born germs and sporal germs are completely removed, including those which are heat resistant and those which cannot be removed by the conventional step of washing the material soybean in water. The flakes and food stuffs made therefrom are rendered less perishable and highly wholesome. The processing of the soybeans in the patent includes, after the brushing step, a step of adjusting the water content of the soybeans to facilitate separation of the skin portion of the soybean from the flesh portion thereof. The soybean is then separated into skin portion and flesh portion, and simultaneously the flesh portion of each piece of soybean is divided into four to eight parts. The soybean granules thus obtained are passed through flat-pressing rollers, whereby a product in the form of a mass of uniformly distributed flakes results. The adjustment of water content of the soybean facilitates skin/flesh separation and also dries the flesh, so that a product having a low moisture content and good storage stability can be obtained when the flesh is reduced to flakes. Said water content adjustment is carried out such that the temperature of the soybean material does not exceed temperatures which will not cause thermal denaturing of the soy protein. The temperature of the soybean material does not exceed 55° C.; and more preferably 50° C. “Full fat” refers to soybean flakes where no fat has been removed, except that very small amount lost during washing and dehulling.
Many suitable varieties of soybeans are available, including yellow and/or clear variety hilum soybeans. Use of black hilum soybeans is less desirable due to the carry over of color into the inventive composition and inventive product, which some find less aesthetic or appetizing. Also, available are single, double or triple null soybean varieties. Triple-null soybeans are bred to be essentially free of the native lipoxygenase enzyme that causes an unpleasant and generally undesired flavor in soy foods. Soybean flakes made from clear hilum soybean variety are preferred for the boiling water method of making the inventive cereal. Soybean flakes made from triple null soybean variety are most useful and critical in the method of making applicants' cereal using microwave.
Applicants have also discovered that the use of soybean flakes provides an unexpected difference in the flavor and texture perception of the cereal product made therefrom, as compared with the use of soy granules or powder. During preparation of soybean granules and especially powder, the surface area of the soybean material is increased, with consequent increased degradative exposure to oxygen, moisture, and additional heating during grinding. Soy flour and powder have significant textural and handling problems, and potential flavor problems as the result of milling. Moreover, the cereal of the present invention, which is prepared from full fat, enzyme active flakes made from mechanically dehulled and processed soybeans, qualifies as “natural”, and is free from “harmful” additives. When the soybeans qualify as organically grown, applicants' soybean cereal would likewise qualify as “organic”.
The inventive cereal is prepared, in the boiling water method, by placing the soybean flakes in a filter or holding means which is readily permeable to water, but retains the flakes during cooking. Said holding means must be such that it retains the flakes, while permitting water to freely pass therethrough into contact with the flakes. The holding means containing the flakes is immersed in boiling or near boiling water for a time sufficient to form the soybean cereal, e.g., about 5 to 10 minutes, preferably about 10 minutes. The holding means is removed from the water and the soybean cereal emptied in the a container suitable for serving. Soy or dairy milk is normally added to the cereal. Traditional hot cereal flavorings (e.g., cinnamon, maple syrup, fruit, honey, etc.) may also be added.
An illustrative example of a boiling water method of preparing the inventive soybean cereal includes the following steps (illustrative amounts and times are included):
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The invention relates to a soybean cereal having excellent nutritional, taste and texture properties; and method of making said soybean cereal from full fat, enzyme active soybean flakes made from mechanically dehulled soybeans.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from and benefit of the pending European Application No. 14198958.2 filed on Dec. 18, 2014, the disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The invention relates to an inductive power coupling device for coupling electrical power between two units that are rotatable against each other, and, specifically for power couplers used in computer tomography scanners. Such power couplers are also known as rotary joints.
[0004] 2. Description of Relevant Art
[0005] In computer tomography (CT) scanners and other related machines high-power in the range from 10 kW up to more than 100 kW is transferred from a stationary side to a rotating side. There, a high voltage in the range of above hundred kilovolts is generated to produce x-ray radiation.
[0006] In U.S. Pat. No. 7,054,411 a multiple channel inductive rotary joint is disclosed. It has inductive channels for transferring power from the stationary side to the rotating side. There is an auxiliary power and a main power circuit. Furthermore a capacitive feedback link for power control is provided. There may be some failure states such as a short circuit of a rotating power channel to protective earth, which may cause dangerous high voltages at the rotating part and which may cause the rotating part of the feedback link to be inoperative and, therefore, may interfere with the communication to a primary power controller.
SUMMARY
[0007] The embodiments of the invention are directed to increasing the safety of devices that utilize inductive power couplers between rotating parts. Such devices may be CT scanners. Specifically, a short circuit of a rotating power channel to protective earth should no more cause excessive voltages at the rotating part. Furthermore, means and methods should be provided to detect such a short circuit from the stationary side without requiring communication from the rotating side.
[0008] Inductive rotary joints usually are built like power transformers, where one side is rotating against another side. For example, in CT scanners, power has to be transferred from the stationary to the rotating side. Therefore, the power coupler is a transformer having a stationary primary winding and a secondary rotating winding. For simplicity, the following explanations and embodiments refer to a CT scanner rotary joint. The same concepts can be applied to any rotary joint in general and furthermore to a rotary joint configured to transfer power from a rotating side to a stationary side.
[0009] As a transformer can only transfer AC (alternating current), it is either fed by an AC line voltage or by an inverter, generating an AC voltage of a higher frequency which can better be transferred via a rotating transformer. At the output side, in most cases this AC voltage is converted to a DC voltage to provide a DC output. This may be done by a bridge rectifier, followed by a filtering capacitor to generate a smooth DC voltage. Although the secondary winding of the rotating transformer and the DC voltage generated thereof are floating, there is a significant capacitance between the secondary DC circuit and the mechanical base holding the components of the rotating part. This is specifically the case with a CT scanner, with a large number of electronic components mounted to a rotating disk forming the mechanical base of the rotating part. The mechanical base is further also referred as secondary or rotating ground. Furthermore, there may be capacitors for suppressing noise, which are connected between the DC voltage supply and the mechanical base, which may further be connected by a galvanic slip ring to stationary protective earth. This connection to protective earth further prevents high voltage at the rotating part in the case of certain failures against ground, and therefore prevents electrical shock of persons operating the device when touching the device in such failure state.
[0010] Basically, the secondary winding is isolated against the mechanical parts, and therefore against the protective earth. Under certain circumstances, the isolation may fail. The applicable circumstances may include, for example, a mechanical failure due to mechanical damaging of the isolation, which may occur at ends of the isolation or at locations where the isolated wire of the secondary winding is connected to the external device, such as a rectifier. There may be other failure modes, such as thermal failures that may be caused by overheating, or electrical failures that be caused by longtime degradation of the isolation, or by sparking or arcing, or even a combination of some of these failure modes.
[0011] When such a failure of a short circuit occurs, the ground capacitor (the previously mentioned capacitance between the secondary output and the rotating ground) is connected parallel to at least one of the bridge rectifier diodes. The bridge rectifier now acts as a voltage doubler. As a consequence, the DC output voltage may become twice the normal DC output voltage. With a high probability, this will result in a failure of many of the electrical or electronic components attached to the DC output voltage.
[0012] In a first embodiment, there is a low impedance galvanic connection between a DC output line, which may either be the positive DC output or the negative DC output, and the mechanical base.
[0013] It is preferred if a galvanic connection is provided between the stationary and rotating sides which is also connected to said DC voltage output. The galvanic connection preferably is a slip ring having a brush sliding on a sliding track. In another embodiment, the galvanic connection may be made by a bearing, which for example may be a ball bearing between the rotating and the stationary parts. Most preferably, this bearing is further complemented by a parallel galvanic low current slip ring. Under normal operating conditions, there is no current flowing through the galvanic ground connection. Therefore, this galvanic ground connection has an extremely long lifetime, as there is not wear of the brushes and the sliding tracks due to arcing which usually occurs under high currents. There is also no wear or corrosion, if a bearing is used.
[0014] In a further embodiment, a control unit is provided at the primary side of the rotating transformer, which side preferably is the stationary side. This control unit preferably is measuring the current through the galvanic ground connection. In the failure case of a short circuit of the secondary winding towards the secondary ground, there will be significant ripple current flowing through this line, which can easily be detected by the control unit. This control unit may further issue an emergency switch-off signal to disable the power supply from the device. Such a signal may control a primary inverter supplying an AC voltage to the primary winding of the capacitive rotating transformer. In another embodiment, the control unit may be connected to a voltage and/or current sensor at the primary winding and/or at the primary input, detecting abnormal voltages/currents to detect said short circuit.
[0015] During standstill a ball bearing holding the rotating part may provide a sufficient grounding or protective earth. Grounding may further be increased by a grounding jumper which may be inserted manually for maintenance and service.
[0016] In a further embodiment, there may be a switch for generating a short circuit as described above, for example by shorting a diode. This switch may be used to trigger a power off at the primary side from the secondary side. It could be used as an emergency shutoff if there is any fault at the secondary side.
[0017] These embodiments provide a significant improvement in reliability and safety over the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] In the following, the invention will be described by way of example, without limitation of the general inventive concept, on examples of embodiment and with reference to the drawings.
[0019] FIG. 1 shows a circuit diagram of a preferred embodiment.
[0020] FIG. 2 shows the positive current path in a first failure mode in a first embodiment.
[0021] FIG. 3 shows the negative current path in a first failure mode in a first embodiment.
[0022] FIG. 4 shows a circuit known from the prior art.
[0023] FIG. 5 shows the positive current path in a first failure mode according to prior art.
[0024] FIG. 6 shows the negative current path in a first failure mode according to prior art.
[0025] FIG. 7 shows the positive current flow in normal operation.
[0026] FIG. 8 shows the negative current flow in normal operation.
[0027] FIG. 9 shows a CT scanner.
[0028] Specific embodiments of the invention are shown by way of example in the drawings and will herein be described in detail, and are subject to modifications and alternative forms each of which is within the scope of the invention. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION
[0029] In FIG. 1 , a circuit diagram of a preferred embodiment is shown. An apparatus like a CT scanner may comprise a primary side 100 which preferably is stationary and a secondary side 200 which preferably is rotating. There is a rotating transformer having a primary winding 110 and a secondary winding 210 for inductively coupling electrical signals from the primary side to the secondary side. The primary winding 110 is fed by an inverter 120 which converts input voltage received via primary inputs 131 , 132 into an alternating voltage, preferably a voltage in a frequency range from between 1 kHz and 100 kHz, most preferably about 20 kHz. The voltage output of the secondary winding 210 is provided at secondary winding contacts 254 , 255 , which are connected to a rectifier. Preferably, the rectifier is a bridge rectifier comprising four diodes 221 - 224 . The output of the rectifier preferably is connected to a filtering capacitor 230 . Furthermore, connected to the filtering capacitor 230 may be a positive output voltage pin 251 and a negative output voltage pin 252 , by which a load 240 may be connected. In a CT scanner, the load may comprise an X-ray tube and/or multiple electrical or electronic circuits, like a computer, a detector and imaging processing means. One of the output pins 251 , 252 is connected to a secondary ground 253 . Preferably, the negative output 252 is connected thereto. The secondary ground 253 is preferably based on mechanical parts at the rotating side, which may be the rotating part of a gantry of a CT scanner.
[0030] It is further preferred to have a slip ring 280 comprising at least one sliding track 281 and a at least one brush 282 for electrically connecting said secondary ground 253 to a protective earth 134 (which may be a primary ground), which may further be connected via a protective earth connector 133 to a main power system, or a specific ground pad.
[0031] It is further preferred to have a control unit 150 for controlling the inverter 120 or any other control means at the primary side. The controller 150 may be connected to a ground current sensor 151 for measuring a current between the secondary ground 253 and the protective earth 134 . It may also measure a current through the primary winding 110 , preferably by use of a second current sensor 153 . Based on the measurement results, a trigger signal 152 may be generated.
[0032] In an inductive rotating coupler, certain faults may occur. One of these faults may be a short circuit of the secondary winding to the secondary ground 253 . In this embodiment, a short circuit of the second secondary winding contact 255 is marked as a dashed line 270 indicating the short circuit. A similar scenario takes place, if the first secondary winding contact 254 has a short circuit to the secondary ground 253 . There may also be a short circuit of any other part of the secondary winding 210 to secondary ground 253 . By the short circuit, depending on the kind of short circuit, one of the rectifier diodes 221 , 223 is shorted. The function is explained exemplarily by the kind of short circuit as indicated by dashed line 270 . In this case, the rectifier diode 223 is shorted. As the rotating transformer is operated with an AC signal, it delivers positive and negative half waves at its output. When the secondary winding 210 delivers a positive output, where the voltage at the first secondary winding contact 254 is higher than the voltage at the second secondary winding contact 255 , the circuit works as usual, as the rectifier diode 222 lets the current flow into the filtering capacitor 230 and the load 240 . When a negative half wave is delivered, the voltage at the first secondary winding contact 254 is lower than the voltage at the second secondary winding contact 255 , then the diode 224 provides a short circuit of the secondary winding. This short circuit leads to an asymmetrical current flow through the rotating transformer, which may easily be detected at the primary side, for example by second current sensor 153 , but it would also generate a signal which may be detected by the ground current sensor 151 at the primary side.
[0033] Due to the asymmetrical short circuit of the secondary winding 210 by one of the rectifier diodes, it is impossible that the circuit works as a voltage doubler, as the prior art, as shown in FIG. 4 .
[0034] In FIG. 2 , the positive current path in a first failure mode with a short circuit 270 is shown as a dashed line with arrows indicating the direction of the current. When the output voltage at the first secondary winding contact 254 is higher than the voltage at second secondary winding contact 255 , then a current flows through the circuit as shown. It flows through a rectifier diode 222 into the capacitor 230 and back via secondary ground 253 and the short circuit 270 to the second secondary winding contact 255 . This kind of current flow results in a normal charge of the capacitor 230 .
[0035] A negative current flow into the opposite direction, as indicated by FIG. 2 is shown in FIG. 3 by a dashed line with arrows indicating the direction of the current. The current flows from the second secondary winding contact 255 via the short circuit 270 and secondary ground 253 through diode 224 back to the first secondary winding contact 254 . This is a short circuit via the diode 224 of the secondary winding 210 . There are further parasitic capacitive currents flowing via the slip ring 280 to the protective earth 134 which may be detected by the control circuit 150 . Furthermore, the asymmetrical load can easily be detected by a second current sensor 153 at the primary side of the inductive rotary joint.
[0036] In FIG. 4 , an embodiment as known from the prior art is shown. Here, there is no slip ring 280 and no controller 150 with the associated circuits and components. Furthermore, there is a ground capacitor 260 . This capacitor is required to provide a high frequency connection between the output of the circuit and the secondary ground 253 . In this embodiment, the negative output of the power supply is connected to the secondary ground 253 . If a short circuit between the secondary winding 210 and the secondary ground 253 occurs as indicated by dashed line 270 , the circuit acts as a voltage doubler, causing approximately doubling of the regular output voltage at the capacitor 230 . This would affect the operation of a connected load 240 . There is a high probability that sensitive electronic components within the load may be destroyed or at least damaged.
[0037] In FIG. 5 , the positive current path in a first failure mode according to prior art is shown as a dashed line with arrows indicating the direction of the current. In the case of a positive output voltage of secondary winding 210 , current is flowing through rectifier diode 222 into capacitor 230 and therefrom via capacitor 260 , secondary ground 253 , and the short circuit 270 back to the second secondary winding contact 255 . As will be shown in the next Figure, the capacitor 260 was charged by a current of the preceding negative half wave output of secondary winding 210 to a negative voltage having the inverse polarity to the voltage at capacitor 230 . Therefore, the ground capacitor's 260 positive side is at the secondary ground 253 , whereas its negative side is at the negative output 252 . As the total voltage over the capacitor 230 and the ground capacitor 260 equals to the output voltage of the secondary winding 210 , the capacitor 230 must have twice the output voltage of the secondary winding 210 . This leads to twice the output voltage at the load 240 .
[0038] In FIG. 6 , the current flow in a negative direction according to the prior art is shown as a dashed line with arrows indicating the direction of the current. The current flows from the second secondary winding contact 255 via short circuit 270 and secondary ground 253 through ground capacitor 260 , and diode 224 back to the first secondary winding contact 254 . It can be seen how the ground capacitor 260 is charged with a charge current in the opposite direction to capacitor 230 , as mentioned in the description of the previous Figure.
[0039] In FIG. 7 , a positive current flow in normal operation of a preferred embodiment is shown. Here, the current flows from the first secondary winding contact 254 to diode 222 , capacitor 230 , and diode 223 back to the second secondary winding contact 255 .
[0040] In FIG. 8 , a negative current flow in normal operation of a preferred embodiment is shown. Here, the current flows from the second secondary winding contact 255 via diode 221 , capacitor 230 , and diode 224 back to the first secondary winding contact 254 .
[0041] FIG. 9 shows schematically a CT (Computed Tomography) scanner gantry. The stationary part is suspended within a massive frame 810 . The rotating part 809 of the gantry is rotatably mounted with respect to the stationary part and rotates along the rotation direction 808 . The rotating part may be a metal disk which supports an X-ray tube 801 , a detector 803 and further electronic and mechanic components. This disk may define a secondary ground. The X-ray tube is for generating an X-ray beam 802 that radiates through a patient 804 lying on a table 807 and which is intercepted by a detector 803 and converted to electrical signals and imaging data thereof. The data obtained by the detector 803 are transmitted via a contactless rotary joint (not shown) to an evaluation unit 806 by means of a data bus or network 805 . Electrical power from a stationary power supply unit 811 may be transmitted by an inductive power coupler 800 to the rotating part.
[0042] Modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as the presently preferred embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Changes may be made in the elements described herein without departing from the spirit and scope of the invention as described in the following claims.
LIST OF REFERENCE NUMERALS
[0000]
100 primary side
110 primary winding
120 inverter
131 , 132 primary input
133 protective earth connector
134 protective earth
150 control unit
151 ground current sensor
152 trigger signal
153 second current sensor
200 secondary side
210 secondary winding
221 - 224 rectifier diode
230 capacitor
240 load
251 positive output
252 negative output
253 secondary ground
254 , 255 secondary winding contacts
260 ground capacitor
270 short circuit
280 slip ring
281 sliding track
282 brush
800 inductive power coupler
801 x-ray tube
802 x-ray beam
803 x-ray detector
804 patient
805 network
806 evaluation unit
807 patient table
808 rotation direction
809 rotating part
810 frame
811 power supply unit
10 Gantry
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An inductive rotating power transfer circuit, preferably for transferring electrical power from the stationary part to the rotating part of a CT scanner comprises an inductive power transformer having a stationary primary side and a rotating secondary side. The secondary side is connected via a rectifier to a filtering capacitor, delivering electrical power to a load. One of the output pins of the filtering capacitor is connected to a secondary ground at the rotating part which is further connected to a stationary protective ground via a galvanic slip ring. In the case of a short circuit between a secondary transformer winding and the secondary ground, the secondary winding is partially short-circuited by one of the rectifier diodes. This causes an asymmetric current load at the primary side and a current flowing through the slip ring. Both currents may be used to detect a failure of the secondary winding.
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TECHNICAL FIELD
This invention relates generally to memory tree searches and, more particularly, to employing hash table entries and their associated tree fragments.
BACKGROUND
In modern microprocessor systems, the speed of the main memory tends to be substantially slower than the speed of the processor core. A typical DRAM main store coupled to a high-frequency microprocessor takes several hundred processor cycles to access. In the future, problems resulting from the mismatching of memory speed versus processor speed will, in all likelihood, become ever more acute.
One major cause of these problems is memory access latency. For example, the time between the issue of a LOAD instruction to main memory and the actual transfer of a first Word from a main memory is usually very long, and can impose many stall cycles on the processor core. However, once the first word has been transmitted, consecutive words can be transferred quickly. The quick transference of consecutive words is generally referred to as the “burst-mode effect.”
Typically, a microprocessor system employs a local store, such as a cache, to take advantage of the burst-mode effect. This occurs by transferring a whole cache line (that is, the minimum number of bytes that is to be loaded when a local store or cache data is replaced) from main memory and storing the whole cache line in the local store, instead of just transferring the smaller words that are requested directly from the main memory.
If the likely data to be read in the near future has a sufficient amount of spatial locality (that is, data stored in a sufficiently substantially contiguous area in the main memory) with the data now requested, and is therefore also stored in the local store, memory efficiency is improved. This is typically because the memory information that is likely to be needed is already stored in the faster cache, thereby reducing memory access times. The same effect can be achieved if the microprocessor system features a memory architecture, whereby the microprocessor system transfers the memory blocks from the main memory to a local store. The local store is comparable to a cache, such as a software-managed cache. The local storage can be a function of memory burst access size, bus transfer size and cache line size.
In conventional technology, methods exist to implement tree searches within a cache, by the cache hardware or software managed. During a search of a decision tree, such as a binary tree, after reaching a decision node, a subset of the appropriate tree nodes are accessed as the tree is traversed. This process continues until reaching the appropriate leaf node which contains the desired data. Only a few bytes are read during each tree node access.
Conventional tree search implementations use indirect pointers in each tree node to reference the parent and child nodes, and tree nodes are usually distributed across the whole address space. These approaches have at least two major drawbacks.
The first drawback of existing tree search implementations is that since the nodes, both decision and leaf, are typically distributed across the whole address space, multiple memory accesses to random memory locations need to be performed. Spatial locality is low or nonexistent, which leads to long waiting times for the microprocessor to wait upon memory access because the needed information is stored in noncontiguous areas. The second disadvantage is that the indirect pointers within a tree node consume memory.
Therefore, there is a need for employing tree nodes with memory accessing in a cache that overcomes the shortcomings of existing memory accessing methods.
SUMMARY
The present invention employs tree fragmentation in combination with a single hash table lookup scheme. A plurality of tree fragments is determined from a data tree structure. Each member of the determined plurality of tree fragments has at least one decision node and one leaf node. Each tree fragment is stored in its own contiguous memory segment. Decision nodes are stored in a contiguous block of memory in a relative position based on the position of the decision node in the tree structure, including blank positions. Leaf nodes are stored in a contiguous block of memory based on the position of the leaf node in the tree structure, concatenating leaf nodes to eliminate blank positions. At least one table entry corresponding to each tree fragment is hashed, thereby creating at least one hash key and at least one hash table entry. In one aspect, the data structure is most advantageously employed to implement a prefix search algorithm.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following Detailed Description, taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a microprocessing system for employment of sub-tree fragments comprising a microprocessor, a main memory, a main memory bus, and a local store;
FIG. 2 illustrates a fragmentation of a binary tree;
FIG. 3A illustrates a method for initializing a data structure employing tree fragments;
FIG. 3B illustrates a method for performing a search with the data structure employing tree fragments;
FIG. 4A illustrates a layout of a sub-tree fragment organized in memory;
FIG. 4B illustrates headers for the application of sub-tree fragments to longest prefix matches (LPMs);
FIG. 5 illustrates an example of the format of a decision node;
FIG. 6 illustrates a Patricia tree; and
FIG. 7 illustrates an example of a layout of the tree fragments in memory.
DETAILED DESCRIPTION
In the following discussion, numerous specific details are set forth to provide a thorough understanding of the present invention. However, those skilled in the art will appreciate that the present invention may be practiced without such specific details. In other instances, well-known elements have been illustrated in schematic or block diagram form in order not to obscure the present invention in unnecessary detail. Additionally, for the most part, details concerning network communications, electromagnetic signaling techniques, and the like, have been omitted inasmuch as such details are not considered necessary to obtain a complete understanding of the present invention, and are considered to be within the understanding of persons of ordinary skill in the relevant art.
It is further noted that, unless indicated otherwise, all functions described herein may be performed in either hardware or software, or some combination thereof. In a preferred embodiment, however, the functions are performed by a processor, such as a computer or an electronic data processor, in accordance with code, such as computer program code, software, and/or integrated circuits that are coded to perform such functions, unless indicated otherwise. In a further embodiment, the computer program is embodied upon or within a computer program product, such as a floppy disk or compact disk, or other storage medium.
Referring to FIG. 1 , illustrated is an exemplary microprocessing system 100 . The system 100 comprises a microprocessor 110 , a main memory control bus 115 , a main memory 120 , a memory data bus 125 , a local store 130 , and a local store bus 135 . Typically, the microprocessor is further functionally coupled to an Internet bus, which is coupled to the Internet or some other networked environment.
Generally, in the system 100 , search trees, such as binary search trees, are stored within the main memory 120 . The search tree has been divided into tree fragments, as illustrated in FIG. 2 . Each of these tree fragments represents a subset of a search tree, and is a tree itself. Referring back to FIG. 1 , all the nodes, both decision nodes and leaf nodes, that belong to a sub-tree fragment are typically stored in the main memory 120 in consecutive memory locations (that is, in two separate blocks). In one embodiment, all tree fragments are equal in size.
In the system 100 , a tree fragment is loaded into the local store 130 , through the memory data bus 125 , through the employment of one burst memory access step. The size of a sub-tree fragment to be loaded through the memory data bus 125 is subject to the minimum-size constraints of memory access granularity. Memory access granularity is generally defined as the minimum amount of data transferred from main memory in one load in a parallel data bit transmittal.
In one embodiment, the size of the fragment (that is, the total number of nodes) is as large as allowable by a function of the memory access granularity and size of a decision node. Typically, a quantity of 2 n−1 nodes yields a balanced partitioning of a balanced binary tree. In general, the maximum allowable number of nodes can be calculated by the following formula:
Number of nodes=((Memory Access Granularity)−(Size of Fragment Header))/(Size of a Node) 1.
The microprocessor 110 determines in which sub-tree fragment the desired information is likely to be located through employment of hash function, hash key and hash table entries. In one embodiment, the hash table is a 1:1 hash table. In other words, there is a unique 1:1 correspondence between an entry in the hash table and the resulting value. The microprocessor 110 then requests, through the main memory control bus 115 , information from the main memory 120 and loads the appropriate sub-tree fragment into the local store 130 in one load sequence. After being loaded into local store 130 , the sub-tree fragment is traversed (searched) by the microprocessor 110 . In a further embodiment, the local store 130 has a plurality of desired leaf nodes stored within it, as the loaded sub-tree fragment has a high degree of spatial locality. Therefore, a line in the local store 130 is accessed multiple times for one tree search, thereby saving substantial time when the microprocessor 110 accesses memory values. If the local store is organized as a cache, memory accesses associated with searching the tree fragment result in “cache hits;” that is, the hardware detects that the requested memory word is present in the cache. In the case of a “software managed” cache, this knowledge is part of the compiled program.
In a further embodiment, the microprocessor system 100 comprises a memory hierarchy with different levels of access granularity for each level of the memory hierarchy. For example, a processor reads single words from the local store 130 , but the local store 130 can load only whole cache lines from a second cache. The second cache then accesses the main memory 120 , or a third cache, with an even larger granularity.
Turning now to FIG. 2 , illustrated is an example of a fragmentation of a binary tree 200 . The pointer 240 in the table 260 points to the root node of the binary tree 200 , which comprises, among others, the tree fragments 210 , 220 and 230 .
The illustrated embodiment of the binary tree 200 is employable for finding a longest prefix or LPM (longest prefix match). One context in which LPM arises is in utilizing a routing table lookup in Internet protocol (IP) forwarding. Typically, in IP forwarding, a routing decision is made based upon the destination address of an IP packet. Typically, the LPM is employed to find the longest bit pattern of length n within a table that matches the first n bits of the destination address. In this embodiment, the binary tree is a Patricia tree, which allows for an efficient LPM, although other tree types are within the scope of the present invention. The Patricia tree is combined with a table lookup. There is one table with 65536 entries, with one entry in the table matching the first 16-Bit of a 32-Bit IPv4 IP-Address.
An entry of this lookup table might contain one of the following three: 1) a pointer to a Patricia tree, that is, fragmented similar to the binary tree 200 ; 2) a pointer to the route information itself (in this case the longest prefix is exactly 16-Bit long); and 3) nothing. In the third case, the longest prefix for the considered IP-Address might be shorter than 16-Bit, which will make it necessary to search another Patricia tree which contains prefixes shorter than 16-Bit. This Patricia tree can be fragmented as well.
In FIG. 2 , a table with 65536 entries, corresponding to the first 16-Bit of an IP-Address is illustrated. Such a table is the most simple form of a hash table with a 1:1 mapping. Those skilled in the art will understand that there are other hash tables that are employable within the scope of the present invention.
Generally, one important attribute of a tree fragment of the present invention is that all of its nodes are stored in main memory at consecutive memory locations; that is, the tree fragment is stored as a block. In this example, a tree fragment format as described in the following paragraphs will be used. Those of skill in the art will understand that the fragment format might be arbitrary, and that the only condition for successfully fragmenting a tree is that tree fragments are stored in blocks.
Turning now to FIGS. 3A and 3B , disclosed is a method 300 for initializing a data structure employing a sub-tree fragment given an initial table ( FIG. 3A ) and a corresponding search algorithm ( FIG. 3B ).
Turning first to FIG. 3A , the data structure is initialized as follows. In step 305 , an appropriate hash function is determined and a corresponding hash table is initialized to the empty state. In step 310 , an entry is removed from the input search data table and added to the new data structure by first computing the hash key. In step 315 , the hash table entry is examined. If the hash table entry is empty, it is updated to point to a new (sub-tree) block in memory, in step 320 . If the hash table entry is not empty, the element is added to the corresponding tree fragment in step 325 . In step 330 , the tree fragment is examined for size using the formula:
Fragment Size=((Memory Access Granularity)−(Fragment Header Size))/(Node Size).
If the tree fragment exceeds the size of the memory access granularity, the tree fragment is further fragmented into smaller tree fragments, in step 335 . In step 340 , the initial data structure is reexamined. If it is empty, initialization is complete. If it is not empty, the algorithm returns to step 310 . In step 345 , the method finishes.
Turning next to FIG. 3B , the corresponding search algorithm follows the following steps. In step 350 , the search key is hashed to determine the index into the hash table. In step 355 , the corresponding entry in the hash table is loaded from memory. Generally, this will require an access to main memory. In step 360 , the hash table entry is examined. If the entry is empty, the search is indicated to be unsuccessful, in step 365 . In a further embodiment, a backup data structure can be searched, if available. If the entry is valid, the indicated block is loaded in step 370 . Generally, this will require a second access to main memory.
In step 375 , the block is examined. If it is a tree fragment, such as a Patricia tree, it is searched until a leaf node is reached in step 380 . If the leaf node indicates a further tree fragment, the algorithm is repeated from step 370 . In a further embodiment, if the tree fragment contains another structure, such as a fragment header, the location of the data record is retrieved. In step 385 , the data record is retrieved from memory. Generally, this will require a third access to main memory. This step can require more retrievals if multiple tree fragments were traversed.
In one embodiment, in step 390 , the keys of the data record are compared against the search key. If the keys match the search, it is indicated to be successful, in step 390 .
In one embodiment, each fragment of a fragmented tree has the same size. However, those skilled in the art will know that simple modifications will allow for individual sized tree fragments, for example, by indicating the size of the fragment in the later described fragment header.
In FIG. 4A , the tree fragment of FIG. 2 is stored in main memory. The binary tree fragment 220 has three decision nodes and four leaf nodes. The decision nodes are stored in main memory as a block (or array) 410 . Using this layout, the address of the left and right descendant of a decision node can be determined from the base address of the tree fragment using simple algebraic expressions. In one embodiment, this makes it unnecessary to store pointers for the left and right descendants within each decision node, thus saving memory. In this embodiment, if decision node 2 was non-existent and there was a leaf node in the place of decision node 2 , the space in the block 410 for decision node 2 would be empty and unused, as indicated in the array 430 ; that is, if decision nodes are non-existent, they still consume memory.
In FIG. 4A , the leaf nodes are not stored along with the decision nodes. Instead, when the search algorithm traverses the tree fragment and finally determines the proper leaf node, it determines the index number (here 1 - 4 ) of the leaf node, rather than its address in main memory. The leaf node can be either a tree fragment, which again needs to be traversed by the search algorithm, or the final route information. Leaf nodes of a tree are stored in main memory as a block 420 in consecutive memory locations in a similar manner to the decision nodes. In a further embodiment, block 420 can be an array. All leaf nodes are equal in size, but their size might be different from the size of a decision node. If a leaf node is non-existent, the corresponding place in the block (or array) 420 will not be empty and unused, but will be occupied by the next existing leaf node. In other words, there are no empty spaces in the block 420 . From only knowing the index number of the leaf node (here 1 - 4 ), the algorithm needs to determine the address of the leaf node, as explained in FIG. 4B .
Turning now to FIG. 4B , illustrated is one embodiment of a tree fragment header 450 . In the binary tree 200 , each tree fragment 210 , 220 , 230 , etc. is stored as a contiguous block in memory. Each tree fragment is also preceded by the tree fragment header 450 . The tree fragment header 450 comprises a base address pointer 460 , indicia of the size of a leaf node 470 , and a bit mask of occupied tree leaves 480 . Typically, the base address pointer 460 indicates the location of the first tree leaf of the sub-tree fragment in memory.
The leaf node 470 comprises the size in memory occupied by a tree leaf structure. In one embodiment, the size is a power of 2, and can be expressed as a binary number up to 16 significant digits. However, those skilled in the art understand that sizes other than those of a power of 2 are also within the scope of the present invention. The address, and therefore the location, of a tree leaf in memory, either in the main memory 120 or the local store 130 , can be calculated by multiplying the leaf index with the leaf size and adding it to the base address.
The fragment header 450 , as shown in FIG. 4B , is used for more efficient operations. Element 460 of the fragment header stores the base address of the leaf node block 420 . Element 470 stores the size of a leaf node. Finally, element 480 contains a bit mask. The bit mask 480 indicates which of the leaf nodes of the tree fragment actually exist and which ones are non-existent. A bit in the bit mask corresponds to a possible leaf node, and will be set to ‘1’ if the leaf node exists, or set to ‘0’ if it does not. For instance, the tree fragment 210 with four leaf nodes will have a bit mask of length 4-Bit with all bits set to ‘1’ since all leaf nodes are present. If, for example, leaf node 3 was non-existent, Bit 3 in the bit mask would be cleared (set to ‘0’).
This fragment header allows for more efficient calculation of a leaf node address. If, for example, the search algorithm determines leaf node i to be the result, all bits in the bit mask, including and above i, would be cleared. Afterwards, the number of bits in the resulting bit mask is counted, for example, using a “count ones”-instruction, which can be found in many modern microprocessor architectures. This result is multiplied with the leaf node size 470 and then added to the base address 460 to obtain the address of the leaf node. Then, the leaf node is loaded from main memory to local store. In case it is another tree fragment, it would be traversed just like the tree fragment before.
In one embodiment, the single Bit 455 is employable as an optional element in the fragment header. Generally, a leaf node of a tree fragment can either be another tree fragment or a leaf node of the original, unfragmented tree (that is, routing information in the IP-example). The table entry 240 can point to either of these two types. The Bit 455 is located in the fragment header to be employable to distinguish between these two types. If the bit is set to ‘1’, a fragment header including a tree fragment follows the Bit 455 . If the bit is ‘0’, no fragment header and no tree fragment follows the Bit 455 , but instead the routing information can be found at these memory locations.
There are several degrees of freedom in how this header can be built. In one embodiment, if the leaf node size 470 is a power of two, the multiplication step in the leaf node address calculation would be realizable with a simple shift-operation. Then, however, the leaf node size does not need to be encoded with 16-Bit. Instead, fewer bits are sufficient if the possible leaf node sizes can be encoded with these bits. For example, if the leaf node size is either 1024 Bytes or 2048 Bytes, the field 470 need only be 1-Bit wide, since 1-Bit is sufficient to distinguish between two different sizes. Hence, the field 470 might be omitted if there is only one possible leaf node size.
In a second embodiment, the Bit 455 might be omitted and its purpose realized in another way. For example, in order to indicate routing information, the address 460 might be set to all zeros, or to another impossible value. Also, the type fields 515 resp. 535 (described below) can be used to distinguish the types of their children. However, when employing 515 resp. 535 , a means needs to be found to distinguish the type of the object to which the table entry 240 points. This, however, might be realized with a Type-field (like 1-Bit) within the table entry 240 .
Turning to FIG. 5 , an example of the format of a decision node is illustrated. Two examples of decision nodes are shown, labelled 510 and 530 , in the form of a 4-Bit node and an 8-Bit node. However, it is obvious that these are only examples and there are many possible formats for decision nodes. The 4-Bit node might be advantageous with IPv4, whereas the 8-Bit node might be better suitable for IPv6. Both nodes have in common a Type-field 515 , 535 respectively, and an NBT-field 520 , 540 , respectively. The NBT-field indicates the “Next Bit to Test” and represents an offset to the next bit in the IP-Address to decide on in this decision node. Those skilled in the art will know how the NBT-field is used for LPM. The decision node 530 additionally has one unused Bit 545 .
The Type-field allows encoding of four different types of decision node, but more or less types might be desirable for a particular application. The following four types seem to be advantageous for a given application:
00: Decision Node has two child nodes, which both itself are decision nodes.
01: Decision Node has two child nodes, the left of which is a decision node, the right is a leaf node.
10: Decision Node has two child nodes, the left of which is a leaf node, the right is a decision node.
11: Decision Node has two child nodes, both of which are leaf nodes.
Turning now to FIG. 6 , a tree search shall now be clarified with an example. This example is in no way limiting and describes only one possible way the invention might be applied.
In one embodiment, a set of IP-Address prefixes exist:
1.
0010
0101
1100
1111
010
2.
0010
0101
1100
1111
110
3.
0010
0101
1100
1111
1101
1
4.
0010
0101
1100
1111
1101
0
5.
0010
0101
1100
1111
1101
01
All of these prefixes share the same first 16-Bit. A Patricia tree is created using the remaining 3- to 6-Bits of the prefixes, which will then be fragmented. A pointer to the root of the first fragment will be stored in the 65536 entry table at position 0010 0101 1100 1111 2 =35CFH.
In FIG. 6 , the route that an IP-packet with a destination address matching one of the prefixes takes will be labelled R 1 through R 5 , corresponding to the prefixes 1 through 5 . A Patricia tree is created from this set of prefixes. The Patricia tree is fragmented into two tree fragments 600 and 650 . If the Patricia tree were a balanced binary tree, the fragments would have seven decision nodes and eight leaf nodes.
Turning briefly to FIG. 7 , the Patricia tree is a non-balanced binary tree, which leads to the layout of the decision nodes and leaf nodes. The decision nodes of tree fragment 600 are stored in main memory as the block 700 . This block starts with the fragment header, followed by the decision nodes of the tree fragment 600 . Memory was allocated for seven decision nodes, as a balanced binary tree would have seven decision nodes. The nodes missing in tree fragment 600 , compared to a balanced binary tree, will remain empty and unused. The leaf nodes of the tree fragment 600 are stored in main memory as the block 710 . In this block, the third stored leaf node is the tree fragment 650 . The remaining leaf nodes are the route information R 1 through R 3 . All these leaf nodes are equal in size. If necessary, padding bits or padding bytes need to be inserted to make them equal in size.
The decision nodes of the tree fragment 650 are stored as block 750 in main memory, its leaf nodes as the block 760 . Both blocks are structured similar to the blocks 700 and 710 .
Turning back to FIG. 6 , the algorithm determines route information for an IP-packet with the destination address 0010 0101 1100 1111 1101 0100 1111 0000. In the illustrated embodiment, the first 16-Bit are used as a hash key to lookup the corresponding entry in the 65536 entry table. The memory block pointed to by this entry (or associated with this entry) is loaded from main memory and it is determined that the loaded memory block is a tree fragment. In the illustrated embodiment of FIG. 7 , the loaded memory block is the previously described memory block 700 .
The method of FIG. 3B , employing an algorithm, then traverses this tree fragment, testing bits 1 , 4 and 5 from the remaining 16-Bits of the IP-Address. The system then loads the determined leaf node of the tree fragment from memory block 710 , which comprises another tree fragment 650 in the form of the memory block 770 . After testing bit 6 of the remaining 16-Bits of the destination IP-Address, the leaf node 665 is determined to be the proper tree fragment leaf node. This leaf node is loaded from the memory block 760 . The algorithm of the system calculates that it is not a new tree fragment, but actual route information. Since only a subset of the IP-prefix bits were tested, the complete prefix has to be stored within this route information and tested against the IP-destination address of the IP-packet. If there is a match, the algorithm of the system has determined the correct route information and can then forward the packet. If there is no match, the method of FIG. 3B takes further action, such as searching for a prefix match shorter than 16-Bits in a separate Patricia tree dedicated to short prefixes.
It is understood that the present invention can take many forms and embodiments. Accordingly, several variations may be made in the foregoing without departing from the spirit or the scope of the invention.
Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered obvious and desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
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A data structure and corresponding search methods are disclosed for improving the performance of table lookups. A data structure for the table is employed using a single hash table with hash table entries pointing to tree fragments that are contiguous in main memory and can be efficiently loaded into a local data store or cache. Decision nodes are stored in a contiguous block of memory in a relative position based on the position of the decision node in the tree structure, including blank positions. Leaf nodes are stored in a contiguous block of memory based on the position of the leaf node in the tree structure, concatenating leaf nodes to eliminate blank positions. Leaf nodes of the tree fragments contain indicia of a data record, or indicia of another tree fragment. The data structure and corresponding search algorithm are employed for searches based on a longest prefix match in an internet routing table.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 from U.S. Provisional Patent Application Ser. No. 60/822,584, filed on Aug. 16, 2006 and entitled “Fence Post Connector,” which is herein expressly incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to fence post connectors and fences buildable therewith. More particularly, the invention relates to a cast metal fence post connector for a so-called steel fence and to a steel fence having those fence post connectors. In addition, the invention relates to methods of making the connector and the fence.
[0004] 2. Discussion of the Related Art
[0005] Livestock fences, particularly horse fences, are typically formed from horizontally extending, tubular steel rails mounted on vertical tubular posts anchored to the ground. This “steel fence” is widely considered to be superior to split rail and other types of fences because it is rigid and extremely durable. However, the individual rail sections of the typical steel fence must be welded to the vertical fence posts. This welding requirement adds considerable time and labor to building the fence because a portable welder must be employed to weld the opposite ends of each and every rail to the posts on which it is supported. The welds must then be ground to a smooth finish and painted. The welds are subject to rust and peeling, requiring periodic maintenance for the lifetime of the fence.
[0006] More recently, a non-welded connector for steel fences has been introduced. This connector, known as the “440 Fence” connector, is manufactured by the 440 Fence Company of Aubrey, Tex. It is also the subject matter of U.S. Design Pat. No. 495,434. The 440 Fence utilizes two stacked connectors at each joint. Each connector is generally L-shaped, having a vertical section for slipping over the fence post and a generally horizontal section that receives the end of a rail section. The horizontal section is hinged to the vertical section so as to permit limited pivoting of the horizontal section relative to the vertical section in order to accommodate inclines of the fence. In use at a “mid-joint” of the fence (i.e. a location along the fence in which the rails extend in opposite directions from the fence post), two connectors are stacked in a mirror image fashion such that the vertical sections of the two connectors abut one another and the horizontal sections extend outwardly from the vertical section in opposite directions in alignment with one another. With these connectors, a steel fence can be built without welding—dramatically reducing labor when compared to traditional steel fence construction. Post-assembly maintenance is also dramatically reduced.
[0007] However, the 440 Fence connector still suffers from drawbacks. For instance, its multi-piece hinged construction makes it relatively expensive to produce. In addition, two connectors and a total of six setscrews are required at each mid-joint in the fence. It also does not automatically center the pipe of the rails in the connector. In addition, although it can accommodate significant changes in elevation, it can also permit round or odd shaped corrals due to its ability to be pivoted about the post.
[0008] The need therefore has arisen to provide a simplified connector for fences including steel fences.
[0009] The need has also arisen to provide a connector that can be installed quickly and with minimal effort.
[0010] The need has also arisen to provide a connector that lacks a hinge yet can accommodate adjacent rail sections that are inclined and/or extend in different directions relative to one another.
SUMMARY OF THE INVENTION
[0011] In accordance with various aspects of the invention, at least some of the above-identified needs are met by providing, e.g., a cast metal mid-joint connector for a steel fence or the like. The connector is formed from, preferably, a single unitary piece, yet can mount two adjacent rail sections on a post using only a single mount attaching the connector to the post. It preferably has a vertical throughbore for receiving the post and a horizontal throughbore that intersects with the vertical throughbore at approximately its mid-point. Each end of the horizontal throughbore forms a receptacle or socket for receiving an end of an associated rail section. Preferably, the socket is oversized as compared to the rail section. In this configuration, the clearance or “rocking tolerance” provided by the oversized socket enables the connector device to movably house the end of an elongate rail. As one example, the rail section can be multiaxially movable with respect to the socket and/or the remainder of the connector device. The socket can be configured to provide a rocking tolerance of at least about 12 degrees, 15 degrees, 20 degrees, or otherwise as desired, of angular deviation from a neutral position, where the rail extends directly axially from the socket.
[0012] In some implementations, the connector includes a threaded internal boss extending into the vertical throughbore and adapted and configured to receive a setscrew assembly. The setscrew assembly includes a setscrew which can have, e.g., a hardened steel insert, and/or a resilient member extending from an end surface thereof for temporarily fixing the connector to and interfacing with the post.
[0013] An isolating member such as, e.g., a grommet or another elastomeric, polymeric, or otherwise resilient member, is mounted in each receptacle for centering the associated rail section end in the receptacle, locking the rail section from rotation. The grommet also accommodates limiting pivoting or actuation of the rail section relative to the connector in both the horizontal and vertical planes, hence, accommodating both inclination and directional changes in the fence. The grommet can be generally annular or cylindrical with opposing, generally circular side surfaces. The side surfaces can have differently sized openings, each of which opens into a common bore. Preferably, in the complete assemblage, the relatively larger opening is proximate the rail section whilst the relatively smaller opening is distal the rail section. This configuration facilitates the insertion of the rail section through the larger opening and corresponding resists its withdrawal from the smaller opening, whereby the rail section is relatively easy to place into the connector yet relatively more difficult to remove therefrom.
[0014] In some embodiments, the connector and the rail segment are made of dissimilar materials, whereby the grommet electrically isolates the connector and rail from each other. This configuration provides, e.g., a dielectric union between the connector and the rail segment and correspondingly mitigates the likelihood of galvanic-type corrosion event, based on two interfacing dissimilar metals.
[0015] In other implementations, the end of the rail segment includes a projection extending radially therefrom. Such projection can be an integral part of the rail segment or it can be provided by way of, e.g., a cap or other structure connected to the end of the rail. The projection can be a discrete element or can extend about a portion or the entirety of an outer circumferential surface of the end of the rail segment. In any event, the projection provides a mechanical abutment or interference between it and the grommet which prevents the non-desired withdrawal of the rail segment from the connector.
[0016] Other connectors, having the same post mount but specialized receptacle configurations, may be provided for corner or end posts. Yet other connectors can allow post penetration at an angle for extreme slopes.
[0017] Connectors configured as discussed above and elsewhere herein are also provided, methods of making connectors configured as discussed above are also provided, and methods of building fences using various connectors configured as discussed herein are also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Preferred exemplary embodiments of the invention are illustrated in the accompanying drawings, in which like reference numerals represent like parts throughout, and in which:
[0019] FIG. 1 is perspective view of a fence post connector constructed in accordance with a preferred embodiment of the invention, viewed from in front of, above, and from the left side of the connector;
[0020] FIG. 2 is a front elevation view thereof;
[0021] FIG. 3 is a rear elevation view thereof;
[0022] FIG. 4 is a top plan view thereof;
[0023] FIG. 5 is a bottom plan view thereof;
[0024] FIG. 6 is a left-end elevation view thereof, with the right end being a mirror image of the left end;
[0025] FIG. 7 is an exploded perspective view of the connector;
[0026] FIG. 8 is a sectional plan view showing the connector in use; and
[0027] FIG. 9 is a side elevation view of a section of fence incorporating the connectors of FIGS. 1-8 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Referring to FIGS. 1-7 , a fence post connector 10 constructed in accordance with a preferred embodiment of the invention is illustrated. As seen in FIGS. 8 and 9 , the connector 10 is configured for use as a mid-joint connector for a steel fence 12 formed from horizontal rails sections 14 and vertical posts 16 formed from steel tubes. The posts 16 and rail sections 14 are typically of a common diameter, most typically 2.875″ or 2.375″. The connector 10 comprises a body 18 , a setscrew assembly 20 for affixing the body 18 to a fence post 16 , and a pair of grommets 22 , 24 .
[0029] Referring to FIGS. 1-6 , the body 18 preferably is formed from cast aluminum because aluminum cannot rust. However, the body 18 could be formed from other materials such as cast iron, and could be formed from other processes as well, such as by machining a rolled tube. If it is formed from a cast material, the body 18 is even more preferably formed from casting a semi-solid shot of a thixotropic material such as thixotropic aluminum about a core of a material, such as zinc, that has a lower melting point than the solid to semi-solid transition temperatures of the thixotropic alloy. The core is later melted away to form internal features of the body 18 such as threads, undercuts, etc. Hence, the entire body 18 can be formed without any post-casting machining. This casting process is described, for example, in U.S. Pat. Nos. 6,564,856 and 6,427,755; and U.S. application Ser. No. 10/438,954, filed May 15, 2003, all of which are assigned to the assignee of this application, and the disclosures of all of which are hereby incorporated by reference in their entirety.
[0030] Still referring to FIGS. 1-6 , the body 18 , which weighs about 1.0 lb (as opposed to 3.7 lbs. if it were formed in cast gray iron), is essentially tubular in shape, having a length of about 7″ and an outer diameter of about 4″. The body 18 has a vertical throughbore 26 for receiving the fence post 16 and a horizontal throughbore 28 that intersects with vertical throughbore 26 at approximately its mid point. Each end of the horizontal throughbore 28 forms a socket 30 , 32 for receiving an end of an associated rail section 14 . The vertical throughbore 26 is formed from aligned radial openings 34 , 36 at approximately the longitudinal mid-point of the connector 10 . The vertical throughbore 26 should be slightly larger in diameter than the fence post 16 over which it is adapted to slide. In the illustrated embodiment in which the connector 10 is configured for use with a fence post 16 and rail sections 14 each having an outside diameter of 2.875″, the vertical throughbore 26 has a diameter of 2.92″. The horizontal throughbore 28 should be significantly larger in diameter than the diameter of the ends of the rail sections 14 so as to allow substantial rocking of the ends of the rail sections 14 relative to the post 16 . About 12 degrees to 20 degrees of rocking tolerance is preferred when the rail sections 14 are fully inserted into the corresponding sockets 30 , 32 in an abutting relationship with the fence post 16 as seen in FIG. 8 , with a rocking tolerance of 15 degrees being especially preferred. This rocking is accommodated by oversizing the horizontal throughbore 28 and by the flexible grommets 22 , 24 , described below. In the illustrated example in which the connector 10 is configured for use with rail sections 14 having a diameter of 2.875″, the horizontal throughbore 28 has an inner diameter of about 3.5″, reduced to a minimum of 3.0″ at the grommets 22 , 24 . The grommets 22 , 24 are mounted in grooves 40 , 42 formed in the extreme outer ends of the horizontal throughbore 28 . The grooves 40 , 42 may, if desired, be circumferentially segmented to form a number of fingers (not shown) for gripping the grommets 22 , 24 . Finally, a threaded internal boss 50 is formed at the axial mid-point of the connector 10 , circumferentially spaced about 90 degrees from the vertical throughbore 26 , for receiving the setscrew assembly 20 . The threads 52 , like the grooves 40 , 42 and all undercuts, are preferably formed during the casting and subsequent core melt-out processes, negating the need for any post casting machining.
[0031] Each grommet 22 , 24 functions to hold the end of the corresponding rail section 14 in place in the corresponding socket 30 , 32 and to center the rail section 14 end in the socket 30 , 32 while accommodating the desired side to side and vertical rocking of the rails 14 relative to the connector 10 . Each grommet 22 , 24 has an outside diameter of 3.67″ and an inside diameter of 2.85″. The grommets 22 , 24 can be inserted into the grooves 40 , 42 after the body 18 is inserted. The grommets 22 , 24 are preferably formed from a rubber material having a hardness of 60 Durometer Shore A. An EPDM elastomer is preferred because of its relatively high resistance to ozone and UV, as well as its toughness and low cost.
[0032] As noted above, steel fences 12 often are constructed from rail sections 14 and fence posts 16 having a diameter of 2.375″. In this case, the entire connector 10 can be downsized to meet the requirements of the smaller rails and posts. For instance, the vertical throughbore 26 has a diameter of 2.42″. The horizontal throughbore 28 has a diameter of about 3.0″, reduced to a minimum of 2.5″ at the grommets 22 , 24 .
[0033] The setscrew assembly 20 could be formed from or replaced by any number of devices capable of securing the connector 10 to the fence post 16 . In the illustrated embodiment, a single setscrew assembly 20 is employed. As best seen in FIGS. 7 and 8 , the setscrew assembly 20 preferably comprises a zinc setscrew 54 fitted with a hardened steel insert 56 for gripping the fence post 16 .
[0034] Referring to FIGS. 8 and 9 , to use the mid-joint connector 10 , the installer simply mounts the connectors 10 at the appropriate heights on the first fence post 16 using the setscrew assemblies 20 , resulting in four spaced connectors on the post 16 , in the case of the four rail fence illustrated in FIG. 9 . The operator then inserts a rail section 14 into the socket 32 of the lowermost connector 10 , slides a connector 10 over the second post 16 A, and slides that connector 10 down to a position in which the rail section 14 is tilted up at least 5 degrees, which provides sufficient spacing between the end of the rail section 14 and the post 16 A to provide clearance for the end of the rail section 16 A and the opening of the socket 30 . As the installer continues to lower the connector 10 , the end of the rail section 14 become fully inserted into the socket 30 by the time the rail is horizontal, whereupon the installer fastens the connector 10 to the post 16 A using the setscrew assembly 20 . The installer then repeats the procedures for the second and subsequent connectors and rail sections 14 on the post 16 A. The grommets 22 , 24 hold the rail sections 14 in place without damaging the finish on the rail sections 14 . They also center the rail sections 14 in the connector 10 . Hence, two rail sections 14 are mounted on a post 16 using a single connector 10 and a single setscrew 54 . Comparing post 16 to post 16 A in FIG. 9 , significant rail inclination and change in direction are accommodated by the grommets 22 , 24 and the oversizing of the sockets 30 , 32 . Rail sections 14 can be mounted on corner posts and end posts using 440 Fence connectors or specialized connectors illustrated in the materials collectively attached as Appendix A, the subject matter of which is hereby incorporated by reference in their entirety. Inclinations more severe than that, which can be accommodated by the mid-joint connectors, can be accommodated by specialized connectors, also illustrated in Appendix A.
[0035] The fence post connector configured as described above has many advantages over the 440 Fence connector. For instance:
It is much easier to produce with the entire body, including the grommet receiving grooves, threads, and undercuts being castable in one step with no post casting machining being required. Only one connector is required at each joint, as opposed to two with the 440 Fence connector. Only one setscrew is required to couple two adjacent rail section ends to a fence post, as opposed to six being required for the 440 Fence connector. This reduces damage to the tubing and reduces labor. The aluminum connector cannot rust. The connector is much lighter than the 440 Fence connector. The simplified construction results in labor savings of nearly 30% per installation.
[0042] Although the best mode contemplated by the inventors of carrying out the present invention is disclosed above, practice of the present invention is not limited thereto. It will be manifest that various additions, modifications, and rearrangements of the features of the present invention may be made in addition to those described above without deviating from the spirit and scope of the underlying inventive concept. The scope of some of these changes is discussed above. The scope of other changes to the described embodiments that fall within the present invention but that are not specifically discussed above will become apparent from the appended claims and other attachments.
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A connector for a steel fence or the like is provided. The connector is formed from a single, cast metallic piece yet can mount one or multiple adjacent rail sections on a post using only a single mount or piece of hardware attaching the connector to the post. It has a vertical throughbore for receiving the post and a horizontal throughbore that intersects with the vertical throughbore at approximately its mid-point. Each end of the horizontal throughbore forms a receptacle for receiving an end of an associated rail section. A grommet is mounted in each receptacle for centering the associated rail section end in the receptacle, locking the rail section from rotation. The grommet also accommodates limited pivoting of the rail section relative to the connector in both the horizontal and vertical planes, hence, accommodating both inclination and directional changes in the fence.
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TECHNICAL FIELD
This invention relates to batteries and more particularly to lithium (Li) based batteries.
BACKGROUND
A typical Li-ion cell contains a negative electrode, the anode, a positive electrode, the cathode, and a separator region between the negative and positive electrodes. One or both of the electrodes contain active materials that react with lithium reversibly. In some cases the negative electrode may include lithium metal, which can be electrochemically dissolved and deposited reversibly. The separator and positive electrode contain an electrolyte that includes a lithium salt.
Charging a Li-ion cell generally entails a generation of electrons at the positive electrode and consumption of an equal amount of electrons at the negative electrode with the electrons transferred via an external circuit. In the ideal charging of the cell, these electrons are generated at the positive electrode because there is extraction via oxidation of lithium ions from the active material of the positive electrode, and the electrons are consumed at the negative electrode because there is reduction of lithium ions into the active material of the negative electrode. During discharging, the opposite reactions occur.
Li-ion cells with a Li-metal anode may have a higher specific energy (in Wh/kg) and energy density (in Wh/L) compared to batteries with conventional carbonaceous negative electrodes. This high specific energy and energy density makes incorporation of rechargeable Li-ion cells with a Li-metal anode in energy storage systems an attractive option for a wide range of applications including portable electronics and electric and hybrid-electric vehicles.
At the positive electrode of a conventional lithium-ion cell, a lithium-intercalating oxide is typically used. Lithium-intercalating oxides (e.g., LiCoO 2 , LiNi 0.8 Co 0.15 Al 0.05 O 2 , Li 1.1 Ni 0.3 Co 0.3 Mn 0.3 O 2 ) are typically limited to a theoretical capacity of ˜280 mAh/g (based on the mass of the lithiated oxide) and a practical capacity of 180 to 250 mAh/g, which is quite low compared to the specific capacity of lithium metal (3863 mAh/g).
Moreover, the low realized capacities of conventional Li-ion cells reduces the effectiveness of incorporating Li-ion cells into vehicular systems. Specifically, a goal for electric vehicles is to attain a range approaching that of present-day vehicles (>300 miles). Obviously, the size of a battery could be increased to provide increased capacity. The practical size of a battery on a vehicle is limited, however, by the associated weight of the battery. Consequently, the Department of Energy (DOE) in the USABC Goals for Advanced Batteries for EVs has set a long-term goal for the maximum weight of an electric vehicle battery pack to be 200 kg (this includes the packaging). Achieving the requisite capacity given the DOE goal requires a specific energy in excess of 600 Wh/kg.
Various materials are known to provide a promise of higher theoretical capacity for Li-based cells. For example, a high theoretical specific capacity of 1168 mAh/g (based on the mass of the lithiated material) is shared by Li 2 S and Li 2 O 2 , which can be used as cathode materials. Other high-capacity materials include BiF 3 (303 mAh/g, lithiated) and FeF 3 (712 mAh/g, lithiated) as reported by Amatucci, G. G. and N. Pereira, “Fluoride based electrode materials for advanced energy storage devices,” Journal of Fluorine Chemistry, 2007. 128(4): p. 243-262. Unfortunately, all of these materials react with lithium at a lower voltage compared to conventional oxide positive electrodes. Nonetheless, the theoretical specific energies are still very high (>800 Wh/kg, compared to a maximum of ˜500 Wh/kg for a cell with lithium negative and conventional oxide positive electrodes).
One Li-based cell that has the potential of providing a driving range above 300 miles incorporates a lithium metal negative electrode and a positive electrode reacting with oxygen obtained from the environment. The weight of this type of system is reduced since the positive-electrode active material is not carried onboard the vehicle. Practical embodiments of this lithium-air battery may achieve a practical specific energy of 600 Wh/kg because the theoretical specific energy is 11,430 Wh/kg for Li metal, and 3,460 Wh/kg for Li 2 O 2 .
During discharge of the lithium-air cell, Li metal dissolves from the negative electrode, while at the positive electrode, lithium ions (Li + ions) in the electrolyte react with oxygen and electrons to form a solid discharge product that ideally is lithium peroxide (Li 2 O 2 ) or lithium oxide (Li 2 O), which may coat the conductive matrix of the positive electrode and/or fill the pores of the electrode. In an electrolyte that uses a carbonate solvent the discharge products may include Li 2 CO 3 , Li alkoxides, and Li alkyl carbonates. In non-carbonate solvents such as CH 3 CN and dimethyl ether the discharge products are less likely to react with the solvent. The pure crystalline forms of Li 2 O 2 and Li 2 O are electrically insulating, so that electronic conduction through these materials will need to involve vacancies, grains, or dopants, or short conduction pathways obtained through appropriate electrode architectures.
Abraham and Jiang published one of the earliest papers on the “lithium-air” system. See Abraham, K. M. and Z. Jiang, “A polymer electrolyte-based rechargeable lithium/oxygen battery”; Journal of the Electrochemical Society, 1996. 143(1): p. 1-5. Abraham and Jiang used an organic electrolyte and a positive electrode with an electrically conductive carbon matrix containing a catalyst to aid with the reduction and oxidation reactions. Previous lithium-air systems using an aqueous electrolyte have also been considered, but without protection of the Li metal anode, rapid hydrogen evolution occurs. See Zheng, J., et al., “Theoretical Energy Density of Li-Air Batteries”; Journal of the Electrochemical Society, 2008. 155: p. A432.
An electrochemical cell 10 is depicted in FIG. 1 . The cell 10 includes a negative electrode 12 , a positive electrode 14 , a porous separator 16 , and a current collector 18 . The negative electrode 12 is typically metallic lithium. The positive electrode 14 includes carbon particles such as particles 20 possibly coated in a catalyst material (such as Au or Pt) and suspended in a porous, electrically conductive matrix 22 . An electrolyte solution 24 containing a salt such at LiPF 6 dissolved in an organic solvent such as dimethyl ether or CH 3 CN permeates both the porous separator 16 and the positive electrode 14 . The LiPF 6 provides the electrolyte with an adequate conductivity which reduces the internal electrical resistance of the cell 10 to allow a high power.
The positive electrode 12 is enclosed by a barrier 26 . The barrier 26 in FIG. 1 is formed from an aluminum mesh configured to allow oxygen from an external source 28 to enter the positive electrode 14 . The wetting properties of the positive electrode 14 prevent the electrolyte 24 from leaking out of the positive electrode 14 . Oxygen from the external source 28 enters the positive electrode 14 through the barrier 26 while the cell 10 discharges, and oxygen exits the positive electrode 14 through the barrier 26 as the cell 10 is charged. In operation, as the cell 10 discharges, oxygen and lithium ions combine to form a discharge product such as Li 2 O 2 or Li 2 O.
A number of investigations into the problems associated with Li-air batteries have been conducted as reported, for example, by Beattie, S., D. Manolescu, and S. Blair, “High-Capacity Lithium-Air Cathodes,” Journal of the Electrochemical Society, 2009. 156: p. A44, Kumar, B., et al., “A Solid-State, Rechargeable, Long Cycle Life Lithium-Air Battery, ” Journal of the Electrochemical Society, 2010. 157: p. A50, Read, J., “Characterization of the lithium/oxygen organic electrolyte battery,” Journal of the Electrochemical Society, 2002. 149: p. A1190, Read, J., et al., “Oxygen transport properties of organic electrolytes and performance of lithium/oxygen battery,” Journal of the Electrochemical Society, 2003. 150: p. A1351, Yang, X and Y. Xia, “The effect of oxygen pressures on the electrochemical profile of lithium/oxygen battery,” Journal of Solid State Electrochemistry: p. 1-6, and Ogasawara, T., et al., “Rechargeable Li 2 O 2 Electrode for Lithium Batteries,” Journal of the American Chemical Society, 2006. 128(4): p. 1390-1393. Nonetheless, several challenges remain to be addressed for lithium-air batteries. These challenges include limiting dendrite formation at the lithium metal surface, protecting the lithium metal (and possibly other materials) from moisture and other potentially harmful components of air, designing a system that achieves acceptable specific energy and specific power levels, reducing the hysteresis between the charge and discharge voltages (which limits the round-trip energy efficiency), and improving the number of cycles over which the system can be cycled reversibly.
The limit of round trip efficiency occurs due to an apparent voltage hysteresis as depicted in FIG. 2 . In FIG. 2 , the discharge voltage 40 (approximately 2.5 to 3 V vs. Li/Li + ) is much lower than the charge voltage 42 (approximately 4 to 4.5 V vs. Li/Li + ).
The equilibrium voltage 44 (or open-circuit potential) of the lithium/air system is approximately 3 V. Hence, the voltage hysteresis is not only large, but also very asymmetric.
The large over-potential during charge may be due to a number of causes. For example, reaction between the Li 2 O 2 and the conducting matrix 22 may form an insulating film between the two materials. Additionally, there may be poor contact between the solid discharge products Li 2 O 2 or Li 2 O and the electronically conducting matrix 22 of the positive electrode 14 . Poor contact may result from oxidation of the discharge product directly adjacent to the conducting matrix 22 during charge, leaving a gap between the solid discharge product and the matrix 22 .
Another mechanism resulting in poor contact between the solid discharge product and the matrix 22 is complete disconnection of the solid discharge product from the conducting matrix 22 . Complete disconnection of the solid discharge product from the conducting matrix 22 may result from fracturing, flaking, or movement of solid discharge product particles due to mechanical stresses that are generated during charge/discharge of the cell. Complete disconnection may contribute to the capacity decay observed for most lithium/air cells. By way of example, FIG. 3 depicts the discharge capacity of a typical Li/air cell over a period of charge/discharge cycles.
What is needed therefore is an energy storage system that can recover disconnected and or poorly connected discharge particles electrochemically. A further need exists for a lithium based energy storage system that exhibits reduced over-potential of the cell during charging operations.
SUMMARY
In accordance with one embodiment, an electrochemical cell includes a negative electrode including a form of lithium, a positive electrode spaced apart from the negative electrode and including an electron conducting matrix, a separator positioned between the negative electrode and the positive electrode, an electrolyte including a salt, and a charging redox couple located within the positive electrode, wherein the electrochemical cell is characterized by the transfer of electrons from a discharge product located in the positive electrode to the electron conducting matrix by the charging redox couple during a charge cycle.
In a further embodiment, an electrochemical cell includes a negative electrode, a positive electrode spaced apart from the negative electrode and including an electron conducting matrix, a separator positioned between the negative electrode and the positive electrode, an electrolyte including a salt, and a charging redox couple located within the positive electrode, wherein the electrochemical cell is characterized by the transfer of electrons from an electrically insulating discharge product located in the positive electrode to the electron conducting matrix by the charging redox couple during a charge cycle.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 depicts a schematic view of a prior art lithium-ion cell including two electrodes and an electrolyte;
FIG. 2 depicts a discharge and charge curve for a typical Li/air electrochemical cell;
FIG. 3 depicts a plot showing decay of the discharge capacity for a typical Li/air electrochemical cell over a number of cycles;
FIG. 4 depicts a schematic view of a lithium-air (Li/air) cell with two electrodes and a reservoir configured to exchange oxygen with a positive electrode for a reversible reaction with lithium which includes a concentration of charging redox couples which function as electron shuttles during charging of the Li/air cell;
FIG. 5 depicts a schematic view of the Li/air cell of FIG. 4 with discharge products formed on the conductive matrix of the positive electrode and some disconnected discharge product located on the bottom of the positive electrode; and
FIG. 6 depicts a schematic view of the Li/air cell of FIG. 5 with gaps formed between the discharge products formed on the conductive matrix and the conductive matrix as a result of charging or discharging the Li/air cell.
DETAILED DESCRIPTION
A schematic of an electrochemical cell 100 is shown in FIG. 4 . The electrochemical cell 100 includes a negative electrode 102 separated from a positive electrode 104 by a porous separator 106 . The negative electrode 102 may be formed from lithium metal or a lithium-insertion compound (e.g., graphite, silicon, tin, LiAl, LiMg, Li 4 Ti 5 O 12 ), although Li metal affords the highest specific energy on a cell level compared to other candidate negative electrodes.
The positive electrode 104 in this embodiment includes a current collector 108 and carbon particles 110 , optionally covered in a catalyst material, suspended in a porous matrix 112 . The porous matrix 112 is an electrically conductive matrix formed from a conductive material such as conductive carbon or a nickel foam, although various alternative matrix structures and materials may be used. The separator 106 prevents the negative electrode 102 from electrically connecting with the positive electrode 104 .
The electrochemical cell 100 includes an electrolyte solution 114 present in the positive electrode 104 and in some embodiments in the separator 106 . In the exemplary embodiment of FIG. 4 , the electrolyte solution 114 includes a salt, LiPF 6 (lithium hexafluorophosphate), dissolved in an organic solvent mixture. The organic solvent mixture may be any desired solvent. In certain embodiments, the solvent may be dimethyl ether (DME), acetonitrile (MeCN), ethylene carbonate, or diethyl carbonate.
A barrier 116 separates the positive electrode 104 from a reservoir 118 . The reservoir 118 may be the atmosphere or any vessel suitable to hold oxygen and other gases supplied to and emitted by the positive electrode 104 . While the reservoir 118 is shown as an integral member of the electrochemical cell 100 attached to the positive electrode 104 , alternate embodiments could employ a hose or other conduit to place the reservoir 118 in fluid communication with positive electrode 104 . Various embodiments of the reservoir 118 are envisioned, including rigid tanks, inflatable bladders, and the like. In FIG. 4 , the barrier 116 is a mesh which permits oxygen and other gases to flow between the positive electrode 104 and the reservoir 118 while also preventing the electrolyte 114 from leaving the positive electrode 104 .
The electrochemical cell 100 may discharge with lithium metal in the negative electrode 102 ionizing into a Li + ion with a free electron e − . Li + ions travel through the separator 106 in the direction indicated by arrow 120 toward the positive electrode 104 . Oxygen is supplied from the reservoir 118 through the barrier 116 as indicated by the arrow 122 . Free electrons e − flow into the positive electrode 104 through the current collector 108 as indicated by arrow 124 .
With reference to FIG. 5 , the oxygen atoms and Li + ions within the positive electrode 102 form a discharge product 130 inside the positive electrode 104 , aided by the optional catalyst material on the carbon particles 110 . As seen in the following equations, during the discharge process metallic lithium is ionized, combining with oxygen and free electrons to form Li 2 O 2 or Li 2 O discharge product that may coat the surfaces of the carbon particles 110 .
As discharge continues, some of the discharge product 130 may flake off or in some other way become dislodged from the carbon particles 110 as depicted by the disconnected discharge product 132 .
When desired, the electrochemical cell 100 may be charged from the discharged state. Electrochemical cell 100 may be charged by introducing an external electric current which oxidizes the Li 2 O and Li 2 O 2 discharge products into lithium and oxygen. The internal current drives lithium ions toward the negative electrode 102 where the Li + ions are reduced to metallic lithium, and generates oxygen which diffuses through the barrier 116 . The charging process reverses the chemical reactions of the discharge process, as shown in the following equations.
The discharge products 130 in the form of Li 2 O and Li 2 O 2 donate electrons according to the foregoing equations which are transported to the current collector 108 by the electrically conductive matrix 112 . This reaction may occur most rapidly with the discharge products 130 immediately adjacent to the particles 110 resulting in a gap 134 as depicted in FIG. 6 . In some instances, the gap 134 may electrically isolate the discharge products 130 from the electrically conductive matrix 112 . In other instances, the gap 134 enables portions of the discharge product 130 to flake off, resulting in an increase in the disconnected discharge product 132 .
A gap 134 may also form as a result of charging a cell. By way of example, the Li 2 O 2 adjacent to the electronically conducting matrix may react first due to the low electronic conductivity of Li 2 O 2 , thereby liberating O 2 , Li+, and electrons and leaving a gap between the conducting matrix and the remaining Li 2 O 2 .
Regardless of the mechanism by which a disconnected discharge product 132 or poorly connected discharge product 130 is formed, reduction of the disconnected discharge products 132 and the poorly connected discharge products 130 in the electrochemical cell 100 is enabled by the electrolyte solution 114 . Specifically, the electrolyte solution 114 includes a charging redox couple which scavenges electrons from the discharge products 132 and the discharge products 130 and transports the electrons to the electrically conductive matrix 112 whereat the charging redox couple is oxidized as shown in the following equations:
Li 2 O 2 +2R→O 2 +2Li + +2R − (discharge products)
Li 2 O+2R→1/2O 2 +2Li + +2R (discharge products)
2R − →2R+2e − (conductive matrix)
Once the charging redox couple has been oxidized, it is available to transport additional electrons from additional discharge products 132 and discharge products 130 . Nonetheless, to provide optimal performance of the charging redox couple, the selected charging redox couple may exhibit a high solubility in the electrolyte solution 114 to ensure that a sufficient concentration of the charging redox couple is present in the electrolyte solution 114 to function as a rapid redox shuttle between the discharge product 132 , the discharge products 130 , and the electrically conductive matrix 112 . When provided as an additive in the electrolyte solution 114 , the charging redox couple is typically selected such that the charging redox couple does not react with the electrolyte, binder, separator, negative electrode, or current collectors. In one embodiment, the charging redox couple is a minor constituent of the electrolyte so that it does not adversely affect the transport properties of the electrolyte.
Performance of the electrochemical cell 100 is further optimized by proper selection of the equilibrium voltage of the charging redox couple. For example, the equilibrium voltages for Li 2 O 2 and Li 2 O are, respectively, 2.96 and 2.91 V. Thus, selecting an equilibrium voltage for the charging redox couple that is slightly above 2.96 V, such as between 3 and 3.1 V, limits the over-potential during cell charge.
Exemplary classes of compounds that could be used as a charging redox couple in the electrochemical cell 100 include, but are not limited to, metallocenes (e.g., ferrocene), halogens (e.g., I-/I3-), and aromatic molecules (e.g., tetramethylphenylenediamine). Some specific materials within the foregoing classes which are suitable for use in a Li/air cell with an equilibrium voltage between 2.9 and 4.5 V include Ferrocene which has an equilibrium voltage between 3.05 to 3.38 V, n-Butylferrocene which has an equilibrium voltage between 3.18 to 3.5 V, N,N-Dimethylaminomethylferrocene which has an equilibrium voltage between 3.13 to 3.68 V, 1,1-Dimethylferrocene which has an equilibrium voltage between 3.06 to 3.34 V, 1,2,4-Triazole, sodium salt (NaTAZ) which has an equilibrium voltage of 3.1 V, and Lithium squarate which has an equilibrium voltage of about 3.1 V.
For a given embodiment, the charging redox couple may be selected to provide high reversibility approaching 100% coulombic efficiency. A highly reversible charging redox couple is desirable to allow the charging redox couple to be cycled many times during a single cell charging step. A charging redox couple that exhibits fast kinetics (i.e., its exchange current density is high) is also desirable. Fast kinetics results in a small difference between the charging redox couple's charge and discharge voltage, resulting in more efficient charging.
As described above, the charging redox couple activity is confined to the positive electrode. Therefore, in contrast to overvoltage redox couples, used to provide overvoltage protection, which require high mobility to travel between the positive electrode and the negative electrode, a high mobility is not necessary for a charging redox couple. For example, while movement on the order of 10 s of μm is needed in providing overvoltage protection, the charging redox couples in the electrolyte solution 114 may travel about 1 μm or less.
If desired, a charging redox couple with high mobility may be used to function as a rapid redox shuttle between the discharge product 132 , the discharge products 130 , and the electrically conductive matrix 112 . Because the high mobility charging redox couple, if unconstrained, may also be reduced at the negative electrode, transport of the oxidized species to the negative electrode may be blocked by applying a protective layer on the negative electrode. The charging redox couple is thus confined to the positive electrode and the separator. One material that may be used as a protective layer is Li 1.3 Ti 1.7 Al 0.3 (PO 4 ) 3 , a lithium-ion conducting glass-ceramic material commercially available from Ohara Corporation of Rancho Santa Margarita, Calif.
By incorporation of an optimally selected charging redox couple, the over-potential of the electrochemical cell 100 during charging is lowered. By way of example, for an exemplary electrochemical cell 100 which has discharge products 130 and disconnected discharge products 134 of Li 2 O 2 or Li 2 O, the equilibrium voltage of the discharge products 130 and disconnected discharge products 134 is about 2.9 to 3 V. By selecting a charging redox couple (R/R−), wherein species R− is the reduced form of species R) with an equilibrium voltage of 3.1 V, all of the charging redox couple will be in a reduced form (species R−) during discharge, when the cell voltage is below the equilibrium voltage of the discharge product.
During charge of the exemplary electrochemical cell 100 , as the potential of the positive electrode with respect to Li/Li+ climbs above 3.1 V, the reduced species R− will be oxidized at the surface of the conducting matrix 112 to form species R. Species R can then react with the discharge product Li 2 O 2 or Li 2 O (chemically or via a corrosion reaction) to form species R−, Li+, and O 2 , because the discharge product 130 and disconnected discharge product 134 have an equilibrium voltage lower than that of the charging redox couple. The freshly formed species R− can subsequently yield its charge to the conducting matrix 112 , while the liberated Li+ can migrate toward the negative electrode 102 , where it is plated as Li metal.
Accordingly, even poorly connected discharge product 130 or disconnected discharge product 134 can be consumed electrochemically during charge at a voltage only slightly above that of the charging redox couple. Assuming a discharge voltage of 2.8 V, reducing the charge voltage from ˜4 V to ˜3.2 V could yield an improvement in energy efficiency from 70% to more than 87%.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. Only the preferred embodiments have been presented and all changes, modifications and further applications that come within the spirit of the invention are desired to be protected.
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In accordance with one embodiment, an electrochemical cell includes a negative electrode including a form of lithium, a positive electrode spaced apart from the negative electrode and including an electron conducting matrix, a separator positioned between the negative electrode and the positive electrode, an electrolyte including a salt, and a charging redox couple located within the positive electrode, wherein the electrochemical cell is characterized by the transfer of electrons from a discharge product located in the positive electrode to the electron conducting matrix by the charging redox couple during a charge cycle.
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FIELD OF THE INVENTION
The present invention relates generally to a hair dryer and in particular to a hair dyer wherein heat is generated from chemical energy by burning gas rather than from electrical energy.
BACKGROUND OF THE INVENTION
Hair dryers have been widely used to blow dry wet hair or other wet article. Conventionally, the hair dryer is powered by electrical energy which is converted into heat and which is also used to drive a fan for blowing hot air flow. Since generating hot air flow by converting electrical energy into heat would consume a great quantity of electricity, usually at least 500 W, the conventional hair dryer is designed to be powered by main electricity from, for example, a wall outlet. Such a design has several disadvantages, such as:
(1) Electrical voltage may be different from country to country which prohibits the general consumers to use their own hair dryers in traveling in different countries, unless an adapter or transformer is used.
(2) The conventional hair dryer may not be used at areas where no main electricity is supplied, such as camping in the wilds.
(3) Using the conventional hair dryer in a humid environment (such as in a bathroom) may have the risk of electrical shock.
Thus, it is desirable to provide a hair dryer that is not powered by electrical main so as to overcome such problems encountered in the prior art.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide a hair dryer which is operated by burning fossil fuel to generate heat so that no electricity from the main is needed in operating the hair dryer.
Another object of the present invention is to provide a hair dryer in which catalytic oxidation reaction is performed on fossil fuel, such as gas, so as to provide a safe, flameless burning of the fuel for generation of heat, the fuel being supplied from, for example, a cigarette lighter so that it may be obtained easily.
A further object of the present invention is to provide a hair dryer which is not powered by electricity from the main so that electrical shock to the hair dryer user may be avoided.
In accordance with the present invention, there is provided a hair dryer comprising a casing inside which a heat generation device for generation of heat by burning fossil fuel supplied from a removable internal fuel container and a fan for generation an air flow passing through the heat generation device to be heated thereby for the provision of heated air stream are arranged. The heat generation device comprises a cordierite-based ceramic body on which a platinum-based oxidation catalyst is coated. An initial ignition device is provided to cause an initial burning of the fuel supplied thereto for heating the catalyst to the working temperature thereof. Once reaching the working temperature, the catalyst itself maintains the oxidation or combustion of the fuel in a flameless manner and the heated airflow is continuously supplied until the fuel supply is cut off and the fan turned off.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood from the following description of a preferred embodiment thereof, with reference to the attached drawings, wherein:
FIG. 1 is a cross-sectional view showing a hair dryer constructed in accordance with the present invention in a de-activated condition;
FIG. 2 is a cross-sectional view showing the hair dryer of the present invention in an activated condition;
FIG. 3 is an enlarged sectional view of the heat generation device adapted in the hair dryer of the present invention; and
FIG. 4 is an exploded perspective view showing the heat generation device of the hair dryer of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings and in particular to FIG. 1 wherein a hair dryer constructed in accordance with the present invention is shown, the hair dryer of the present invention comprises a casing 1 in the form of a pistol having a body portion 10 defining an axis and a handle portion 11 extending from the body portion 10. The body portion 10 of the casing 1 has an axially front open end defining an air outlet 14. A heat generation device 7 is mounted inside the body portion 10 of the casing 1 in the proximity of the air outlet 14. A fan assembly 2 is also mounted inside the body portion 10 of the casing 1 at the axially rear end of the body portion 10. The fan assembly 2 which may have a construction that is known to the art is powered by a power supply assembly 5 comprises an internal power source, such as batteries 52, electrically connected to the fan assembly 2 to cause an air flow from the rear end toward the front end 14 of the body portion 10 of the casing 1 which air flow passes through the heat generation device 7 and then goes out of the casing 1 through the air outlet 14.
Preferably, an inner wall member 15 is provided inside the body portion 10 of the casing 1 which extends from the axially rear end of the body portion 10 of the casing 1 to the axially front end 14 of the casing 1 to define an air tunnel 12 with the heat generation device 7 arranged therein so that the air flow generated by the fan assembly 2 is conducted to substantially completely pass through the heat generation device 7. The provision of the air tunnel 12, however, is optional for the body portion 10 of the casing 1 may be shaped to constitute the tunnel.
In accordance with the present invention, the heat generation device 7 is operated by burning fossil fuel, such as butane, preferably in gaseous form, to generate heat. In a preferred embodiment of the present invention, the heat generation device 7 is catalytic reaction based device. As shown in FIGS. 3 and 4, the heat generation device 7 comprises an outer heater casing 70, preferably a cylindrical member axially extending in the direction of the air flow caused by the fan assembly 2 and defining therein an interior space for receiving a tubular member 72 which is fixed inside the casing 70, preferably in a co-axial manner, by means of radiating fins 71 which radially extend between the inside surface of the heater casing 70 and the outside surface of the tubular member 72. The radiating fins 71 are spaced from each other in a circumferential direction and preferably the radiating fins 71 are equally spaced in the circumferential direction to define therebetween air passages through which the air flow may pass and thus be heated by heat transferred from the radiation fins 71. A central bore 721 is formed, preferably co-axially, in the tubular member 72 into which catalytic oxidation reaction means 73 is inserted and held. The catalytic oxidation reaction means 73, of which the operation is similar to a catalytic converter adapted in a gasoline engine of a vehicle, such as volatile organic compound catalytic device comprising an extruded ceramic body, preferably made of cordierite based material, on which a noble metal coating, such as platinum, serving as catalyst for oxidation reaction of the fossil fuel, such as butane, is formed to activate oxidation or combustion of the fossil fuel when it is at a raised temperature, is made as an elongated member inserted into and securely held in the bore 721 so that when the catalytic oxidation reaction means 73 is at a raised temperature, by applying the fossil fuel thereto, a flameless burning is caused and heat generated. The heat generation by the flameless burning occurring in the catalytic oxidation reaction means 73 is not only transferred to the air flow passing therethrough, but is also used to maintain the chemical reaction occurring thereon.
The tubular member 72 is made of a heat conductive material to facilitate conduction of heat generated by the catalytic oxidation reaction means 73 from the tubular member 72 to the radiating fins 71 and the outer casing 70 from which the heat is transferred to the airflow.
If desired, the body of the catalytic oxidation reaction means 73, which in the embodiment illustrated is made of extruded ceramic material, may be made to have for example honeycomb structure as shown in FIG. 4 to enhance the mechanical property thereof
A fuel supply system 3 is provided inside the casing 1, comprising a fuel container 31, such as a cigarette lighter as shown, having fossil fuel, such as butane, contained therein. The fuel container 31 is removably fixed inside the handle portion 11 of the casing 1 by means of a lid 13 which is movably fixed to the handle portion 11 of the casing 1 to openably close an opening (not labeled) through which the fuel container 31 is put into the handle portion 11 of the casing 1. The fuel container 31 has a fuel release button 311 which when actuated allows the fuel contained therein to escape out of the container 31 through a fuel outlet (not shown). A tube 32 defining a fuel passage is provided inside the casing 1, extending from the fuel outlet of the fuel container 31 to the heat generation device 7 for conducting the fuel from the fuel container 31 to the catalytic oxidation reaction means 73 of the heat generation device 7. An ignition device 6 is arranged and securely fixed inside the handle portion 11 of the casing 1, comprising an electronic igniter 61 having a control button 611 which when triggered or actuated causes the electronic igniter 61 to generate spark for ignition of the fuel supplied to the heat generation device 7. Such an electronic igniter 61 has been widely used in for example gas range so that no further detail is needed herein. The ignition device 6 has an electrical wire 612 extending from the igniter 61 and ending at a position between the fuel passage tube 32 and the heat generation device 7 for causing an initial burning or combustion of the fuel supplied from the fuel container 31 to the heat generation device 7 via the tube 32 by means of the spark generated by the igniter 61. The igniter 61 is powered by means of the electricity supplied from the power source built in the hair dryer, namely the batteries 52. A switch assembly 4 is provided on the handle portion 11 of the casing 1 to allow a user to simultaneously start the fan assembly 2, open the fuel container 31 for supplying the fuel from the fuel supply system 3 to the heat generation device 7 and actuate the electronic igniter 61 of the ignition device 6 for causing the fuel supplied to the heat operation device 7 to burn. The initial burning or combustion of the fuel in the heat generation device 7 caused by the spark generated by the igniter 61 heats up the catalytic oxidation reaction means 73 to the working temperature thereof so as to activate the flameless burning of the fuel in the catalytic oxidation reaction means 73.
The switch assembly 4 comprises a slidable member 41 which is slidably mounted on the handle portion 11 of the casing 1 to be movable between an activated position (FIG. 1) and a deactivated position (FIG. 2). The slidable member 41 has an inward projection 411 which is in contact engagement with the control button 611 of the electronic igniter 61 so that when the slidable member 41 is moved from the de-activated position to the activated position, the control button 611 of the igniter 61 is triggered, FIG. 2, to activate the igniter 61 for the generation of spark.
The switch assembly 4 also comprises a rocking arm 42 which is pivoted at 42 inside the handle portion 11 of the casing 1. The rocking arm 42 has a first end in contact engagement with the fuel release button 311 of the fuel container 31 and a second end coupled to the slidable member 41 so that the movement of the slidable member 41 from the de-activated position to the activated position causes the rocking arm 42 to rotate about the pivot 421 in such a direction to actuate the fuel release button 311 by means of the engagement between the fuel release button 311 and the first end of the rocking arm 42, see FIG. 2.
The power supply assembly 5 that comprises the built-in power source (the batteries) 52 also comprises a power ON/OFF switch 51 which is coupled to the slidable member 41 for controlling the supply of the electrical power from the batteries 52 t the fan assembly 2. For example, the power ON/OFF switch 51 may have a projection 511 extending into and engaging a recess formed on the slidable member 41 to provide a coupling therebetween so that the power ON/OFF switch 51 may be movable in unison with the slidable member 41. Thus, the movement of the slidable member 41 causes the power ON/OFF switch 51 of the power supply assembly 5 to move between ON and OFF positions for controlling the supply of the power to the fan assembly 2. By moving the slidable member 41 to the activated position as shown in FIG. 2 to actuate the switching assembly 4, the fuel is released from the fuel container 31 of the fuel supply system 3 to the heat generation device 7. At the same time, the electronic igniter 61 of the ignition device 6 is triggered, causing a spark at the remote end of the wire 612 which in turn ignites the fuel supplied to the heat generation device 7. The fuel thus burns and heats up the catalytic oxidation reaction means 73. The catalyst of the catalytic oxidation reaction means 73 is thus heated to the working temperature thereof, for example 200° C., and initiating the flameless burning. A burning flame is initially and temporarily generated in the heat generation device 7 but may be maintained only for a very short period unit the catalyst is heated to the desired working temperature. As a result, there is no burning flame generated during the operation of the hair dryer except for the very short initial period. Hazard or damage caused by burning flame is thus significantly reduced or even eliminated. The airflow caused by the fan assembly 2 is conducted by the air tunnel 12 to the heat generation device 7 and passes through the heater casing 70 to be heated thereby. Heated air the flows out of the hair dryer through the front outlet 14 of the casing 1.
Although the preferred embodiment has been described to illustrate the present invention, it is apparent that changes and modifications in the specifically described embodiment can be carried out without departing from the scope of the present invention which is intended to be limited only by the appended claims.
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A hair dryer includes a casing inside which a heat generation device for generation of heat by burning fossil fuel supplied from a removable internal fuel container and a fan for generation of an air flow passing through the heat generation device to be heated thereby for the provision of heated air stream are arranged. The heat generation device includes a cordierite based ceramic body on which a platinum based oxidation catalyst is coated. An initial ignition device is provided to cause an initial burning of the fuel supplied to thereto for heating the catalyst to the working temperature thereof. Once reaching the working temperature, the catalyst itself maintains the oxidation or burning of the fuel in a flameless manner and the heated air flow is continuously supplied until the fuel supply is cut off and the fan turned off.
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This application is a continuation in part of U.S. patent application Ser. No. 329,149, filed Dec. 10, 1981, now U.S. Pat. No. 4,402,629 entitled RESONANTLY DRIVEN PAVEMENT BREAKER; which is a continuation-in-part of U.S. patent application Ser. No. 157,138, filed June 5, 1980, entitled RESONANTLY DRIVEN VERTICAL IMPACT SYSTEM, now U.S. Pat. No. 4,340,255.
BACKGROUND OF THE INVENTION
The present invention relates to a counterweight support for a resonantly driven tool such as a pavement breaker.
U.S. Pat. No. 4,340,255 describes a vertical impact system used to break the pavement or tamp down the ground underlying a mobile vehicle. The vehicle includes a resonant beam supported at its nodes and excited at one end near its resonant frequency. A tool projects downwardly from the output end of the beam to break the pavement or tamp down the ground. A large weight is superimposed over the forward node of the beam to counteract the reaction forces of the tool striking the underlying surface. The weight is suspended from the vehicle so that the reaction forces are not transmitted by the weight to the vehicle, isolating the vehicle itself from the reaction forces.
The impact system design of U.S. Pat. No. 4,340,255, has been found to be quite useful, but there have been various problems in implementing the design concept. Specifically, gross movement of the weight relative to the forward node must be prevented, because such movement results in the weight bearing down on the beam at some distance from its actual node. The beam is essentially stationary at its node, but vibrating everywhere but the node, and even a small movement of the weight relative to the node position greatly increases the vibratory forces imparted to the vehicle. However, slight movement must be allowed between the beam and the weight because some small vibration of the beam relative to the weight is inevitable, even if all attempts are made to support the beam exactly at the node position.
Relatively large reaction forces are imparted to the weight by the tool through the beam. The support system must prevent gross movement of the weight relative to the beam, while permitting slight movement, and still accomplish the transmission of the relatively large forces. The pad assembly connecting the weight to the beam, and the pivotal support of the weight at a position above the resonant beam, as described in the referenced patent, have been found less effective than desired in accomplishing these objectives.
SUMMARY OF THE INVENTION
The present invention provides an improved mechanism for positioning the weight relative to the resonant beam in resonantly driven impact systems of the type described in U.S. Pat. No. 4,340,255. The weight is linked to the resonant beam at the node proximate the output end of the beam. A member is fastened to the weight and extends to a position adjacent the node of the beam proximate the input end of the beam. The member is pivotally mounted to the frame at the node proximate the input end of the beam so that the member and attached weight are rotatable about the same axis as the resonant beam. As a result, the weight does not move relative to the node proximate the output end of the beam as the beam itself pivots about its aft node support.
The present invention further provides a recess in the lower portion of the weight, and a plate is located within the recess. Resilient, deformable material is provided intermediate the plate and the walls of the recess to prevent direct contact between the plate and the recess. Preferably, a slight gap is allowed between the deformable material and the plate to allow slight relative movement. The plate is linked to the resonant beam at the node proximate its input end.
Pivoting both the weight and the resonant beam about the same axis, namely, the support axis for the aft node of the resonant beam, prevents gross movement of the weight relative to the beam. Providing a recess in the lower end of the weight, and a plate in the recess but isolated from the walls thereof by deformable material, provides a large bearing surface for the weight so that the weight can absorb large reaction forces transmitted by the tool through the beam. The resiliency of the deformable material, and preferably a slight gap provided as well, allow for slight vibratory movement of the beam relative to the weight. The present invention thus provides a substantial improvement in the design shown in the referenced patent by accommodating large reaction forces while preventing gross movement of the weight relative to the beam but allowing slight movement therebetween.
The novel features which are characteristic of the invention, as to organization and method of operation, together with further objects and advantages thereof will be better understood from the following description considered in connection with the accompanying drawings in which a preferred embodiment of the invention is illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of a preferred embodiment of a vertical impact system incorporating the present invention;
FIG. 2 is a plan view of the embodiment of FIG. 1;
FIG. 3 is a fragmentary elevation view of the forward section of the embodiment of FIG. 1 with portion broken away;
FIG. 4 is a plan view of the embodiment of FIG. 1 with portions broken away;
FIG. 5 is a fragmentary elevation view showing the attachment of the weights of the beam in the embodiment of FIG. 1;
FIG. 6 is a front elevation similar to that of FIG. 5;
FIG. 7 is an enlarged fragmentary view taken along lines 7--7 of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment 10 of a vertical impact system incorporating the present invention is illustrated generally by way of reference to FIGS. 1 and 2 in combination. Impact system 10 includes a carrier vehicle with a forward frame 12 connected to a rear frame 14 by an articulating joint 16. Hydraulic actuators 17, 18 extend between forward and rear frames 12, 14 to control articulation of the vehicle. The carrier vehicle rides on wheels 20 over a surface 22 which is to receive vertical impact forces for some purpose, such as old pavement to be broken up and removed, a roadbed to be tamped down, and the like.
An engine 24 is mounted on rear frame 14, and provides both motion power for the wheels 20 and hydraulic power from a reservoir 26. The operator of the vehicle rides in a control cab 28 projecting forwardly and to one side of the remainder of the vehicle.
A solid, homogeneous resonant beam 30, typically steel, is supported by the carrier vehicle, as depicted in more detail by way of reference to FIGS. 3 and 4. In the preferred embodiment, resonant beam 30 is approximately 121/2 feet long, and has a resonant frequency of about 45 cycles per second when vibrating transversely about forward and aft nodes spaced inwardly from its ends. While resonating in this fashion, resonant beam 30 has antinodes (locations of maximum amplitude) at its opposite ends and approximately at its center. A tool, such as the pavement cutting tool 31 illustrated, depends from the forward end of beam 30.
Resonant beam 30 is supported at its aft node by a shaft 32 which projects through the beam at the location of the aft node (see U.S. Pat. No. 4,320,807). Shaft 32 is supported by a pair of pneumatic tires 33, 34 embedded in frame members 35, 36 forming part of the forward frame 12 of the vehicle. Since shaft 32 passes through a node position of beam 30, vibration of the beam at the node position is relatively small (theoretically zero) and the transmission of vibratory forces from the beam to the frame is minimized. The beam is further isolated from the frame by the use of pneumatic tires 33, 34 for support.
A massive weight 38 is superimposed over beam 30 toward its forward end. A large bracket 40 is fixed to beam 38 by bolts 42. A hydraulic cylinder 46 depends from a pin 48 attached to a portion 50 of the forward frame 12, and is fixed to bracket 40 by pin 44. Hydraulic cylinder 46 is of the single acting type, in which the cylinder can be contracted to lift weight 38, but cannot be extended to push down on the weight. Use of such a single acting cylinder allows weight 38 to be raised for transportation of the system, but inhibits the transmission of reaction forces from weight 38 to frame element 50 of the vehicle.
Bracket 40 is welded to a support member 52 having a zigzag configuration, the aft portion of which runs parallel to resonant beam 30. A collar 54 is formed in support member 52, and circumscribes shaft 32 to which resonant beam 30 is fixed at its aft node. Collar 54 is rotatable relative to shaft 32, so that support member 52, with weight 38 attached, is rotatable about the same axis as resonant beam 30.
Resonant beam 30 includes an enlarged housing 56 at one end, in which an eccentric oscillator is mounted. An hydraulic motor 58, which drives the oscillator, is located within enlarged portion 60 at the aft end of support beam 52. Since support member 52 and resonant beam 30 rotate in unison about shaft 32, the location of hydraulic motor 58 is fixed relative to the oscillator within housing 56.
The manner in which weight 38 is attached to resonant beam 30 is illustrated in FIGS. 5-7. A recess 62 is formed in the lower portion of weight 38, and a plate 64 is located in the recess. Both recess 62 and plate 64 have complementary ridges such as 65, 66 and 67, 68 which define a plurality of cavities overlying the plate. Pads 70 of resilient, deformable material are located within these cavities, leaving a slight vertical gap 72 on the order of 1/16 to 1/8 inch. Pads 70 essentially isolate weight 38 from the high frequency vibrations of resonant beam 30, yet provide a large surface area through which the downward force of weight 38 can be imposed on the resonant beam. Corresponding pads 74 are located beneath plate 64 overlying cross member 76 to vertically support the forward portion of resonant beam 30 when the resonant beam is not in operation, i.e., when the upward reaction forces from the tool do not force the resonant beam upwardly against the weight.
Plate 64 includes a pair of downwardly projecting stirrup members 77, 78 which attach to a transverse pin 80. Links 81, 82 are fixed to the respective ends of pin 80, as will be illustrated in more detail hereinafter, and connect pin 80 to abutments 83, 84 projecting transversely from resonant beam 30 at its forward node location.
The attachment of link 82 to abutment 84 is illustrated in detail in FIG. 7. A bushing 86 circumscribes abutment 84. Link 82 is confined between the flange portion 88 of bushing 86 and a cap 90, which is fixed to the end of abutment 84 by bolts 92. The width of link 82 is slightly less than the distance between flange portion 88 of bushing 86 and cap 90, preferably on the order of about 1/16 to 1/8 inch. O-ring seals 93, 94 define a cavity into which grease can be inserted through fitting 96 to minimize friction between link 82 and bushing 86. The attachment of link 82 to the end of pin 80 is similar, as is the attachment of link 81 to abutment 83 and pin 80.
In operation, when tool 31 is performing a breaking or tamping operation, reaction forces from the tool striking the underlying surface are transmitted through beam 30, through various links to plate 64. The deformability of resilient pads 70, together with a slight gap between the pads and plate 64, dampen high frequency vibrations but transmit the reaction forces to weight 38. The reaction forces are substantially absorbed by weight 38, and not transmitted to the vehicle as a whole.
As the underlying terrain varies, or as the depth of cut of the tool varies, resonant beam 30 will pivot about shaft 32 at its aft node support. Weight 38 is supported by support member 52 which also pivots about shaft 32, and thus the weight and resonant beam will pivot in unison. As a result weight 38 remains superimposed directly over the forward node, and the fixed node support described herein can be utilized.
When the impact system is not in the process of performing a breaking or tamping operation, weight 38, acting through various links, supports the forward end of resonant beam 30. Single acting cylinder 46 is contracted to hold the weight and the resonant beam in position so that the vehicle can be moved from place to place.
While a preferred embodiment of the present invention has been illustrated in detail, it is apparent that modifications and adaptations of that embodiment will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention, as set forth in the following claims.
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The present invention provides an improved mechanism for positioning the weight relative to the resonant beam in resonantly driven impact systems.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to playing card wagering games that can be played with playing cards, including a standard deck(s) of cards or by video machine technology, particularly in a casino environment. In particular, it relates to a method and apparatus for playing a wagering game, wherein the game includes bonus awards for predetermined card combinations, hands or ranks to a player, and where all players at the table have an option at the beginning of the game to place a side bet to participate in all awards to any player for obtaining such predetermined card combinations or hand ranks.
[0003] 2. Background of the Art
[0004] There are many wagering games used for gambling. Such games should be exciting to arouse players' interest and uncomplicated so they can be understood easily by a large number of players. Ideally, the games should include more than one wagering opportunity during the course of the game, yet be able to be played rapidly to a wager resolving outcome. Exciting play, the opportunity to make more than one wager and rapid wager resolution enhance players' interest and enjoyment because the frequency of betting opportunities and bet resolutions is increased.
[0005] Wagering games, particularly those intended primarily for play in casinos, should provide players with a sense of participation and control, the opportunity to make decisions, and reasonable odds of winning, even though the odds favor the casino, house, dealer or banker. The game must also meet the requirements of regulatory agencies.
[0006] Wagering games, including wagering games for casino play, with multiple wagering opportunities are known. U.S. Pat. Nos. 4,861,041 and 5,087,405 (both to Jones et al.) disclose methods and apparatus for progressive jackpot gaming, respectively. The former patent discloses that a player may make an additional wager at the beginning of a hand, the outcome of the additional wager being determined by of a predetermined arrangement of cards in the player's hand. U.S. Pat. No. 4,836,553 (to Suttle and Jones) discloses a modified version of a five card stud poker game.
[0007] Additional symbols may be added to the usual means of playing a game to increase wagering opportunities. This is disclosed in U.S. Pat. No. 5,098,107 (to Boylan et al.). Somewhat similarly, U.S. Pat. No. 3,667,757 (to Holmberg) discloses a board game and apparatus, including a way to allow the player to make a choice with respect to several different alternative types of game play and risk bearing strategies. The alternative play is based on providing cards with additional symbols and therefore, a new set of odds. The game and apparatus disclosed by Holmberg requires new sets of rules, relatively complicated procedures and time for a player to learn the game.
[0008] U.S. Pat. No. 5,154,429 (to LeVasseur) involves the dealer playing multiple hands against a player's single hand, whereby the number of hands played in the same amount of time is increased.
[0009] U.S. Pat. No. 5,288,081 (Breeding) describes the game Let It Ride® stud poker which is played in many casinos around the world. That wagering game is played with a single, typical (standard) fifty-two card poker deck and broadly involves the generally well recognized and accepted set of rules, procedures and wager-resolving outcomes of five card poker. The game method comprises each player placing an initial, three-part wager to participate in the game. A separate bonus wager (a side bet wager) may be placed to play against a pay table. Cards are dealt by a dealer, three down to each player and two down to the dealer. Players inspect or “sweat” their cards, and the dealer asks “take it or leave it?” or as the name of the game implies, “Let It Ride®?” with regard to the first part of the initial bet. Players can choose to retrieve or remove from play the first part of their initial bet, or leave the first part in play or at risk, based on the value of the three cards in their hand. The side wager or bonus wager cannot be withdrawn and is immediately withdrawn by the house in the play of the game. The dealer then turns over one of the dealer's cards and the dealer's query is repeated with regard to the second part of the initial bet. Players can choose to retrieve or remove from play the second part of their initial bet or leave the second part in play or at risk, based on the value of the four cards consisting of the three cards in the player's hand and the exposed dealer's card. Players have no option with the third part of the bet. Finally, all cards are shown and the payouts and collections are resolved according to the ranking of the poker hand of each player, i.e., the players are not playing against each other or the dealer.
[0010] Another element of play in casino games and particularly casino table card games in the wagering structure. There are a multitude of card games that are based on one or more decks of conventional playing cards. Among the most popular of these games is poker, wherein a player's fortunes are determined by a well-known hierarchy of card combinations. Card games that are variants of poker are also very popular, such as Let It Rides stud poker, Caribbean Stud™ poker, Three Card™ poker and the like. This is due, at least in part, to the basic nature of the underlying game itself, combining elements of both strategy and luck. Additionally, poker-variants allow an existing player-base to capitalize on their preexisting knowledge of a game and to apply that knowledge in novel settings. The two most popular forms of traditional poker are draw poker and stud poker.
[0011] In a conventional hand of draw poker, a single 52-card deck of shuffled playing cards is used. Each player begins a hand by contributing an initial or “ante” bet to a common pool or “pot”, the pot ultimately going to the owner of the winning hand. The dealer then distributes five face-down cards to each player, the remaining cards in the deck being set aside for later use. Each player evaluates the cards that he or she has been dealt and each, in turn, is given an opportunity to discard one or more cards from the dealt hand. The dealer gives the player replacement cards for those that have been discarded by dealing additional cards face-down from the top of the deck. Following the deal, one or more rounds of betting take place, during which time each player may make an initial raise, a check wager, fold (drop-out), match a previous raise or raise a previous bet. The meanings of these wagering terms are well know to those skilled in the art and typical definitions of same may be found in, for example, Hoyle's Rules of Games , pp. 75-102, by Morehead and Mot-Smith, 1963, the disclosure of which is incorporated herein by reference. At the conclusion of the wagering rounds, the players display their hands and the holder of the highest ranking poker hand takes all of the money in the pot.
[0012] Stud poker is the most popular form of “open poker,” wherein each player is dealt some cards that are face-up and, hence, available for viewing by the other players. Stud poker comes in two varieties: 5-card and 7-card, the two being of approximately equal popularity. In five-card stud poker, the dealer gives each player a face-down (or “hole” card) and then a face-up card. Thus, at the start each player knows his own two cards and one card of each of his opponents. After the first two cards are dealt, a wagering round ensues, during which time each player contributes his or her wager to the pot. A typical description of the rules that govern this round might be found in, for example, Hoyle's Rules of Games, pp. 75-102, by Morehead and Mot-Smith, 1963, the disclosure of which is incorporated herein by reference. After the wagering round, another card is dealt face-up to each player. This is followed by another wagering round. Alternating dealing and wagering rounds continue until each player has a total of five cards: four face-up and a concealed hole card. After the final bets have been placed, each player who has not dropped out during the deal/wager rounds reveals his or her hole card. The owner of the highest ranking 5-card poker hand wins and takes whatever amount is in the pot.
[0013] Seven-card stud poker differs slightly from 5-card poker. First, in 7-card poker each player initially receives two cards face-down and one card face-up. A bidding round then ensues. The dealer then gives each player another face-up card, which is followed again by a bidding round. Deals (of one face-up card) and bids are alternated until each player has four face-up cards and two face-down cards. Finally, a third face-down card is dealt to each player (making a total of seven cards). This is followed by a last bidding round. The winner of the hand is the player who can form the highest ranking 5-card poker hand from his seven cards.
[0014] As is well known to those skilled in the art, five-card poker hands are ranked from “Royal Flush” (highest) to “High Card(s) in Hand” (lowest) according to the following ordering:
Hand Description Example Royal Flush The five top cards of A, K, Q, J, 10 a suit (suited) Straight Flush Five cards in sequence e.g., 5, 6, 7, 8, 9 in the same suit (suited) Four of a Kind Any four cards of the e.g., 2, 2, 2, 2, J same rank, Full House Three of a kind and a 2, 2, 2, J, J pair Flush Five cards of the same 2, 4, 8, 10, A suit (suited) Straight Five cards in sequence 6, 7, 8, 9, 10 (unsuited) Three of a Kind Three cards of the same 2, 2, 2, 9, J rank Two Pair Two cards of the same e.g., 2, 2, Q, Q, A rank and two others (unsuited) of a different rank One Pair Two cards of the same e.g., 9, 9, 5, 8, K rank High Card(s) in Hand Five unmatched cards A, 9, 5, 3, 2 (unsuited)
[0015] In some variations of poker, the ace may also act as the lowest card in the deck to form a straight when used in a sequence like A, 2, 3, 4. Additionally, a “wild card”—often the “joker” card may be designated, so that a person who holds that card may declare its value to be that of any card in the deck, the presumption being that the declared card value will help that player form a better poker hand.
[0016] At its core, poker is a vehicle for gambling. Commonly the quantities wagered are monetary, but that is not strictly required and poker chips, matches, and other non-pecuniary tokens have been used in place of money to help the players determine who is winning without exposing them to financial loss. Of course, casinos are in the business of providing people with the opportunity to gamble and, given the popularity of poker among the general populous, it only stands to reason that casinos would desire to offer this game in some form or another to those who seek to play it. However, conventional-rules poker is not particularly well suited for use in a casino.
[0017] A casino that offers traditional poker to its clientele typically does so by providing a dealer and a room in which to play, but the casino's dealer does not actually participate in the game as a player: his or her function is just to distribute the cards and referee the game. The casino makes its money by taking some percent of all of the money wagered (the “rake”) or by leasing the room to the participants. The cost of the lease may be measured in time (e.g., a fixed amount per hour) or by a count of the number of hands played. Traditional poker games are not particularly favored by casinos because the casino does not make as much money acting as a landlord as it would if it were an active participant in the game.
[0018] Similarly, from the standpoint of the gaining public, traditional poker has some disadvantages which have tended to make it less desirable as a casino game. First, traditional poker is readily available “at home,” e.g., at the Friday night poker session, and there is no particular need for most people to travel to a casino to play it. Second, when an individual wins at traditional poker it is at the expense of the other players/participants. Many people prefer to play against the “house” (i.e., the casino) so that their winning hand does not necessarily result in a loss by a fellow player, who may be an acquaintance. Finally, traditional poker does not offer the excitement associated with “jackpot” type games. That is, a royal flush in traditional poker—as improbable as that card combination is—will result in winning only the amount in the pot and nothing more. Many players seek out games where there is some possibility of “winning big,” an option that is not available under conventional poker rules.
[0019] As a consequence of these disadvantages, casinos have introduced a variety of poker-type game variants to address the shortcomings discussed previously. One obvious advantage of these poker-type games from the casino's point of view is that the casino becomes an active participant in the game (as the house) and can, as a consequence, increase the revenue taken from the game. Additionally, these poker-type games are very attractive to many of the gambling public, and the mere fact that they are available in a particular casino has the potential to increase consumer traffic and revenue there.
[0020] A variety of innovative stratagems have been employed to make poker-type games more appealing to casino gamblers. For example, many poker-variants are designed to let the players compete against the house, rather than against each other. In other cases, progressive betting has been utilized, wherein the player may increase his or her bet during the play of a hand. This makes the game more exciting to the player and potentially more profitable for the casino. Jackpots have been introduced, wherein certain card combinations in the player's hand result in an enhanced payout to that player. Finally, computer implementations of these games is always an attractive possibility, with video based casino games becoming increasingly popular. One such video implementation of a poker-type game is taught by Weingardt, U.S. Pat. No. 5,042,818. Of course, a natural next step is to offer these same video based casino games over the Internet, thereby making the games available to a potentially enormous audience. The most successful casino table poker games to date are Let It Ride® stud poker (as originally described in U.S. Pat. No. 5,288,081), Caribbean Stud™ poker (originally described in U.S. Pat. No. 4,836,533), and Three Card™ poker (as described in U.S. Pat. No. 6,237,916).
[0021] In most casinos, a game of blackjack begins by having each player place an initial wager. The blackjack dealer then distributes two cards face-down to each player and two cards—one face up and another face down—to him or herself. After the player has examined the two dealt cards and compared those cards with the face-up dealer's card, a number of options present themselves to the player. The player may “stand” (i.e., take no further cards), draw one or more additional cards in order to increase the numeric sum of the hand, double down (a form of progressive wagering), or split the two cards. Additionally, if the dealer's face-up card is an ace, the player may elect to buy insurance against the possibility that the dealer has a blackjack. If, after the dealer's face-down card is revealed, the dealer does not have a blackjack, the player loses the amount that was paid as insurance (although he or she may go on to ultimately win that deal). If, on the other hand, the dealer has a blackjack, the player collects double the amount of insurance bought (but may still lose the amount of the original wager). The option of purchasing insurance is unique to blackjack type games and has not, heretofore, been available in poker-style games. The broad rules of blackjack are generally known to those skilled in the art and a fuller description may be found in the materials previously incorporated by reference.
[0022] In addition to novel games being introduced into casinos, novel betting formats have also been introduced. Side bets have always been common in wagering environments, but the use of side bets for jackpots and bonuses in casino table card games was believed to have been first practiced by David Sklansky in about 1982 in a public showing of Sklansky's Poker in Las Vegas, Nev. The play and/or betting structure of Caribbean Stud™ poker was modeled after that game. Blackjack has allowed surrender play at many tables, where half the original wager is withdrawn and the other half is forfeit to the house at the election of the player. U.S. Pat. No. 5,820,460 (Fulton) describes a method for playing a casino table card game wherein wagers are changed after some cards are viewed by the player. Let It Ride® stud poker advanced that theory significantly as described in U.S. Pat. No. 6,273,424, where specific segments of wagers could be withdrawn from an original wager that was in multiple parts.
[0023] It is still beneficial to provide additional wagering formats and structures to add both interest to the game and better control over house retention and player awards.
[0024] The desired attributes of wagering games outlined above are in large measure provided by the method and apparatus for a wagering game in accordance with the present invention. The game is uncomplicated, exciting and provides the opportunity for players to make multiple wagers and choices regarding those wagers.
SUMMARY OF THE INVENTION
[0025] The wagering game of the present invention is played with at least a single standard fifty-two card poker deck and broadly involves the generally well recognized and accepted set of rules, procedures and wager-resolving outcomes of card games, especially five card poker and variations of five card poker. The table bonus wager and format of the present game is amenable to use with any casino table card game or video gaming equivalent where multiple players play at the same time against a pay table or against the house, and bonus awards are provided for hands or at least a predetermined rank. Each player has the option (before seeing sufficient cards to provide even a preliminary evaluation of the likelihood of winning) of placing a side bet wager that a player at the table will obtain a hand of a predetermined rank that will receive a bonus payout. This is called a table wager, community wager, group wager, or the like. The player may also make an optional individual wager that he/she will receive a hand of a predetermined rank that will receive a bonus payout.
[0026] The preferred game method played with this wagering format comprises Let It Ride® stud poker, and a new variant of that game where each player placing an initial, four-part wager (as opposed to the required three-part wager used in Let It Ride® stud poker) to participate in the game. Cards are dealt by a dealer, three down to each player and two down to the dealer. Players inspect or “sweat” their cards, and the dealer asks “take it or leave it?” or “Let It Ride®?” with regard to the first part of the initial bet. Players can choose to retrieve or remove from play the first part of their initial bet, or leave the first part in play or at risk, based on the value of the three cards in their hand. The dealer then turns over one of the dealer's cards and the dealer's query is repeated with regard to the second and third parts of the initial bet, except that withdrawal of the second part results in the house claiming the third part of the wager. This step requires that two parts (the second part and the third part) of the four-part bets (usually equal parts) be considered at the same time of play. Players can choose to retrieve or remove from play the second part and forfeit the third part of their initial bet or leave the second part and third part in play or at risk, based on the value of the four cards consisting of the three cards in the player's hand and the first exposed dealer's card. Players have no option with the fourth part of the bet, which is referred to as the contract wager, as it must remain in play through the conclusion of play of the game. Finally, all cards are shown and the payouts and collections are resolved according to the ranking of the poker hand of each player, i.e., the players are not playing against each other or the dealer.
[0027] The pay table in this game (to be marketed as “Dakota Stud™” table card game) can be adjusted from the pay tables in Let It Ride® poker to reflect the change in betting/wagering structure. For example, to compensate for the required forfeit of the third wager part if the second wager part is withdrawn, the qualifying hand for a win may be lowered from the pair of 10's ordinarily required to win against the pay table in Let It Ride® stud poker. For example, the minimum winning hand may be any pair, a pair of 2's, 3's, 4's, 5's, 6's, 7's, 8's or 9's. Additionally, higher odds may be paid on higher ranked hands to make play of the game more attractive to players. The game may also be modified to provide the player with five cards and the dealer with two hole cards or common cards, with the best five-card poker hand playing against a pay table, or with the player being dealt four cards, and the dealer receiving three cards. This may be done with the dealer having one of the three cards exposed immediately before consideration of withdrawal of the first part of the wager, or with three cards provided face down. In the latter circumstance, the dealer's face down cards may be exposed one-at-a-time, or preferably two at one time and one card at another time in the betting/wagering sequence. Two cards may be exposed before consideration of withdrawal of the second (and third) parts of the wager, or first one card exposed at this stage and then two cards exposed at the end of play, after withdrawal of the second and third parts has been considered and exercised.
[0028] More specifically, in the preferred play of the game the initial wager placed by each player comprises four equal parts and is made or placed before any cards are dealt. Each player is dealt three cards face down in the customary fashion. Two common cards are dealt face down in front of the dealer for use by all of the players. Each player will use the two common cards in front of the dealer in combination with his or her three cards to create a five card hand. After all players have placed their four wagers/bets (and in an optional play of the game, a special bonus wager or jackpot wager for extra or extraordinary awards for high ranking hands against a pay table) and received and examined their cards, each is given the opportunity to retrieve one part (if equal wagers are placed, that is one-fourth) of the initial wager before the dealer reveals one of the two down cards previously placed in front of him. After all of the players have been queried and decided whether to withdraw the first part of their wager, the dealer turns one of the down cards face up. Each player now has the benefit of four cards, the three he or she is holding down plus the common card, and the dealer again gives each player the opportunity to retrieve further part(s) of the initial wager, In this case, with equal wagers, the player has the option of leaving the second and third parts in play or withdrawing the second part and forfeiting the third part before exposing the second common down card. After the second common down card is revealed, the players turn up the three cards they are holding thereby forming five card hands made up of the three cards dealt to each player and the two dealer cards. The dealer examines each of the players hands and determines what payout, if any, each player is entitled to receive according to that players' remaining wager and a preselected payout schedule. Payouts are made to players with winning hands and the losing wagers are collected. The cards are then reshuffled for the next hand. Where a separate side bet has been placed as a bonus or jackpot wager (against a pay table and/or against a progressive jackpot), that wager must also be resolved.
[0029] Apparatus is disclosed for playing the wagering game according to the method outlined above. A typical gaming table, with a playing surface, is modified to include specific areas that provide locations for placing the wagers and for displaying the common cards. A card shuffling machine such as that disclosed in U.S. Pat. No. 4,807,884 or other shuffling machines manufactured by Shuffle Master Gaming, Inc. of Las Vegas, Nev. for facilitating and speeding the play of the wagering game may be used. A display device may be associated with the apparatus for displaying game information, shuffle status, or other information relevant to the dealer, the players or the house.
[0030] The present invention provides an exciting and interesting wagering game. The wagering game is easy to learn, largely being based on five card stud poker and the well known ranking of poker hands. The present invention provides a new variation of a well known wagering game, five card poker, and in particular Let It Rideg stud poker, which is made more interesting by providing the opportunity for players to make multiple wagers and decisions related to those wagers based on the progress of the game.
[0031] Still another aspect of the present invention is to provide a wagering game that is easy to learn, yet demands skill of players in making strategic decisions about whether to let part of their bet ride. It is yet another aspect of the present invention to provide a unique, exciting card game for play in casinos or at home and on various media including casino tables, video poker machines, video lottery terminals or home computers. It is an advantage of the game of the present invention that wagering decisions are inherent in the game. The game enhances players' sense of participation and takes advantage of players' inclination to let wagers ride once placed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 depicts the table layout and apparatus used in playing the wagering game of the present invention; and
[0033] FIG. 2 is a block diagram representing the flow of play in the game.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Referring to FIG. 1 , the apparatus for the wagering game of the present invention includes a typical casino gambling or gaming table 10 . The table 10 has a curved side 12 for accommodating up to seven players and a straight side 14 for accommodating the dealer. The table 10 has a flat surface 16 covered with felt or other appropriate material. Although seven playing positions or locations 18 a - g for individual players are provided, it is not essential to the game that exactly seven persons play and as many as sixteen players may participate. For casino play, a maximum of seven players provides for a game that is easily manageable by the dealer and house, and one in which the individual players feel more involved. A house dealer position 20 , including an area suitable for displaying the dealer's cards 21 , is provided.
[0035] Each of the playing positions 18 a - g includes a wagering zone 22 , comprising four separate and distinct wagering or betting areas 22 a, b, c, d . A separate wagering area 22 e may be provided for placing of a bonus or jackpot (e.g., progressive jackpot) wager. Each position 18 a - g also includes a card area 19 a - g for receiving and displaying cards dealt to the player occupying the position. The wagering areas 22 a, b, c, d are designed to receive appropriate wagering indicators or settling means such as chips (not shown).
[0036] At one side of the dealer station 20 , the apparatus for practicing the method of the present invention may include a microprocessor or computer controlled shuffling machine 32 supported by a table extension 34 . The shuffling machine 32 may be of the type disclosed in U.S. Pat. No. 4,807,884 or any other single deck or multideck shuffling apparatus manufactured by Shuffle Master Gaming, Inc., the disclosure of which patent is incorporated herein by reference. The shuffling machine 32 may include a dealing module for automatically and sequentially dealing cards and also may include a display means for displaying wager amounts, the identity of winning players, or other game related information.
[0037] Referring to the flow diagram of FIG. 2 , the initial step in playing the game of the present invention is preparing or shuffling a deck of cards, represented at block 40 , by activating the shuffling machine 32 or by hand-shuffling a deck to provide a shuffled deck. Next, the players place the initial wager, block 42 , by putting equal amounts in each of the four betting areas 22 a, b, c, d . Two of the parts of this initial wager, the parts placed in wagering area 22 a and 22 b are retrievable at the option of the player. The third portion placed in area 22 c is a wager that is forfeited if the second wager at 22 b is withdrawn. The fourth part 22 d of the four part wager is a nonwithdrawable bet. After the placing of the wager by each player, the cards are dealt, block 44 , preferably three cards being dealt down to each player and preferably two cards are dealt down in front of the dealer. The players inspect or “sweat” their cards in preparation for reaching decision block 46 . At decision block 46 , the players are queried by the dealer about whether the first part of the initial wager, the part placed in wagering area 22 a , should be left or whether the player wishes to withdraw that portion of the bet. Each player makes the decision at decision block 46 on the basis of the three cards forming the player's incomplete hand at this point. Once each player has been queried and has decided whether or not to let the first portion of the bet ride, and those bets the player chooses to retrieve or remove are physically removed from area 22 a and returned to the player, the dealer shows one of the down common cards, block 48 . Now, each player has four cards to consider, the three cards dealt to that player originally and the single common card showing on the table. Each player must then decide whether to let the second part of the initial wager ride or whether to withdraw it from the game. As noted, if the second part of the wager is withdrawn, the third part of the wager is forfeit and is collected by the house. After each player is queried and decides what to do with regard to the second part of the bet, and those bets to be withdrawn are physically removed from area 22 b (and 22 c if the third part is forfeit) and returned to the player, the dealer reveals the second common down card, as represented at block 52 . Each player now has a five card hand comprised of the three cards each player was originally dealt plus the two revealed common cards. The third bet, the bet placed at wagering area 22 d , is a nonretrievable portion of the initial bet and the flow of the game proceeds to block 54 wherein the players show or reveal their three cards to the dealer. The dealer resolves each player's bet (which includes all three parts, the second and third part or only the third part, depending on the player's choices during play of the hand) based on the five card hand at block 56 and determines what payout, if any, the player is entitled to receive according to the payout schedule at the particular gaming table or casino. Bets on non-winning hands are collected by the dealer or house. The hand is then over and the flow of the game returns to block 40 , preparing and shuffling the deck for a new hand.
[0038] The award or payoff is given for each of the optional bets that were allowed to ride to the end of the hand and for the non-withdrawable part of the bet. A typical pay table would be as follows:
Pair, Sixes or Better 1-1 (even money) Two Pairs 2-1 Three of a Kind 3-1 Straight 5-1 Flush 8-1 Full House 11-1 Four of a Kind 50-1 Straight Flush 200-1 Royal Flush 1,000-1
The method of the present invention is not limited to five card poker games, but may be applied or used in other appropriate games such as seven card poker, as described elsewhere herein. The method of the present invention does not require a shuffling machine 32 , dealing module 33 or a display means 36 . However, these facilitate and expedite the play of the game as well as add interest to the game. While the initial wager of the present invention is preferably comprised of four equal bets, the bets do not necessarily have to be equal. The second and third parts should be equal, or the third part may be smaller than or greater than the second part. Similarly, the first, second, third and fourth parts may be of different values, but the fourth bet must be at least equal to a table minimum and may be required to be at least equal to or greater than any other wager part. While equal bets are highly preferred for casino play, unequal bets may be used in home play, if desired. The wagering game of the present invention might be played live in casinos with a dealer, or in casinos or homes in interactive electronic or video form with automatic coin or betting means receptacles and payout capability, wherein appropriate symbols for cards, wagers or score keeping would be displayed electronically. A “board-type game” suitable for home, club or casino use may also be provided for practicing the method of the present invention.
[0039] In combination with or separate from the play of Dakota Stud™ casino table poker, a new wagering structure resulting in different bonus structures may be used. The pure wagering structure described above, where the third part of the wager is tied to the election made by the player on the separate part of the wager is itself novel. The use of that wagering structure in combination with certain pseudo-pooling payout outcomes at the table is a further advance in the structure of wagering and play at casino table card games.
[0040] An example of the additional wagering structure and alternative payout structures include the use of excess retention by the house because of the unique wagering structure described above in the four-part wager (e.g., retaining a pair of 10's or other rank higher than 6's, 7 's, 8 's, or 9 's as the winning hand) or by providing the option of a side bet to enter the additional award structure described below. Once the player is entered into the additional award structure (either automatically or with the optional or required side bet), the payout can be altered as follows. Those players that are entered into play of the additional award structure can participate in winning awards at the table, even where the awards occur in different hands, that is, hands of other players.
[0041] In present table gaming with bonuses or jackpots with side wagers, only the player receiving the hand is paid on the achievement of the bonus hand of at least a predetermined rank. In some poker clubs, certain events are paid both to players at the table and to the winning player from a pool when certain unusual events occur. For example, house rake may be partially deposited in a pool account Where when the event occurs, the pool is paid to the table where it occurs and the money in the pool is distributed proportionally. Such a situation would occur where, for example, the winning event in a pool was where a losing hand at a card table was at least a full house with at least three Aces and two 10's as the losing hand. The pool is distributed among the players and the sometimes the dealer at the table as, for example (70% to the winning hand, 10% to the losing hand and 20% to the remaining players at the table; or 70% to the winning hand, 15% to the second place hand, 20% to the remaining players at the table, and 5% to the dealer). The pool is a form of progressive jackpot which is incremented according to discretionary rules of the poker club or casino. All players at the table partake of the pool winnings if they anted in the play of the hand where the winning event occurred. No distinct side wager or particular wagering element is required to enter into the chance to win the pool, which occurs with only a single specific event occurring, as described.
[0042] In the practice of the present invention, accruing take from the third wager (automatically entering the player in the bonus event during the game) or preferably requiring a separate side wager to enter the bonus payout event is used to enable a player to enter the bonus event. The player is either required to place a side bet or has the option of placing a side bet to enter the bonus event. The bonus event is played against a pay table, whereby whenever any player at the table achieves a hand of predetermined rank, all players that are entered into the bonus event (either automatically or by placing the side bet) partakes of the bonus award for the predetermined hand. The rules may vary, so that a) only players that made the side bet wager can participate in the bonus, b) only players that made the side bet wager and remain in the game at the end of the hand can participate in the bonus, c) only players that made the side bet wager and have a qualifying hand can participate in the bonus, or d) only players that made the side bet wager and have a hand that beats the dealer's hand can participate in the bonus. The preferred method of play is a). The play of this bonus event with side bet can even be extended to include multiple tables. For example, certain progressive jackpot games link tables for the jackpot or bonus awards taken out of the jackpot pool. The tables can be linked by having players who had made the side bet wager at a distal table in the last hand before the bonus event was won at a proximal table. This is not a preferred embodiment (because of potential complexities in synchronization of play or debating when hands were played relative to distal side bets), but is within the skill of play and design. Additionally, the bonus may be paid either when any hand at the table achieves the predetermined hand rank, or only when a player that has made a side bet achieves a hand of the predetermined rank. The second format is preferred to stimulate more persons at the table to make the wager.
[0043] An aspect of this pay structure is to increase the frequency of bonus events at a table. With more players at a table, there are more hands per game at the table, and the hit frequency of bonus hands increases. Even though the actual size of individual awards per player decreases, the increased frequency improves the overall ambiance of the game. For example, if there are six players at a table, the frequency of bonus hands statistically increases to six times what the frequency was with a single player at the table.
[0044] The payouts for each player will necessarily vary according to the number of players that are in the game and/or have made the side bonus bet. The house may require a minimum number of players to engage play of this side bet bonus event, primarily to limit the number of pay tables that must be displayed It is also possible to have a display device (e.g., screen, monitor LED, liquid crystal display, plasma screen, etc.) that is fed by data from a computer or microprocessor or other image source to show the applicable pay table for the number of players involved in the payout for the hands. For example, the display may show separate screen for 2 player, 3 player, 4 player, 5 player, 6 player and 7 player bonus events, each screen having different odds and payouts. Automated equipment indicating the number of wagers placed, the number of players entered, the rank of the hand, and other factors can be provided. For example, camera, scanners, digital readers, and software interpreting the data such as that provided in U.S. Pat. Nos. 6,313,871; 6,460,848; 6,126,166; 5,941,769; and the like could be used to assist in automating the reading of cards, ranks, wagers, and the number of players.
[0045] It is also possible for players to elect to play a “double bonus.” In this format, rather than a typical one dollar side bet being placed, two separate one dollar wagers or a single two dollar wager may be placed to enter the player in both an individual bonus payout event and the shared bonus event discussed above. Except where the bonus was a progressive bonus, this system could be highly attractive to players. The rules must be clear in the event that a progressive jackpot is used, so that it would be understood that a 100% jackpot win by a player with both side bets placed would win 50% of the total jackpot for him/herself, and the remaining 50% would be split among players in the bonus event, including the winning player. With a fixed bonus pay table, one of five players at a table with both side bets having been placed (the individual bonus and the shared bonus or group bonus wager) would receive a payment of the fixed amount for obtaining a predetermined rank hand and ⅕ th of the award for the group award on the ranked hand. For example, if the ranked hand were a Straight Flush with a $2,000 fixed award, the player with that hand would win $2,400-$2,000 for the individual bonus side bet and ⅕ th of $ 2,000 ($400) for the group bonus wager.
[0046] The side bets may be made on sensing systems or by placing tokens, chips or money on the table that remain on the table at appropriate locations until conclusion of the game. Typical sensing devices include coin drops, photooptical sensors, proximity detectors, cameras, scales, and the like.
[0047] The format of this game is particularly compatible with any poker-type games where bonus awards are provided from a pay table, such as Let It Ride® stud poker, Three Card™ poker, Four Card poker, 3-5-7™ Poker table game, and the like. It is also useful in games where progressive jackpots are used, alone or in combination with pay tables, such as with certain formats of Caribbean Stud™ poker. The wager could also be used in games where there are special bonuses given to players who obtain unique hands. For example, in Pai Gow poker, there may be special awards for perfect Pai Gow hands (e.g., 9, 8, 7, 5, 4, 3 and 2) or uniquely ranked hands (e.g., a front pair of aces and at least four-of-a-kind on the rear hand). The payouts could be made to all players participating in the wager (e.g., on a proportional basis), rather than just to the player who obtains the hand. The bonus wager could also be doubled so that a player could receive both the individual award and the group award for the hand.
[0048] The present invention may be embodied in other specific forms without departing from the essential attributes thereof. It is desired that the embodiments described above may be considered in all respects as illustrative, not restrictive, reference being made to the appended claims to indicate the scope of the invention.
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A method of playing a casino table wagering game with at least two players comprises wagering on an underlying game where players may receive a bonus for obtaining a player hand of at least a predetermined rank; placing a side bet that at least one player of the at least two players will obtain a player hand of at least a predetermined rank; playing a hand of the casino table wagering game to conclusion; determining if at least one of the at least two players has obtained a player hand of said at least a predetermined rank; if a player has not obtained a player hand of at least a predetermined rank, but that player has placed the side bet that at least one player of the at least two players will obtain a player hand of at least a predetermined rank, and if another player has obtained a player hand of at least a predetermined rank, awarding that player a predetermined proportional share of the bonus for obtaining a player hand of at least a predetermined rank.
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This invention relates to the textile industry and more particularly to the field of shuttleless weaving looms.
A well-known means for inserting weft in the shed of a weaving loom of this type consists in making use of a pair of rigid or flexible needles which are driven in reciprocating motion in opposite directions between the selvedges and a point usually corresponding to the center of the cloth which is being woven. Each needle is adapted to carry a clip. The clip which is attached to the so-called entry or feed needle is intended to grip the end of the filling yarn to be inserted in the vicinity of one of the selvedges and introduces it into the shed. At a point near the center of the cloth, the entry-needle clip transfers the filling yarn to the clip which is attached to the other needle designated as the exit or drawing needle which withdraws together with the yarn to the other selvedge.
The invention is more specifically concerned with an improvement to the so-called exit clip which is attached to the end of the exit needle.
This mode of insertion is becoming more and more difficult to apply in practice as weaving looms are designed to operate at increasingly high speeds. In fact, the entry needle takes the filling yarn when this latter is subjected to a considerable acceleration and is thus liable to cause breakage of the yarn, especially if it is fine or delicate. The time allowed for the exchange of filling yarn between the entry needle and the exit needle is of increasingly short duration, with the result that said exchange must therefore take place at a high speed while remaining accurate.
All these considerations point to the need for increasingly lightweight clips which are capable of gripping and releasing the yarn with precision and of traveling within sheds which close at constantly higher speeds.
Patent No. DE-20 61 194 describes an exit clip of an improved type in comparison with the designs which had existed in the prior art. In this patent, the yarn is clamped between a hook-shaped stationary portion which is rigidly fixed to the clip body and a movable central member which has a controllable opening and the end of which is adapted to engage within the hook opening in order to retain the yarn therein. However, the yarn is clamped between two substantially vertical and parallel facets. This produces a double wedge effect, with the result that the yarn has a locking action on the clip. In order to release the clip at the exit of the cloth, it is opened by pressing on the central member in order to cause the clip to move away from the hook, but if the clip body which carries the hook has insufficient rigidity, said body follows the movable portion and the clip fails to open. In order to guard against such a fault condition, provision has to be made for a massive clip which is consequently of substantial weight.
The object of the present invention is to overcome these drawbacks by providing a lightweight exit clip which releases the yarn in a rapid and reliable manner. Jamming of the clip by the yarn is prevented by clamping this latter between facets which are inclined with respect to the plane of displacement of the hook. The hook is no longer carried by the clip body but by the movable portion, thus taking advantage of the pressure of the yarn on the hook in order to increase the force which initiates the closing action of this latter.
The invention consists of an exit clip for insertion of the weft in a shuttleless weaving loom in which the yarn is clamped between a stationary portion and a movable portion, one of said portions being designed in the shape of a hook. The distinctive feature of the invention lies in the fact that the hook is carried by the movable portion and the two facets between which the yarn is clamped are inclined at a predetermined angle with respect to the plane of displacement of the movable portion.
These and other features of the invention will be more apparent to those skilled in the art upon consideration of the following description and accompanying drawings, wherein:
FIG. 1 is a top view showing a clip in accordance with the invention;
FIG. 2 is a side view of said clip;
FIG. 3 is a section view taken along line 3--3 of FIG. 2 showing the clip-carrier needle;
FIG. 4 is, on a larger scale, a sectional view taken along line 4--4 of FIG. 2 and showing a clip in the clamping zone;
FIG. 5 is, also on a larger scale, a detail view showing the active end portion of the body of the clip.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The clip which forms the subject of the present invention is made up of two generally elongated parts, namely a stationary part or body 1 which is rigidly fixed to the needle 2 and a movable part 3. These two parts are rotationally coupled by means of a pivot-pin 4 which passes through the body 1 and is riveted at 5 in order to retain the movable part 3.
The body 1 is composed of a portion 1' (see also FIG. 3) in the form of a right angle which fits closely within the internal walls 9 and 10 of the needle 2 and is secured to said needle by means of screws 11 and 11' but any other known systems such as bonding, riveting and so on may be employed. A blade spring 12, the function of which will be explained in greater detail below, is attached to the body 1 by means of screws 13.
The body 1 terminates in an active yarn-clamping portion 15 adapted to cooperate with a hook 14 formed at the corresponding end portion of the movable part 3.
During operation, the clip travels alternately in the directions 6--6' between the reed P and the fell F of the cloth T which is being formed. The warp threads 7--7' are also shown in FIG. 1.
The active portion 15 of the movable part (shown in FIG. 5) has a first longitudinal edge 101 (see also FIGS. 4 and 5) facing the fell F of the cloth and a second longitudinal edge 102 which is located on the side opposite to the first longitudinal edge and constitutes a facet for clamping the yarn 19 (FIG. 1). Said clamping facet is adapted to cooperate with a corresponding opposite facet 16 formed in the hook 14 and has two angles of slope, namely a first angle of slope with respect to the longitudinal direction of the clip, which provides the end portion 15 of the stationary part with a wedge-shaped configuration, and a second angle of slope with respect to the plane of displacement of the movable part. In the embodiment herein described, the value of said second angle of slope is approximately 20° (as shown in FIG. 4). This value is defined as being substantially equal to or greater than the limiting gangular value which permits irreversibility of the grip created by the active yarn-clamping portion 15 of the body 1 and the hook 14 on the yarn 19 jammed together within the space 14' provided between the two facets 102 and 16 of the body and hook, respectively. The value of this angle is dependent on the coeffient of friction of the contacting surfaces or, in other words, on the nature of the material constituting the stationary and movable parts of the clip and also on the nature of the yarn. Release of the yarn is discussed below. The junction between the inclined facet 102 and the main portion of the body 1 is provided by a curved zone 104 which forms with a corresponding curve of the hook 14 an opening for insertion of the yarn 19. In order to facilitate insertion of the thickest yarns, the angle of slope of the curved zone 104 may be greater than that of the clamping facet 102.
The end of the movable part 3 remote from the hook 14 is applied against the blade spring 12 and is provided with a portion 17 forming a ramp followed by a top portion 18 which is substantially horizontal in the operating position of the clip.
The clip which has just been described and which travels within the shed with the point 22 of the hook 14 directed towards the reed P operates as follows: substantially at the center of the width of cloth, the weft thread 19 fed by an inserting clip (not shown) is introduced between the facets 16 and 102 respectively of the movable part 3 and of the stationary part 1. The taut portion of the yarn 19 which is still joined to the weft reserve (not shown in the drawings) passes over the hook 14 and plays a contributory role in applying it against the opposite portion 15 of the stationary part, thus serving to enhance the closing action produced on the clip by the spring 12.
When the clip has moved back to a point when the hook 14 passes the corresponding selvedge of the fabric, a cam follower which is stationary with respect to the frame of the loom (but not shown in the drawings) progressively presses against the ramp 17, then bears on the top portion 18 of the movable part 3 and displaces this latter in pivotal motion in opposition to the spring 12 about the pin 4 substantially in a plane at right angles to the plane of the hook 14 and in the direction D indicated by an arrow in FIG. 4. Therefore, the hook 14 moves upwards (FIG. 2) and releases the yarn 19. In order to increase the accuracy of motion of the movable part 3, a portion 3A of said part is guided between two blocks 20, 21 of plastic material which are attached to the clip body 1. The portion 3A is in sliding engagement against the two blocks, though permitting pivoting movement of the movable part 3 with respect to the stationary part 1. The movable part 3 is maintained at one point of its length by the pivot 4, and at another point of its length by the two blocks 20, 21. The result is that said movable part 3, and particularly its hook 14 effect an accurate movement in a vertical plane upon pivotal movement of the movable part, thus ensuring a precise and reliable cooperation of the hook 14 and the stationary active yarn-clamping portion 15 of the body.
By virtue of the fact that the hook is carried by the movable part of the clip and that clamping of the yarn takes place between two inclined facets, it is possible to provide a clip which has a greater degree of rigidity, which therefore ensures more reliable operation, and which is of lighter weight than any clips known up to the present time.
It has been stated earlier that the foregoing description applies to the case in which the point 22 of the hook 14 is directed towards the reed of the loom. The clip is also capable of operating, however, if it is so designed that the point 22 of the hook 14 is directed towards the fell of the cloth. In this case, it may prove an advantage to ensure that the plane of the hook 14 is substantially parallel to the top layer of the shed and that the pivot-pin 4 is inclined correspondingly so as to ensure that the movable part 3 undergoes a displacement in a plane which is oblique with respect to a plane at right angles to the plane of the hook 14.
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In a shuttleless loom in which the weft thread is inserted by an entry needle, the yarn is transferred at the center of the width of cloth to an exit needle which carries an exit clip. The stationary clip body has a wedge-shaped end which cooperates with a hook carried by a movable portion for clamping the weft thread. The yarn is held between two clamping facets carried by the wedge-shaped end of the clip body and by the hook, the facets being inclined with respect to the plane of displacement of the movable portion.
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BACKGROUND INFORMATION
[0001] The present invention relates to optical gap measuring tool calibration. More specifically, the invention relates to a system and method for calibrating a hard disc drive magnetic head flying height tester by optical interference techniques.
[0002] [0002]FIG. 1 provides an illustration of a typical hard disc drive. In the art of hard disc drives, magnetic read/write heads 102 are commonly integrated in a slider 102 designed to respond to a flow of air moving with the rotating disc 104 over which the slider 102 travels. The head/slider 102 ‘flies’ close to the surface of the disc 104 . In manufacturing such heads/sliders 102 , it is often necessary to test hydrodynamic characteristics of the heads 102 to verify their performance. It is important that the head 102 not travel too far from or close to the disc 104 surface. Further, it is important to prevent the head 102 from traveling at an improper angle with respect to the disc surface 104 . A head 102 traveling too high above the disc surface 104 will result in a lower than desired areal density. A head 102 traveling too low can cause an interface failure between the head 102 and disc 104 .
[0003] In order to test the flying height of the head, a flying height tester is commonly used. Optical interference techniques are often employed to determine the distance between head and disc. A monochromatic light source is directed at a transparent surrogate disc, such as a glass disc, rotating at speeds similar to that of a magnetic disc, and the head assembly being tested is secured in a holder in its normal flying orientation in relation to the disc. The monochromatic light is directed at the disc at a predetermined angle to the surface thereof. The light is reflected from the surface of the disc closest to the head, as well as from the surface of the flying head itself, and impinges onto a light sensitive sensor.
[0004] The interference effects created by the combined reflections from the disc and the slider surface provide the flying height information. A computer receives data from the flying height tester and calculates the perceived flying height and angle of the head. As hard drives become smaller and increase in data storage capacity, the desired head flying height continually reduces. Therefore, the accuracy of a flying height tester, and thus its calibration, are of critical concern.
[0005] [0005]FIG. 2 illustrates a typical device used to calibrate a flying height tester. A calibration standard, such as is depicted in U.S. Pat. No. 5,552,884, is often utilized. As can be seen in FIG. 2 a , the calibration standard includes a mock head 48 in contact with a transparent disc 44 via a load spring 52 . The transparent disc 44 has a plurality of grooves 60 formed in a surface facing the mock head 48 . A cover case 56 is attached to the glass disc 44 at one end and provides a sealed environment for the interface between the mock head 48 assembly and the transparent disc 44 . Several problems exist with the utilization of this device. For example, in establishing H 1 204 , which is important in evaluating flying height (explained below), the nature of the design causes problems with using optical interference means. Measurement of H 1 205 must not be taken too close to a ridge's 64 edge, or else one (or both) of the measurement light beam's return paths 206 , 208 may travel a portion through air (separated by the walls at 120 and 124 ). The differences in optical properties between air and the transparent disc (glass, etc.) disrupts the travel path and thus causes inaccurate optical interference measurement results (i.e., the resultant beams 206 and 208 are not at the correct positions and/or the correct distance apart for accurate measurement). Therefore, H 1 measurements may only be taken towards the center of the ridges 64 (if at all). This prevents appropriate compensation for surface irregularities 76 in the mock disc 48 . Also, a separate device must be used to determine a minimum and maximum light intensity for the flying height tester, a necessary step in calibration, as explained below. This separate device adds cost and complexity to the calibration process.
[0006] It is therefore desirable to have a system and method for calibrating flying height testers that avoids the above-mentioned problems, as well as having additional benefits.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 provides an illustration of a typical hard disc drive.
[0008] [0008]FIG. 2 illustrates a typical device used to calibrate a flying height tester.
[0009] [0009]FIG. 3 illustrates a flying height tester calibration standard according to an embodiment of the present invention.
[0010] [0010]FIG. 4 illustrates surface irregularity compensation and provides further detailed illustrations of two mock heads according to an embodiment of the present invention.
[0011] [0011]FIG. 5 provides a graphical illustration of the ‘unique fit’ solution utilized for providing a continuous spectrum of uniquely-valued combinations associatable to a range of head/disc gaps under principles of an embodiment of the present invention.
[0012] [0012]FIG. 6 provides an illustration of a mock head design according to an alternative embodiment of the present invention.
[0013] [0013]FIG. 7 provides illustrations of three mock head designs according to alternative embodiments of the present invention.
DETAILED DESCRIPTION
[0014] [0014]FIG. 3 illustrates a flying height tester calibration standard according to an embodiment of the present invention. As can be seen in FIG. 3 a , in one embodiment, the calibration standard 100 includes a transparent mock disc 10 and one or more mock heads 20 placed in substantial contact with the mock disc 10 by one or more load springs 40 . In this embodiment, a cover 50 is utilized to protect the standard from contaminants such as dust and debris. In this embodiment, two screws 71 , 72 are used to secure the cover 50 (and thus, the mock heads 20 ) to the mock disc 10 . In this embodiment, the mock disc 10 is made of a substantially smooth, transparent material such as glass. Further, in this embodiment, the mock head 20 is provided an overcoat by thin film chemical deposition to emulate the optical properties of a head/slider.
[0015] In one embodiment, the height standard 100 plays two roles: a light intensity calibration tool and a height calibration tool. As a light intensity calibration tool, an inclined surface 22 on one or more of the mock heads 20 is utilized. As shown in FIG. 3 b , in one embodiment, the light source 80 of the flying height tester is moved (with respect to the standard) along the inclined surface 22 . As the tester is passed over the inclined surface 22 , optical interference techniques (described below) yield an oscillating, continuous spectrum containing segments of high intensity light as well as darker segments. From this continuous spectrum, values for both maximum light intensity and minimum light intensity received at the detector 90 can be established. In this embodiment, the values of light intensity are stored in a computer (not shown) associated to the flying height tester.
[0016] After establishing the range of light intensity for the flying height tester, in an embodiment, the depth (flying height) of at least one surface recess 302 is measured with the flying height tester to determine at least one ‘observed’ distance between the disc 10 and surface 23 of recessed portion 302 . In this embodiment, the physical dimensions of the mock head 20 may be determined by a device, such as an atomic force microscope (AFM), and thus, the ‘actual’ distance between the disc 10 and the surface 23 of the recessed portion 302 can be compared to the ‘observed’ distance for calibration of the flying height tester. The differential between ‘actual’ and ‘observed’ distance is used to adjust the flying height tester for calibration. In one embodiment, multiple recessed portions 302 of differing depths (heights) are provided to improve calibration (calibration for different heights). Also, because the dimensions of the inclined surface 22 are known, it can be used to perform gap calibration as well (i.e., depth being known at any position x).
[0017] As explained, in one embodiment of the present invention, to calibrate a flying height tester, the calibration standard 100 is placed in the flying height tester in place of the original glass disc (not shown) of the tester under the tester's light source 80 . As shown in FIGS. 3 b and 3 c , in calibrating the flying height tester, height measurements are taken by the tester, yielding ‘observed’ distances. The ‘observed’ distances are compared with the ‘actual’ distances at those locations. In one embodiment, a linear translator and computer (not shown) are utilized to position the standard 100 appropriately for measurement. In this embodiment, at each measurement point, monochromatic light 88 a is directed at the (transparent) mock disc 10 by the light source 80 , as shown in FIG. 3 b . The light 88 a impinges the disc 10 at an angle incident θ to a first mock disc surface 12 and continues through the (glass) mock disc 10 along path 88 b to a second mock disc surface 11 , where it splits and is partially reflected. The reflected portion follows path 88 c through the disc 10 to the first surface 12 , and follows path 88 d to a sensor 90 of the flying height tester (not shown). The remaining light follows path 88 e to the mock slider (head) surface 22 where it is reflected to the mock disc 10 via path 88 f. The light impinges the second surface 11 of the mock disc 10 , follows path 88 g through the disc 10 and follows path 88 h to the tester sensor 90 . The slight angular deviations between paths at the air/disc interface are due to the Snell effect. Both the height h 2 and the incident angle θ have been exaggerated in FIG. 3 b for illustrative purposes. Path 88 a is actually substantially normal to the mock disc surface 12 with typical flying height testers.
[0018] [0018]FIG. 4 illustrates surface irregularity compensation and provides further detailed illustrations of two mock heads according to an embodiment of the present invention. As seen in FIG. 4 a , because of surface irregularities upon the top of each mock head 20 , the distance, He, from disc to mock head surface 21 varies with position. In one embodiment of the present invention, the mock head's surface profile may be determined by a device such as a profilometer. This surface profile, combined with the knowledge of the ‘actual’ dimensions of the mock head 20 (by AFM, etc.) enable improved calibration. The true depth Ha of the recessed portion of the mock head 20 is slightly different than the apparent depth H 1 (because of high points 402 on the mock head 20 surface). Utilizing Ha as the ‘actual’ distance provides a more accurate value. In an embodiment, the acquired surface irregularity information may be used by the flying height tester computer to provide a correction factor or a series of correction factors for the calibration.
[0019] [0019]FIGS. 4 b and 4 c further illustrate a mock head slider 20 with a recessed surface 23 and inclined surface 22 (see FIG. 4 b ) and a mock head slider 20 with a series of recessed surfaces (grooves) 23 at varying depths (see FIG. 4 c ) under an embodiment of the present invention. In one embodiment, recessed surface 23 length L 1 is greater than 50 microns, and the recessed surface 23 depth (flying height) H 1 is greater than 2 nanometers. In one embodiment, inclined surface height (rise) H 2 is between 12 and 13 microinches (0.31-0.33 microns), and inclined surface 22 length (run) L 2 approaches 100 mils (2,540 microns). As stated above, the mock heads 20 can be used together in a calibration standard 100 (see FIG. 3 a ), or they can be used alone in a calibration standard 100 .
[0020] [0020]FIG. 5 provides a graphical illustration of the ‘unique fit’ solution utilized for providing a continuous spectrum of uniquely-valued combinations associatable to a range of head/disc gaps under principles of an embodiment of the present invention. In one embodiment, light of multiple wavelengths (e.g., three wavelengths 501 , 502 , 503 ) is directed at the surface to be measured. In one embodiment, upon varying the distance between the mock head and mock disc to obtain the maximum and minimum light intensity (for light intensity calibration), multiple curves may be developed. After calibrating light intensity at the different wavelengths (equalizing amplitude), the wavelengths displayed superimposed provide multiple curves that may be utilized for a ‘unique fit’ solution spectrum. By optical interference, light intensity 524 received by the detector oscillates repeatedly between the maximum 526 and the minimum 528 as the distance measured increases (or decreases). Although each curve passes through the same light intensity values multiple times as the measured distance increases (or decreases) through the range of possible values, the combination of values 511 , 512 , 513 provided by the multiple-wavelength light source is unique for each distance in the range of possible distances 522 . This ‘unique fit’ solution provides a range of light intensity combinations that is directly and uniquely associatable to the range of possible distances to be measured.
[0021] According to embodiments of the present invention, a calibration device is provided for both light intensity/unique fit theory curves (inclined surface; See, e.g., FIG. 4 b ) and for specific depth (flying height) measurement calibration (recessed surface; See, e.g., FIG. 4 c ). In this embodiment, both mock heads are provided in the same calibration standard (as opposed to requiring a separate standard/device). As stated previously, typical calibration standards in the art provide no more than a series of grooves for gap calibration (on the disc side, not on the head side). For light intensity calibration and the development of theory curves, a separate component (a wedge piece) would need to be added, adding cost to the manufacture and operation. Therefore, in addition to the advantages of having varying-depth grooves on the mock head (as opposed to on the mock disc; as explained above), having all parts integrated in a single calibration standard is advantageous from both a complexity and a cost standpoint. Further, the process of forming grooves (by, e.g., ion milling or chemical etching) in a mock disk of glass, for example, is more difficult because of its hardness than forming similar grooves in a mock head (substrate). Further, etching glass with such methods produces surface roughness (irregularities) as large as 0.4 microinches (˜10 nanometers) or more, exacerbating calibration difficulties.
[0022] Further, employing optical interference techniques with calibration grooves 60 formed in the mock disc 44 , such as in the prior art (see FIG. 2 a ), causes significant inaccuracies. If a measurement location is too close to the edge of a ridge 64 , one or more of the light beam's return paths may pass through the air 212 (glass-air-glass, rather than just glass), altering the path of the light (see FIG. 2 c ). Because the distance in which one of the light beam travels through air defines the height measurement perceived, the light should travel through consistent paths through the glass (i.e., uniform thickness mock disc, such as the present invention).
[0023] [0023]FIG. 6 provides an illustration of a mock head design according to an alternative embodiment of the present invention. In this embodiment, the mock head 20 has two separate inclined surfaces 22 , 24 . In this embodiment they can be formed with differing slopes (H 2 /L 2 and H 4 /L 4 ). An inclined surface 22 , 24 with a shallow slope could be used for fine adjustment calibration and an inclined surface 22 , 24 with a steeper slope could be used for large range adjustment.
[0024] [0024]FIG. 7 provides illustrations of three mock head designs according to alternative embodiments of the present invention. As shown in FIG. 7 a , in one embodiment, the mock head 20 has a cylindrically convex (curved) portion 702 and a recessed surface portion 704 . In this embodiment, the cylindrical portion 702 is used for light intensity calibration and gap spectrum calibration (via light intensity curves, as explained above). In this embodiment, the dimensions of the cylindrical portion 702 may be determined by AFM and known geometric principles to yield ‘actual’ (flying height) distances H 706 (similar to inclined surface 22 ; see FIG. 3 b ). Similar to above, in this embodiment, the recessed portion 704 is utilized for specific flying height calibration. As illustrated in FIG. 7 b , in another embodiment, a mock head 20 with a cylindrical portion 702 is utilized in the calibration standard. In this embodiment, the cylindrical portion 702 is used for light intensity calibration, gap spectrum calibration (via light intensity curves), and specific flying height calibration. In this embodiment, specific gap measurement calibration (via ‘actual’ vs. ‘measured’ differential) is taken at a desired location. As stated the ‘actual’ distance is known by a device such as an AFM. In another embodiment, the curved surface 702 of the designs shown in FIG. 7 a and 7 b is a spherical (convex) surface. In an alternative embodiment, as shown in FIG. 7 c , a curved surface 762 (e.g., spherical, cylindrical, etc.) occupies the top portion of a mock head 20 with an inclined surface portion, providing further flexibility of calibration.
[0025] Although several embodiments are specifically illustrated and described herein, it will be appreciated that modifications and variations of the present invention are covered by the above teachings and within the purview of the appended claims without departing from the spirit and intended scope of the invention.
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A system and method are disclosed for calibrating a hard disc drive magnetic head flying height tester by a calibration standard, which includes a mock slider and mock disc, by optical interference techniques.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an engine idling control device in which an air flow rate control valve is provided along a passage for bypassing a throttle valve and supplying auxiliary or secondary air into an intake pipe.
2. Description of the Related Art
In a normal idling condition of an automotive engine, a negative pressure (for example, −73 kPa (in the order of −550 mmHg)) is generated within an intake pipe of a throttle body when a throttle valve is in a fully closed state. To this end, there has been proposed an automotive engine in which a bypass intake passage is provided on a throttle body, for establishing a communication between an upstream and a downstream side of the throttle valve, whereby a required amount of intake air is supplied by a secondary air supply device such as an RACV or an EACV (an idle control valve) for controlling the opening of the bypass intake passage to thereby perform the idling control of the engine (for example, Japanese Patent No. 2859530).
In an idling condition, however, when the engine load is increased by putting in the operation of several lamps and an air conditioner, in order to cope with the engine load, the opening value of an RACV is increased, but the intake negative pressure decreases (for example, about 29 kPa (in the order of −220 mmHg)), and this causes a problem that a sufficient quantity of intake air cannot be obtained even with the same opening area.
In addition, the recent growing tendency toward energy conservation demands highly fuel economy vehicles, and as a result of such a demand, for example, a so-called hybrid vehicle has been provided in which an engine (an internal combustion engine) and an electric motor are used in combination. Among the hybrid vehicles, there is a vehicle using a small displacement, high compression ratio engine with a view to improving the fuel economy.
However, in the small displacement, high compression ratio engine, the engine torque tends to become insufficient due to the small displacement, and the knocking toughness is reduced due to the high compression ratio. Due to this, particularly at the time of parking while idling in a high temperature atmosphere, the ignition timing is retarded, whereby the intake gauge pressure becomes higher than the normal level, a high load being thereby applied to the engine. When this takes place, the difference in pressure between the upstream side and the downstream side of the secondary air supply device becomes small, and therefore this causes a problem that an expected quantity of secondary air cannot be obtained.
SUMMARY OF THE INVENTION
It is an object to realize an idling control device which can control an engine into a stable idling state against various factors increasing an engine load at the time of idling by solving the aforesaid problem, in particular, for a small displacement, high compression ratio engine.
According to the invention, there is provided an engine idling control device having a secondary air supply device provided along a bypass intake passage communicating with an intake pipe and bypassing a throttle valve, an intake gauge pressure detecting unit for detecting an intake gauge pressure on the intake pipe side, and a secondary air supply control unit for controlling the secondary air supply device so as to open and close the bypass intake passage when an engine is in an idling state, wherein the secondary air supply device is controlled so as to put in any state the opening value relative to the bypass passage, and wherein the secondary air supply control unit controls such that the secondary air supply device increases the opening value relative to the bypass intake passage as the intake gauge pressure becomes higher than the predetermined low load condition in an idling state.
According to the construction, in the idling state, since the opening value of the bypass intake passage is varied in response to the variation of intake gauge pressure, even if the intake gauge pressure exceeds the normal level due to the influence of a retarded ignition timing, for example, at the time of parking while idling in a high temperature atmosphere, a high load being thereby applied to an engine, separately from the increase in load resulting when lamps and an air conditioner are turn on, a variation of intake gauge pressure resulting therefrom can be detected to be obtained a quantity of secondary air which can deal with the increased load.
In addition, the increasing rate of the opening value by the secondary air supply device can be controlled such that it becomes smaller depending on the intake gauge pressure becoming higher, and according to the construction, a required quantity of secondary air can be supplied in a more precisely and preferably control.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing an intake system of an engine to which the invention is applied;
FIG. 2 is a diagram showing a former half of a control flow based on the invention;
FIG. 3 is a diagram showing a latter half of the control flow based on the invention; and
FIG. 4 is a diagram showing a table for use in obtaining a secondary air correction coefficient KIPBG according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A mode for carrying out the invention will be described in detail below with reference to an embodiment shown in the accompanying drawings.
FIG. 1 is a diagram showing an intake system of an engine to which the invention is applied. For example, a throttle body 4 for adjusting the flow rate of intake air and an air cleaner 5 for removing dust in the atmosphere are connected in series to an intake pipe 3 connected in turn to an intake manifold 2 of respective cylinders of an engine 1 comprising, for example, an inline 4 cylinder engine.
Two bypass passages bypassing a throttle valve 6 are provided between an upstream side of the throttle valve 6 in the throttle body 4 and the intake pipe 3 . One of the bypass passages is a slow air passage 8 for regulating the flow rate of basic idling air with a variable jet 7 , and the other is a bypass intake passage 10 along which is provided a bypass air flow rate control valve 9 as a secondary air supply device (an RACV, an EACV or the like) which is controlled in response to the operating condition of the engine in a fully closed state in which mainly the throttle valve 6 is closed.
The correction of the air flow rate of idling air in response to a change in the coolant temperature, and increasing of electric load related to lamps or load related to an auxiliary apparatus such as an air conditioner is designed to be carried out by varying the opening area of the bypass intake passage 10 with the airflow rate control valve 9 . Additionally, a compensation for an insufficient flow rate of intake air at the time of cranking and a correction of the air flow rate at the time of quick closing of the throttle valve are also carried out.
The air flow rate control valve 9 may be constituted by an electromagnetic control valve, the opening value of which is continuously controlled by controlling an exciting current to a coil. As shown in the FIG. 1, an electronic control unit 11 is provided as a secondary air supply control unit for controlling the air flow rate control valve 9 , and inputted into the electronic control unit 11 is the information on the existence of the aforesaid electric load, on/off signals of the air conditioner, coolant temperature, engine speed Ne, throttle valve opening θth and the like.
In addition, a gauge pressure sensor 12 is provided as an intake gauge pressure detecting unit between the throttle body 4 and the intake manifold 2 , and a detection signal representing an intake gauge pressure detected by the gauge pressure sensor 12 is also inputted into the electronic control unit 11 . An automatic control of the air flow rate of intake air passing through the bypass intake passage 10 is performed through the opening adjustment by the air flow rate control valve 9 based on information including the above various pieces of information and the intake gauge pressure such that the then engine speed Ne becomes optimal.
Next, a description will be given the control of the air flow rate of secondary air supplied at the time of idling based on the control of the air flow rate control valve 9 . The air flow rate of secondary air supplied during idling state is controlled by opening and closing the air flow rate control valve 9 as discussed above. To this end, a procedure for calculating a control value IMCD for providing an optional opening value will be described below with reference to a flowchart shown in FIG. 2 .
For example, when the engine is determined to be in an idling state from a detected value of the aforesaid engine speed Ne, a control routine according to this invention starts. In Step ST 1 , whether or not a designated F/S (fail safe) has been detected is determined. This designate F/S is, for example, the determination of a disconnection of the gauge pressure sensor 12 or the like. In the event that the designated F/S has been detected, then the flow goes to Step ST 2 .
In Step ST 2 , whether or not the engine is in an SYS mode (SYSMOD=00 or 01) is determined. The SYS mode means a start or stop mode. In the event that the engine is determined not to be in the SYS mode, then the flow goes to Step ST 3 .
In Step ST 3 , whether or not the value of PBGAVE-timer TPBGAST has become zero “0” (time-up) after the start mode is determined, and when the time-up is determined, then the flow goes to Step ST 4 . In Step ST 4 , whether or not a counter CPBGC of a PBG averaged coefficient CPBG for use in calculating the intake gauge pressure PBG is counted up (=0) is determined. In the event that it is counted up, then the flow goes to Step ST 5 .
In Step ST 5 , the counter CPBGC is returned to an initial value C 1 , and in the following step ST 6 , an intake gauge pressure subtracted value DPBGC is calculated. This intake gauge pressure subtracted value DPBGC is obtained by subtracting the previous intake gauge pressure PBGBF from the present intake gauge pressure PBG. In the following step ST 7 , for calculation in ST 6 for the following cycle, the value of the present intake gauge pressure PBG is substituted in the previous intake gauge pressure PBGBF, and then the flow goes to Step ST 8 .
In Step ST 8 , whether or not the value (the absolute value) of the intake gauge pressure subtracted value DPBGC obtained in Step ST 6 is equal to or greater than an intake gauge pressure subtracted reference value DT is determined, and in the event that the value is determined to be less than the intake gauge subtracted reference value DT, then the flow goes to Step ST 9 , while the value is determined to be equal to or greater than the reference value, then the flow goes to Step ST 10 . In Step ST 9 , a PBGAVE which becomes a reference value for a secondary air correction coefficient table is calculated from the following expression.
PBGAVE=PBG×CPBG+PBGAVE n−1 ×(1− CPBG ) (1)
According to the expression, CPBG is the PBG averaged coefficient, and PBGAVE n−1 is a previously calculated PBGAVE. The PBGAVE obtained from this expression is the PBG averaged coefficient, which is calculated for preventing a variation when the engine is running in a stable condition. Note that in a case where the flow goes to Step ST 10 , the intake gauge pressure PBG is directly substituted into the reference intake gauge pressure PBGAVE without using the expression (1).
Note that in the event that the counter CPBGC is not counted up in Step ST 4 , the flow then goes to Step ST 11 , where the value of the counter CPBGC is subtracted by one, and then the flow goes to Step ST 9 .
The procedure goes to Step ST 12 shown in FIG. 3 after Step ST 9 or Step ST 10 . In Step ST 12 , whether or not an idling flag FIDLE is set (=1) is determined, and in the event that the flag is set, then the flow goes to Step ST 13 , whereas in the event that the flag is not set, the flow goes to Step ST 14 .
In Step ST 13 , a secondary air correction coefficient KIPBG read out from a secondary air correction coefficient table set as shown in FIG. 4 based on the invention is obtained. This ends the control routine of the invention.
Here, as shown in FIG. 4, the secondary air correction coefficient table is set such that the secondary air correction coefficient KIPBG increases from 1.0 as the reference intake gauge pressure PBGAVE increases (as the negative pressure decreases). Furthermore, the rate of increasing is set so as to decrease as the intake gauge pressure increases. Note that in the illustrated example, an optional number of points (P 2 to P 5 ) are provided between point P 1 where the reference intake gauge pressure PBGAVE becomes the atmospheric pressure and P 6 where a predetermined negative pressure is realized where the secondary air correction coefficient KIPBG may be set at 1.0, and the respective points are connected with polygonal lines. This facilitates the programming and arithmetic operation and can provide a smoother control when compared with a case where the correction coefficient table is set in a step-like fashion. Note that the number of point and setting positions are optional and they may be made optimal depending on engines.
Then, the opening value of the air flow rate control valve 9 is controlled using the secondary air correction coefficient KIPBG obtained in Step ST 13 , and the opening area of the bypass intake passage 10 varies in response to the controlled opening. Note that a target quantity ICMD of secondary air determining the opening value is obtained from the following expression.
ICMD =(( IFBN+IDP+ILOAD+IAF )× KIPA+IPA )× KIPBG (2)
Where, IFBN is a term for the engine speed feedback; IPD: a term for a dash pot for adjusting the quantity of shot air when the speed is reduced; ILOAD: a term for load correction when lamps and/or an air conditioner are switched on; IAF: a term for air correction in response to a target air-fuel ratio; KIPA: a term for atmospheric pressure correcting multiplication; and IPA: a term for atmospheric pressure correcting addition.
Thus, the quantity of auxiliary (required) air can be increased or decreased in response to a variation in intake negative pressure by multiplying a quantity of air obtained from the electric load or the like by the secondary air correction coefficient KIPBG, whereby even in a case where the intake gauge pressure exceeds the normal level not only by the presence of an electric load but also by another factor such as the influence of a retarded ignition timing at the time of parking while idling in a high temperature atmosphere, such a change can be detected through a change in intake gauge pressure to thereby obtain an appropriate quantity of secondary air supply.
Additionally, in the event that the flow goes to Step ST 14 , the secondary air correction coefficient KIPBG is obtained by subtracting a predetermined value DKI from a secondary air correction coefficient KIPBG n−1 in the previous cycle. This predetermined value DKI is a term for gradual subtraction from a KIPBG in engine states other than idling which is intended to prevent a drastic reduction. In Step ST 15 following Step ST 14 , whether or not the secondary air correction coefficient KIPBG is equal to or less than 1.0 is determined, and in the event that the coefficient is determined to exceed 1.0, then the control routine of the invention is completed.
Note that in the event that the engine is determined to be in the SYS mode in Step ST 2 , then the flow goes to Step ST 16 , where the value of the timer TPBGAST is returned to an initial value TI, and the flow then goes to Step ST 17 . In addition, in the event that the designated F/S has not yet been detected in Step ST 1 or in the event that the secondary air correction coefficient KIPBG is equal to or less than 1.0 in Step ST 15 , too, the flow goes to Step ST 17 , where the secondary air correction coefficient KIPBG is regarded as 1.0, and the control routing according to the invention is completed.
Thus, according to the invention, even in a case where the intake gauge pressure exceeds the normal level due to the influence of a retarded ignition timing in an idling state, in particular, at the time of parking while idling in a high temperature atmosphere, a high load being thereby applied to the engine, a variation in intake gauge pressure resulting therefrom can be detected to thereby obtain a quantity of secondary air supply matching the high load, whereby an unstable engine speed resulting at idling due to an insufficient quantity of secondary air supply can be prevented. In particular, the invention is effective when the activation of the lamps and air conditioner coincides with the increase in load resulting from the aforesaid engine condition.
Additionally, the quantity of secondary air supply can be controlled in a greater detailed and more preferred fashion through the construction in which the rate of the opening value of the secondary air supply device is controlled to decrease depending on the increasing intake gauge pressure, thereby making it possible to prevent the fluctuation of the feedback term in feedback controlling the engine idling speed.
While only certain embodiments of the invention have been specifically described herein, it will apparent that numerous modifications may be made thereto without departing from the spirit and scope of the invention.
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An engine idling control device includes a secondary air supply device, an intake gauge pressure detecting unit and a secondary air supply control unit. The secondary air supply device is disposed on a bypass intake passage communicating with an intake pipe and bypassing a throttle valve. The intake gauge pressure detecting unit detects an intake gauge pressure on the intake pipe side. The secondary air supply control unit controls the secondary air supply device so as to open and close the bypass intake passage when an engine is in an idling state. The secondary air supply device is controlled to obtain the optional opening value. The secondary air supply control unit controls such that the secondary air supply device increases the opening value when the intake gauge pressure becomes higher than a predetermined low load condition in an idling state.
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FIELD OF INVENTION
This invention relates to rolling and overhead doors and in particular to operating systems for opening and closing doors of this type.
BACKGROUND OF INVENTION
In the prior art rolling and overhead doors, one electric motor is generally used to selectively drive the take-up barrel and the take-down barrel in the case of a rolling door and a drum cable system in the case of overhead doors. In order to accomplish this task, an actuator is required to selectively drive each barrel or drum cable system for opening and closing a rolling or overhead door. Accordingly, the operator of the prior art device has many precision components which are not only bulky increasing the space requirements for installing such a device but also requiring a high degree of servicing increasing operating costs of such devices. Further, since the actuator remains engaged with either the take-up barrel or the take-down barrel, the device may not be operated manually in the event of a power loss. If the door cannot be opened or closed manually, entry of rescue personnel or the exit of trapped workers may be prevented.
U.S. Pat. No. 4,690,195, issued Sep. 1, 1987, discloses an operator for a rolling door which provides a power operator means for both rolling the door up and pulling the door downwards to the closing position. The rolling door is particularly useful in a medium pressure environment such as those found in mines.
In the second embodiment of U.S. Pat. No. 4,690,195, a single drive motor operates the take-up barrel and the take-down barrel by chain drive. The embodiment has found to be unsuitable as the components are required to be of high precision and accordingly have high replacement and servicing costs. Further, such system is slow and unresponsive as the engagement between parts is slow. Further, the sprockets being driven by the chain must be selected in accordance with the door height and the required door opening speed. Further, since the take-up barrel and the take-down barrel are driven at the same time, there are times when the door is either under-tensioned or over-tensioned during the travel since the diameter of the take-up barrel varies with the amount of door extended. Further, since one chain travels around at least three sprockets, the operator cannot be placed over the hood of the device thereby limiting the locations where the device can be installed.
SUMMARY OF THE INVENTION
The disadvantages of the prior art may be overcome by providing a device which selectively drives a take-up roller and a take-down device. In particular, the invention provides an operator which upon rotation drives a take-up roller for opening the roller door, permitting the take down roller to freely rotate and on counter rotation drives a take-down device for closing the door, permitting the take-up roller to freely rotate.
According to one aspect of the invention there is provided a selective clutch for selectively rotating at least two disc means, comprising a shaft having an external thread bounded by a first and second bearing surface, a hub having an axially extending threaded opening for screwingly engaging the thread of said shaft, a first disc means rotatably mounted on said first bearing surface, a second disc means rotatably mounted on said second bearing surface, abutment means on opposite sides of said first and second disc means for retaining said first and second disc means on said shaft, first and second biasing means between said first disc means and abutment means and said second disc means and abutment means, respectively, urging said disc means in frictional contact with said hub. Rotation of said shaft said hub advances therealong and frictionally engages said first disc means until said first disc means and shaft rotate together and said second disc means freely rotates. Counter rotation of said shaft said hub advances back along said shaft and frictionally engages said second disc means until said second disc means and shaft rotate together and said first disc means freely rotates.
According to another aspect of the invention there is provided a rolling or overhead door assembly comprising a shaft having an external thread bounded by a first and second bearing surface, a hub screwingly engaging the shaft and adapted to travel along the shaft, a first disc means rotatably mounted on said first bearing surface and operably connected with a take-down device for unrolling a flexible door or closing an overhead door and a second disc means mounted on said second bearing surface and operably connected with a take-up roller for rolling up the door or with a drum cable system for opening an overhead door, and abutment means on opposite sides of said first and second sprocket. Upon rotation of the shaft said hub advances along said shaft and frictionally engages said first disc means until the first disc means and shaft rotate together and the second disc means rotates freely. Counter rotation of the shaft the hub advances back along the shaft and frictionally engages the second disc means until the second disc means and shaft rotate together and the first disc means rotates freely.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention is illustrated in the drawing, in which:
FIG. 1 is a front elevational view of the roller door and operator according to the present invention;
FIG. 2 is a sectional view along the line I--I of the embodiment of FIG. 1 illustrating the door within the side channels;
FIG. 3 is a partial front elevational view of the embodiment of FIG. 1;
FIG. 4 is a view of the selective clutch drive of the operator of the embodiment of FIG. 1;
FIG. 5 is a plan view of the clutch shaft of the operator of the embodiment of FIG. 1;
FIG. 6 is a sectional view of the screw hub of the operator of the embodiment of FIG. 1;
FIG. 7 is sectional view of a sprocket of the operator of the embodiment of FIG. 1;
FIG. 8 is sectional view of a collar of the operator of the embodiment of FIG. 1;
FIG. 9 is sectional view of a thrust bearing of the operator of the embodiment of FIG. 1;
FIG. 10 is sectional view of a friction disc of the operator of the embodiment of FIG. 1;
FIG. 11 is a side view of the embodiment of FIG. 1;
FIG. 12 is a side view of the embodiment having a belt drive;
FIG. 13 is a front elevational view of the roller door and operator according to the embodiment having a chain drive;
FIG. 14 is a sectional view along the line II--II of the embodiment of FIG. 13 illustrating the door within the side channels;
FIG. 15 is a partial front elevational view of the embodiment of FIG. 13;
FIG. 16 is a side view of the embodiment having a cable drive;
FIG. 17 is a front view of the lower edge component of the embodiment of FIG. 1; and
FIG. 18 is a top sectional view of the lower edge component of the embodiment of FIG. 17.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As illustrated in FIG. 1, the roller door consists of a door curtain 10 which can be rolled up, which is made preferably from a flexible material, and which can be unwound for closing a door opening 12. Above the door opening is mounted a take-up roller 14 connected to door curtain 10. Take-up roller 14 is rotatably mounted about take-up axle 16 for integral rotation therewith. On each side of the door opening 12 is a frame 18 for receiving the edge of door curtain 10. Frame 18 is fixed to the wall surface immediately adjacent to the door opening 12 presenting a channel 20 for receiving door curtain 10.
Guide roller or idler roller 22 is mounted on idler axle 24 which is in turn mounted on frame 18 for rotation substantially perpendicular to the direction of the opening of the door curtain 10. Idler roller 22 guides door curtain 10 into the guide channels 20. At one end of idler axle 24, idler sprocket 26 is fixedly mounted thereon. Similarly at the end of take-up axle 16, take-up sprocket 28 is mounted thereon. Axles 16 and 24 are suitably mounted for rotation in bearings 17 and 25, respectively, mounted on each side frame 18.
Axles 16 and 24 upon being drivenly rotated by sprockets 28 and 26 respectively, will rotate idler roller 22 and take-up roller 14, respectively.
Operator 29 generally comprises a selective clutch drive 30 and a drive motor 32. Drive motor 32 is mounted at a convenient location and operable to rotate clutch shaft 34. Clutch 30 is mounted on clutch shaft 34 and has take-up drive sprocket 36 and idler drive sprocket 38.
Take-up chain 40 extends about take-up drive sprocket 36 and take-up sprocket 28 presenting an endless chain. Similarly, idler chain 42 extends about idler drive sprocket 38 and idler sprocket 26 presenting an endless chain. Mounted on each end of idler axle 24, between frame 18 and idler roller 22 is take-down gear 44 for engaging with take-down screw shaft 46. Take-down screw shaft 46 is mounted in base pads 48 for rotational movement. Dog 50 has an internal bore having a complementary thread and spring loaded trigger for engaging screw shaft 46 while closing and disengaging the screw shaft while opening. The lower outer edge component 49 is connected between dog 50 and door curtain 10. Dog 18 is releasably connected to edge component 49 to permit emergency opening of the door curtain.
Clutch 30 generally comprises retaining ring 52, collar 54, thrust bearing 56, sprockets 36 and 38, friction disc 58 and screw hub 60, all mounted on clutch shaft 34. As illustrated in FIG. 4, clutch 30 has screw hub 60 mounted at the axial mid-length of clutch shaft 34 and axially therefrom has equivalent components on each side thereof.
As illustrated in FIG. 5, clutch shaft 34 has two circumferential bearing surfaces 62 and 64 on opposite sides of external thread 66. At each end of clutch shaft 34, ring groove 68 extends circumferentially about the shaft and below the surface of bearing surfaces 62 and 64. A central bore 70 extends axially of clutch shaft 34. One end of the central bore 70 is counter-bored presenting a larger diameter bore 72. Along the length of central bore 70, keyway 74 extends axially from one end of the clutch shaft 34 to the counter-bore 72. At the end of clutch shaft 34 opposite counter-bore 72, a pair of tapped bores 76 spaced at right angles to each other extend radially through bearing surface 74 to central bore 70.
Screw hub 60 has a central hub 78 having an internally tapped bore 80 extending axially thereof. The screw thread of bore 80 is complementary with external thread 66 of clutch shaft 34. Preferably, the threads can be one of any known threading suitable for power transmission.
Extending from opposite ends of hub 78 are flanges 82 presenting a substantially planar frictional surface 84. The inside corner between flange 82 and hub 78 is illustrated as having a weld 86. However, hub 78 and flanges 82 can be manufactured as an integral unit.
Sprocket 36 has an axially extending central bore 88 having at each end of the bore a counter-bore 90. Bearing 92 is placed within counter-bore 90 to present a circumferentially extending inside bearing surface. Sprocket teeth 94 extend radially at one end of take-up drive sprocket 36. Flange 96 extends from the end opposite teeth 94. However, sprocket 36 and flange 96 can be manufactured as an integral unit. Idler drive sprocket 38 is identical to the construction of take-up drive sprocket 36 although the number of teeth may vary depending on the ratios and speed desired.
Collar 54 comprises a ring having a central bore 98 extending axially therethrough. Extending into one of the axial surfaces of collar 54 is a plurality of bores 100 having a diameter to receive compression springs 99 therein. Compression springs 99 may be replaced by spring discs where loads warrant such change.
Thrust bearing 56 comprises a pair of thrust washers 102. Sandwiched between the thrust washers 102 is a thrust assembly 104 having bearing material 106 extending circumferentially on each face of thrust assembly 104. Each thrust washer and thrust assembly has an axially extending circular opening.
Friction disc 58 comprises a ring of clutch or brake material having a central circular opening 108. Depending on the desired loads, friction disc 58 could comprise two rings of clutch or brake material sandwiched between a metallic ring.
Drive motor 32 has a motor shaft 110 extending therefrom. Motor shaft 110 will have a diameter complementary to the internal bore 70 and counter-bore 72 of clutch shaft 34. Along the narrower diameter portion of the shaft, motor shaft 110 has a keyway complementary to keyway 74. Drive motor 32 is of the type operable to drive shaft 110 in either rotation or counter-rotation direction.
With reference to FIGS. 17 and 18, the leading edge of door curtain 10 has a bottom bar 120. Bottom bar 120 comprises four L-shaped bars 122, 124, 126 and 128 joined to the leading edge of the door curtain 10 by a plurality of nuts and bolts 130. The lower horizontal corners of each bar 122, 124, 126 and 128 have been removed as illustrated in FIG. 18.
Bar 126 has at one end thereof a gudgeon 132 adapted to receive a pintle 134 extending from edge component 49 in a hinged connection. Pintle 134 has an internal bore for receiving a bolt for increasing the frictional engagement between the pintle and gudgeon. Pintle 134 has a transversely extending bore 136 for receiving a shear pin.
Bars 122 and 124 also have a gudgeon on the lower edge and at one end thereof. Bar 128 has a gudgeon on the upper edge and at one thereof.
To install the bars onto the door curtain 10, the lower edge of the curtain 10 has a slot cut on the leading edge near the mid-point of the width of the curtain. The bars are bolted onto the leading edge with a lower gudgeon extending from each side of the leading edge. The gudgeons of bars 122 and 128 meet at the slot cut into the leading edge of the curtain. A pin 138 is inserted through the opening presented when the gudgeons of bars 122 and 128 are aligned. Pin 134 is provided with a transversely extending bore. Bore 146 is provided in the lower gudgeon of bar 122. A shear pin is inserted through bore 146 and pin 134.
Tabs 140 and 142 are bolted onto bars 122 and 124 and onto bars 126 and 128, respectively with nut and bolt 144 to form a rigid connection between bars. When the curtain 10 is impacted and the impact exceeds a pre-determined force, the shear pins will fracture absorbing the energy of the impact before tabs 140 or 142 become deformed. The leading edge of the door curtain can be repaired by replacing the shear pins.
To assemble, screw hub 60 is screwingly engaged with the external thread 66 of clutch shaft 34 until its rests at substantially the midway point of the length of the shaft. Friction disc 58 is mounted onto clutch shaft 34. One friction disc is mounted on each side of screw hub 60. Idler drive sprocket 38 is mounted onto shaft 34 until flange 96 abuts with friction disc 58. Similarly, take-up drive sprocket 36 is mounted onto shaft 34 from an end opposite that of idler drive sprocket 38. As is apparent, screw hub 60 will be sandwiched between take-up drive sprocket 36 and idler drive sprocket 38. A thrust bearing 56 is mounted on each end of clutch shaft 34 until it abuts with sprocket 36 and 38 respectively.
Compression springs 99 are inserted into bores 100 of collar 54. Collar 54 is then mounted onto the shaft 34 until the face having bores 100 abuts with the thrust bearing 56 nearest the idler drive sprocket 38. Retaining ring 52 is an applied about the shaft 34 until it rests within ring groove 68 presenting an abutment surface preventing collar 34 from sliding off shaft 34. Compression springs 99 bias the thrust bearing 56 towards the idler drive sprocket 38.
The partially assembled clutch 30 is then mounted onto motor shaft 110. Key 112 is applied to the keyway 74 until fully registered therein. Hex bolts 114 are screwingly engaged into tapped bores 76 of clutch shaft 34 until the heads of hex bolts 114 rest below the surface of bearing surface 64 and retain the clutch shaft 34 onto motor shaft 110.
A second collar 54 having compression springs 99 inserted within bores 100 is applied to over the end of shaft 34 until it abuts with thrust bearing 56. A second retaining ring 52 is applied to retaining ring groove 68 fully securing collar 54 onto shaft 34. Compression springs 99 bias the thrust bearing 56 towards the take-up drive sprocket 36.
The distance between ring grooves 68 at each end of the shaft 34 must be such that when clutch 30 is fully assembled, screw hub 60 is able to move axially relative to sprockets 36 and 38. When screw hub 60 is closer to sprocket 36 than sprocket 38, sprocket 38 is able to freely rotate. Equally, when screw hub 60 is closer to sprocket 38 than sprocket 36, sprocket 36 is able to freely rotate.
Upon rotation of shaft 34, screw hub 60 will advance along the external thread 66, causing screw hub 60 to move relatively closer to sprocket 36. Upon further advancement of screw hub 60 along shaft 34 towards sprocket 36, the frictional forces between friction disc 58 and screw hub 60 and sprocket 36 will increase up to a point where screw hub 60 and sprocket 36 will rotate together with rotation of screw shaft 34.
Upon counter rotation of the shaft 34, screw hub 60 will retract along the external thread 66 and become disengaged from sprocket 36. Screw hub 60 will continue to detract and move relatively closer to sprocket 38 than sprocket 36 until the frictional forces between screw hub 60 and frictional disc 58 and frictional disc 58 and sprocket 38 increase until screw hub 60 and sprocket 38 rotate together with shaft 34.
When screw hub 60 is rotating together with either sprocket 36 or 38, the opposite sprocket is permitted to freely rotate about the shaft 34.
In operation, upon drivingly rotating idler drive sprocket 38, idler chain 42 rotates idler sprocket 26 and in turn causes idler axle 24 and idler roller 22 to rotate. Idler roller 22 guides the door curtain into the guide channels 20 of frame 18. Rotation of axle 24 and roller 22 causes gear 44 to rotate and in turn causing shaft 46 to rotate. Since dog 50 is not permitted to rotate, it will screwingly advance along the length of shaft 46. Upon rotation of shaft 46, door curtain 10 will be unrolled from take-up roller 14 and opening 12 becomes closed as dog 50 travels down shaft 46.
Upon drivingly rotating take-up drive sprocket 36 will cause take-up chain 40 to drivingly rotate take-up sprocket 28. Take-up sprocket 28 will cause take-up axle 16 to rotate causing take-up roller 14 to rotate. Upon rotation of the take-up roller 14, door curtain 10 will be rolled up opening door opening 12.
Drive sprocket 38 will cause door curtain 10 to close while take-up drive sprocket 36 is disengaged from the drive allowing it to freely rotate. Since take-up drive sprocket 36 freely rotates, take-up roller 14 is free to rotate as the door curtain 10 advances downwardly to close door opening 12. Conversely, when take-up drive sprocket 36 drivingly rotates take-up barrel 14, idler drive sprocket freely rotates permitting idler barrel 22 to freely rotate as door curtain 10 advances upwardly to open door opening 12.
Clutch 30 also acts as a brake when the operator 29 is not in operation. As motor 32 is de-energized, clutch 30 stops acting as a clutch and acts as a brake stopping the door curtain 10 and maintaining the door curtain 10 where it was stopped.
Dog 50 is releasably connected to edge component 49 to permit emergency opening of the door curtain 10. Since clutch 30 will have driven the door curtain to a closed position, take-up roller will still be free to rotate. By releasing dog 50 from edge component 49, take-up roller is free to rotate rolling up the door curtain to an open condition.
Optionally, one edge of channel 20 can be spring loaded to urge the door curtain 10 towards the other edge of edge channel 20. The advantage would be to establish a positive seal between the door curtain and frame 18 so that the greater pressure differentials could exist between opposite sides of the door.
As illustrated in FIGS. 12 to 16, the method used to drive the door curtain 10 to a closed position may be of any known variety. FIG. 12 illustrates a belt drive closing the door. FIGS. 13 to 15 illustrates a chain drive arrangement. FIG. 16 illustrates a cable drive arrangement.
In FIG. 12, take-down gear 44, take-down screw 46, base pads 48 and dog 50 is replaced by a sprocket, toothed belt 246, lower gear 248 and dog 250, respectively.
In FIGS. 13 to 15, take-down gear 44, take-down screw 46, base pads 48 and dog 50 is replaced by a sprocket 344, endless chain 346, lower gear 348 and dog 350, respectively.
In FIG. 16, take-down gear 44, take-down screw 46, base pads 48 and dog 50 is replaced by a spool 444, cable 446, lower gear 448 and dog 450, respectively.
It will be obvious to those skilled in the art that various modifications and changes can be made to the operating system without departing from the spirit and scope of this invention. Accordingly, all such modifications and changes as fall within the scope of the appended claims are intended to be part of this invention.
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A rolling or overhead door assembly is disclosed comprising a shaft having an external thread bounded by a first and second bearing surface, a hub screwingly engaging the shaft and adapted to travel along the shaft, a first sprocket rotatably mounted on the first bearing surface and operably connected with a take-down device for unrolling a flexible door and a second sprocket mounted on the second bearing surface and operably connected with a take-up roller for rolling up the door, and abutments on opposite sides of the first and second sprocket. Upon rotation of the shaft the hub advances along the shaft and frictionally engages the first sprocket until the first sprocket and shaft rotate together and upon counter rotation of the shaft the hub advances back along the shaft and frictionally engages the second sprocket until the second sprocket and shaft rotate together.
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[0001] This application claims the benefit of Taiwan application Serial No. 95124903, filed Jul. 7, 2006, the subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates in general to an image displaying method and a display device using the method, and more particularly to an image displaying method and a display device using the method with the high convenience.
[0004] 2. Description of the Related Art
[0005] Video entertainment has occupied an indispensable position in the life of the modern human beings, and a display device, such as a television, is an indispensable element. In general, audio and video interfaces are provided at a front end or a lateral end of the television so that the consumer can perform the easy installation. After the consumer has installed a peripheral audio-video (AV) apparatus, such as a video game machine or a DVD drive, the television and the video game machine are respectively turned on, and then an input port is selected by switching the channel. Thus, the frame of the peripheral AV signal source can be represented on the frame of the television.
[0006] FIG. 1 (Prior Art) is a state diagram showing operation mode switching of a conventional television 100 . Referring to FIG. 1 , the television 100 has multiple operation modes, such as an off mode 102 , a standby mode 104 , a TV mode 106 , a first AV operation mode 111 and second to n th AV operation modes 112 to 11 n . The television 100 is usually in the off mode 102 , in which the television 100 is not powered on yet. After the television 100 is powered on, the television 100 is in the standby mode 104 .
[0007] When the user turns on the power switch, the television has a chance to be in the TV mode 106 . Then, the input port may be selected by switching the channel, and the operation mode of the television may be sequentially switched to the first AV operation mode 111 to the n th AV operation mode 11 n , or from the n th AV operation mode 11 n to the TV mode 106 . The first AV operation mode 111 to the n th AV operation mode 11 n respectively correspond to the different peripheral AV signal sources, such as a DVD drive or a video game machine. Either the television 100 is in the TV mode 106 or one of the first AV operation mode 111 to the n th AV operation mode 11 n , the television 100 goes back to the standby mode 104 when the user turns off the power switch. The television 100 is in the off mode 102 after it is powered off.
[0008] However, the peripheral AV signal source, such as the video game machine, is frequently used at home by users, wherein most of the users are kids. The kids usually do not understand how to select the operation mode of the television, and thus need the help of the adults in selecting the correct operation mode so that the AV operation mode corresponding to the used peripheral AV signal source may be selected. Consequently, the selection of the operation mode may bring the trouble to the adults for a long time, and the convenience in use is also deteriorated.
SUMMARY OF THE INVENTION
[0009] The invention is directed to an image displaying method and a display device using the same, wherein hardware and software are combined so that an operation mode of a television is switched from a current mode to a first priority mode when the first priority mode of the television is triggered. Thus, the television displays an image corresponding to the first priority mode and the convenience in use can be enhanced.
[0010] According to a first aspect of the present invention, a television capable to be operated in a plurality of operation modes comprising a first priority mode is provided. The television is connected to a plurality of signal sources. The television includes a screen, a plurality of input ports, a detecting circuit and a processor. The input ports respectively connect to the plurality of signal sources, and one of the input ports is corresponding to the first priority mode. The detecting circuit detects whether a first signal is received at the input port corresponding to the first priority mode. When the first signal is received at the input port corresponding to the first priority mode, the television is triggered to operate in the first priority mode. The processor displays the first signal on the screen when the television is in the first priority mode.
[0011] According to a second aspect of the present invention, a method of controlling a display device selectively displaying one of a first signal received from a first signal source and a second signal received from a second signal source is provided. The method includes the steps of: displaying the second signal; detecting whether the first signal is received; and displaying the first signal when the first signal is received by the display device.
[0012] According to a third aspect of the present invention, a display device is provided. The display device includes a screen, a first input port, a second input port, a detecting circuit and a processor. The first input port receives a first signal from a first signal source. The second input port receives a second signal from a second signal source. The detecting circuit detects whether the first signal is presented at the first input port. The processor selectively controls one of the first signal and the second signal to be displayed on the screen. When the detecting circuit determines the first signal is presented at the first input port, the processor displays the first signal on the screen. When the detecting circuit determines the first signal is absent from the first input port, the processor displays the second signal on the screen.
[0013] According to a fourth aspect of the present invention, a method of controlling a display device is further provided. The display device is capable to be operated in a standby mode or a turn-on mode, receives a first signal from a first signal source. The method includes the steps of: setting the display device to operate in the standby mode; detecting whether the first signal is received; and setting the display device to operate in the turn-on mode and displaying the first signal when the first signal is received by the display device.
[0014] According to a fifth aspect of the present invention, a display device is provided. The display device includes a screen, an input port, a detecting circuit, a processor and a standby power circuit. The input port receives a first signal from a first signal source. The detecting circuit detects whether the first signal is presented at the input port. The processor selectively controls the display device to be operated in one of a standby mode and a turn-on mode. The processor controls the display device to be operated in the turn-on mode and displays the first signal on the screen when the detecting circuit determines that the first signal is presented at the input port. The processor controls the display device to be operated in the standby mode when the detecting circuit determines the first signal is absent at the input port.
[0015] The invention will become apparent from the following detailed description of the preferred but non-limiting embodiments. The following description is made with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 (Prior Art) is a state diagram showing operation mode switching of a conventional television.
[0017] FIG. 2 is a flow chart showing an image displaying method applied to a television according to a preferred embodiment of the invention.
[0018] FIG. 3 is a state diagram showing operation mode switching of the television according to the preferred embodiment of the invention.
[0019] FIG. 4A is a state diagram showing an example of the operation mode switching of the television according to the preferred embodiment of the invention.
[0020] FIG. 4B is a state diagram showing another example of the operation mode switching of the television according to the preferred embodiment of the invention.
[0021] FIG. 4C is a state diagram showing still another example of the operation mode switching of the television according to the preferred embodiment of the invention.
[0022] FIG. 5 is a block diagram showing the television having a first priority mode according to the preferred embodiment of the invention.
[0023] FIG. 6 is a circuit diagram showing an example of a detecting circuit 506 according to the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The invention provides an image displaying method and a display device using the same, wherein hardware and software are combined so that an operation mode of a television is switched from a current mode to a first priority mode when the first priority mode of the television is triggered. Thus, the television displays an image corresponding to the first priority mode and the convenience in use can be enhanced.
[0025] FIG. 2 is a flow chart showing an image displaying method applied to a television according to a preferred embodiment of the invention. As shown in FIG. 2 , the television usually has many operation modes including, for example, an off mode, a standby mode and a turn-on mode. The turn-on mode includes, for example, a TV mode, a game mode or many audio-video (AV) operation modes.
[0026] First, in step 200 , the user sets one of the operation modes as a first priority mode. Of course, this first priority mode may also be set as one of the operation modes when the television is shipped out. Then, in step 202 , the television operates in a current mode, which is one of the operation modes. Next, in step 204 , the television has a chance to determine whether the first priority mode is triggered. For example, when the television receives a video signal corresponding to the first priority mode, the television has a chance to determine whether the first priority mode is triggered. If the first priority mode is triggered, the operation mode of the television is switched from the current mode to the first priority mode in step 208 so that the television displays an image corresponding to the first priority mode.
[0027] FIG. 3 is a state diagram showing operation mode switching of a television 300 according to the preferred embodiment of the invention. As shown in FIG. 3 , the television 300 individually receives a television signal from a television signal source, receives a video signal, which is outputted after a video game machine is turned on, from the video game machine, and receives many video signals from the AV signal sources. The television 300 has an off mode 302 , a standby mode 304 , a TV mode 306 , a game mode 308 and many AV operation modes 31 x (x=1 to n). The television 300 displays the television signal, the video signal outputted after the video game machine is turned on and the video signals in the TV mode 306 , the game mode 308 and the AV operation modes, respectively. In this illustrated embodiment, the game mode 308 is set as the first priority mode. When the television 300 is not connected to an external power, such as the mains, the television 300 is in the off mode 302 . When the television 300 is connected to the external power and the video signal outputted from the video game machine does not exists, the television 300 is in the standby mode 304 . After the user turns on the power switch, the television 300 enters the turn-on mode, and the television 300 may be set, in advance, as directly entering the first priority mode (e.g., the game mode 308 ) or staying in the last mode before the user shuts down the television 300 .
[0028] If the television 300 receives the video signal of the first priority mode, which is outputted after the video game machine is turned on, that is, when the television 300 determines that the video signal outputted after the video game machine is turned on exists, the television 300 determines that the first priority mode is triggered. No matter which one of the standby mode 304 , the TV mode 306 and the AV operation modes 31 x (x=1 to n) is entered by the television 300 , the television 300 immediately switches to the game mode 308 so as to display the image corresponding to the video signal outputted from the video game machine after the video game machine is turned on without requesting the user to operate the television 300 again. Thus, the user can start to operate the video game machine and view the operation result on the television 300 .
[0029] When the user wants to switch the operation mode to another mode, he or she can switch the operation mode of the television 300 to one of the AV operation modes 31 x (x=1 to n), to the standby mode 304 , to the TV mode 306 and then back to the game mode 308 sequentially by switching the channel. In addition, when the video game machine is powered off, the television 300 determines whether the video signal, which is outputted after the video game machine boots, is absent and then goes back to the previous current mode, such as the standby mode 304 , the TV mode 306 , or one of the AV operation modes 31 x (x=1 to n).
[0030] Three examples for mode switching will be illustrated in detailed in the following. FIG. 4A is a state diagram showing an example of the operation mode switching of the television according to the preferred embodiment of the invention. As shown in FIG. 4A , when the television 300 is set as the TV mode and receives the television signal from the television signal source, the user may watch the television program. At this time, if the television 300 determines that the video signal outputted after the video game machine is turned on exists, the first priority mode is triggered and the television 300 automatically switches to the game mode 308 so as to display the video signal after the video game machine is turned on without the channel selecting operation being made by the user. When the television 300 determines that the video signal after the video game machine is turned on is absent, the television 300 goes back to the TV mode 306 and displays the image corresponding to the television signal.
[0031] FIG. 4B is a state diagram showing another example of the operation mode switching of the television according to the preferred embodiment of the invention. As shown in FIG. 4B , when the television 300 is set as the first AV operation mode and receives the video signal from the audio-video (AV) signal source, the user may watch a film played by the first AV signal source, such as the film outputted from a VCD player or a DVD player. At this time, if the television 300 determines that the video signal outputted after the video game machine is turned on exists, the first priority mode is triggered and the television 300 automatically switches to the game mode 308 so as to display the video signal outputted after the video game machine is turned on without the channel selecting operation being made by the user. When the television 300 determines that the video signal outputted after the video game machine is turned on is absent, the television 300 goes back to the first AV operation mode 311 and displays the video signal.
[0032] FIG. 4C is a state diagram showing still another example of the operation mode switching of the television according to the preferred embodiment of the invention. As shown in FIG. 4C , when the television 300 is set as the standby mode 304 and the television 300 determines that the video signal outputted after the video game machine is turned on exists, the first priority mode is triggered and the television 300 automatically operates in the turn-on mode so as to display the video signal outputted after the video game machine is turned on without the channel selecting operation being made by the user. When the television 300 determines that the video signal outputted after the video game machine is turned on is absent, the television 300 goes back to the standby mode 304 .
[0033] In the above-mentioned embodiment, the first priority mode is illustrated by taking the game mode 308 as a non-restrictive example, and any other mode may also be set as the first priority mode.
[0034] FIG. 5 is a block diagram showing a television 500 having a first priority mode according to the preferred embodiment of the invention. Referring to FIG. 5 , the television 500 includes a display screen 502 , input ports 504 x (x=1 to n), a detecting circuit 506 and a processor 508 . The input ports 504 x (x=1 to n) respectively receive the video signals, which are respectively outputted from the AV signal sources corresponding to these operation modes. For example, the input ports 504 x (x=1 to n) respectively receive the video signal outputted after the video game machine is turned on from the video game machine, receive the television signal from the television signal source or receive the corresponding video signals from the AV signal sources.
[0035] The detecting circuit 506 detects whether the AV signal source corresponding to the first priority mode outputs the video signal. When the television 500 receives the video signal corresponding to the first priority mode, the detecting circuit 506 determines that the video signal corresponding to the first priority mode exists, and the first priority mode of the television 500 is triggered. The processor 508 can selectively control one of the video signal, the television signal and the video signal outputted after the video game machine is turned on to be displayed on the display screen. When the first priority mode is triggered, the processor 508 outputs the video signal corresponding to the first priority mode to the display screen 502 . When the television 500 cannot receive the video signal corresponding to the first priority mode any longer, the detecting circuit 506 determines that the video signal corresponding to the first priority mode is absent, and the processor 508 outputs the video signal corresponding to the current mode to the display screen 502 . The television 500 further includes a standby power circuit 510 for supplying a standby power to the detecting circuit 506 and the processor 508 when the television 500 is in the standby mode.
[0036] FIG. 6 is a circuit diagram showing an example of the detecting circuit 506 according to the preferred embodiment of the invention. As shown in FIG. 6 , when the television 500 receives the video signal Video corresponding to the first priority mode, a transistor Q 1 turns on through the cooperation of a first inverting amplifier 5061 and a second inverting amplifier 5062 . After a predetermined period of time, a capacitor C 1 is boosted to a fixed voltage so that the transistor Q 1 outputs a high-level processor waking signal Detect_pin to trigger the processor 508 and make the processor 508 output the video signal corresponding to the first priority mode to the display screen 502 so that the video signal can be displayed on the frame of the television 500 preferentially.
[0037] The embodiment of the invention is illustrated by taking the television as an example, and may also be applied to other displays without restricting the scope of the television.
[0038] In the image displaying method and the display using the same according to the invention, the hardware and software are combined so that the operation mode of the television is switched from the current mode to the first priority mode when the first priority mode of the television is triggered. Thus, the television displays the image corresponding to the first priority mode and the convenience in use can be enhanced. In addition, the user needs not to perform any complicated switching operation on the television and the operation mode can be switched to the first priority mode quickly. Thus, the object of enhancing the convenience in use may be achieved in this invention.
[0039] More particularly, when the user is a kid who wants to use the video game machine, the kid can start to use the video game machine by only inserting the connector of the video game machine into the television without any switching operation. Thus, the adult does not have to assist the kid in performing the complicated switching operation and the kid can start to use the video game machine easily. Meanwhile, it is also possible to prevent the kid from damaging the television when the kids incorrectly operate the television.
[0040] While the invention has been described by way of example and in terms of a preferred embodiment, it is to be understood that the invention is not limited thereto. On the contrary, it is intended to cover various modifications and similar arrangements and procedures, and the scope of the appended claims therefore should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements and procedures.
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A method of controlling a display device selectively displaying one of a first signal received from a first signal source and a second signal received from a second signal source is provided. The method includes the steps of: displaying the second signal; detecting whether the first signal is received; and displaying the first signal when the first signal is received by the display device.
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BACKGROUND OF INVENTION
1. Field of Invention
The present invention relates to a method and composition for sizing cellulosic fibers or cellulosic fiber-containing material.
2. Prior Art
Numerous compositions and methods have been suggested heretofore for sizing paper, i.e., rendering the paper more resistant to penetration by liquids. Materials such as resin, various hydrocarbon and natural waxes, starches, glues, casein, asphalt emulsions, synthetic resins and cellulose derivatives have been employed as sizing agents. See, e.g., U.S. Pat. Nos. 3,084,093; 3,084,092; 2,995,483; 2,964,445; 2,941,919; 2,903,391; 2,872,315; 2,830,916; 2,764,483; 2,684,300, etc.
Typically, such derivatives are added directly to the paper making stock as "beater additives" and precipitated on the paper as it is formed to yield "internal" or "engine" sizing. Alternatively, the paper sheet may be passed, after formation, through a size solution, or over a roll wetted with the size solution to produce "tub-sized" or "surface-sized" paper sheets.
Reagents containing functional groups or which are merely precipitated on paper which react with the cellulose content of paper have also been utilized as sizing agents.
For example, U.S. Pat. No. 3,050,437 discloses the use of hydrophobic isocyanates as tub-sizing agents.
U.S. Pat. No. 3,337,636 discloses that various substituted trisulfonylmethanes may be employed to size paper by precipitation thereof on the cellulose fibers of the paper.
Westfelt et al, Cellul. Chem. Technol., Vol. 17(2), pp. 165-77 (1983) discloses the utilization of certain sulfonyl reagents as wet strength additives for paper.
Lukyanwa, Tekst. Prom. (Moscow), Vol. 27(8), pp. 51-2 (1967) [Chemical Abstracts 68, 96720n (1968)] and Rabinovich et al, Khim. Tekhnol. Proizrod. Tsellyul, 1968, pp. 148-56 [Chemical Abstracts, 72, 91609f (1970)] relate to the utilization of cellulose ethanesulfonate as a sizing agent for cellulose fibers. The derivative is, however, precipitated on the fibers.
U.S. Pat. No. 4,043,863 discloses the use of sulfamoylchlorides as cellulose fiber sizing agents.
U.S. Pat. No. 3,576,712 relates to the use of a composition containing a 2-chloroalkyl sulfone, a 2-chloroalkyl sulfoxide or a 2-chloroalkyl sulfide as paper sizing agents.
It is an object of the present invention to provide a novel composition and method for the surface sizing of paper based on the use of certain long chain alkyl sulfonates which react with the cellulose content of the paper.
SUMMARY OF THE INVENTION
The present invention provides a method for sizing cellulose fibers or cellulose fiber-containing material comprising reacting the cellulose fibers with a sizing agent having the formula: ##STR2## wherein: R 1 is an alkyl group having from 1 to 5 carbon atoms, and
R is an alkyl group having from 12 to 24 carbon atoms.
The present invention also provides a composition for sizing paper comprising an organic solvent solution of an organic sulfonate having the formula: ##STR3## wherein: R 1 is an alkyl group of 1 to 5 carbon atoms, and
R is an alkyl group of 12 to 24 carbon atoms.
There is also provided by the present invention, a cellulosic fiber containing material sized according to the above-described method.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is predicated on the discovery that the reaction of organic sulfonates of the above formula with cellulosic fibers greatly increases the hydrophobicity thereof. Therefore, the method and composition of the invention are useful for the treatment of any cellulosic fiber-containing material where it is desired to render the fibers or material resistant to the penetration of liquids, particularly water. Thus, the invention may be utilized to size paper, treat cotton to decrease dye penetration, or increase the hydrophobic character of any other cellulosic material having reactive OH groups.
The reaction between cellulose fibers and the organic sulfonates occurs readily in the presence of a base. Preferably, the reaction is carried out at a pH from about 11 to about 14. Any base inert with respect to the organic sulfonate and the cellulosic fibers may be employed to render the reaction medium basic. Suitable bases include water soluble and water-compatible alkali salts and substituted or unsubstituted ammonium salts which are sufficiently basic to produce the desired pH that do not interfere with the reaction such as sodium hydroxide, tetrabutylammonium hydroxide, and benzyltrimethylammonium hydroxide.
The organic sulfonates of the above formula do not readily lend themselves to "internal" or "engine" sizing procedures inasmuch as the basic conditions required for reaction between the cellulose fibers and the sulfonate generally far exceed those normally found in the head box or other stage of the paper making process during which additives are added to the slurry.
Therefore, when sizing paper according to the method of the invention, it is preferred to "surface size" the paper. Any conventional surface sizing techniques may be employed to carry out the invention. Thus, the paper sheet may be passed through a tub of a solution of the organic sulfonate or passed over a roller or other applicator in contact with a solution of the sulfonate. Those skilled in the art, having been exposed to the principles of the invention, will be aware of suitable techniques for achieving the sizing reaction without the exercise of undue experimentation.
When sizing paper it is preferable to react the cellulosic fibers thereof with about a 2% weight/volume solution of the organic sulfonate. Amounts less than 0.5% weight/volume will not enhance the hydrophobicity of the cellulosic fibers to any significant degree. Generally, amounts greater than about 5% weight/volume will not result in any added degree of hydrophobicity.
The preferred method of carrying out the invention is to pre-wet the paper substrate with an aqueous solution of the base and then wet the substrate with a solution of the organic sulfonate for a time sufficient to allow the reaction to go to completion. Preferably, the paper, pre-wetted with basic solution, is allowed to dry before wetting with the organic sulfonate solution. Drying the pre-wetted paper may be accelerated by heating to a temperature in the range of from about 40° C. to about 75° C.
The preferred organic sulfonate is octadecylmethane sulfonate, i.e., the compound of the above formula wherein R 1 is methyl and R is octadecyl.
The organic sulfonate is preferably dissolved in an organic solvent for reaction with the cellulosic fibers. Any suitable organic solvents for the organic sulfonate may be employed which is inert with respect to the cellulosic fiber-containing material. Suitable such solvents include lower alkyl sulfoxides, N,N-dimethylformamide, sulfolane, etc.
The preferred solvent is dimethylsulfoxide (DMSO). Generally, the solution should contain from about 1.5% to about 5%, preferably from about 2% to about 3%, by weight/volume, of organic sulfonate, in order to enable the reaction with the cellulose fibers to proceed efficiently.
It is preferred to conduct the reaction at a temperature of from about 100° C. to about 125° C. in order to drive the reaction to completion in an economically efficient manner.
The reaction between the cellulosic fibers and the organic sulfonate sizing agent is generally completed in from about 0.5 to about 2 min. when conducted at the above temperatures.
Preferably, the cellulosic fiber-containing material is washed with a suitable liquid, e.g., water, following completion of the reaction to remove excess base, organic sulfonate, solvent, etc.
Following completion of the reaction between the cellulosic and organic sulfonate, the cellulosic fiber-containing material is dried to produce the sized product. Optimal drying may be accomplished by heating the material at a temperature of from about 40° C. to about 75° C.
The invention is illustrated by the following non-limiting examples.
EXAMPLE 1
One side of a sheet of paper, basis weight 25 g/m 2 and Greiner porosity 45 mL/15 sec., containing 25% CaCO 3 filler was contacted with a 5% weight/volume aqueous solution of tetrabutylammonium hydroxide until the paper was thoroughly wetted. The paper was dried by heating to 75° C. for 40 seconds. One side of the dried sheet of paper was contacted with a 3% solution of octadecyl methanesulfonate in dimethyl DMSO at 100° C. until the paper was again thoroughly wetted. The wetted paper was dried at 120° C. for 30 seconds at which time the reaction between the sulfonate and cellulose was complete. The paper was washed twice with water and briefly dried at 50° C.
The effectiveness of the sizing reaction was determined with a Hercules Sizing Tester, Model KA. This instrument measures, by reflectance, the speed of penetration of an aqueous ink through the sheet.
The sized paper exhibited an ink penetration time greater than 500 seconds. The untreated paper exhibited an ink penetration time of 0.5 second.
Those skilled in the art, having been exposed to the principles of the invention, will be able to determine optimum reaction parameters, depending upon the particular cellulosic fiber-containing material to be sized and the organic sulfonate selected without the exercise of undue experimentation.
The alkyl sulfonate esters utilized as sizing agents in the method, composition and product of the invention may be prepared according to the method of Crossland et al [J. Org. Chem., Vol. 35, pp. 3195-96 (1970)]; i.e., the addition of an excess of an alkanesulfonyl chloride to a solution of the esterfying long chain alcohol in an appropriate solvent containing triethylamine. Those skilled in the art will recognize that longer chain alcohol reactants will require less polar solvents.
EXAMPLE 2
An emulsion was prepared by blending water 570 mL, 5% cooked starch suspension 400 mL, sodium lignin sulfonate 2.0 g and octadecyl methanesulfonate 30.0 g in a high-speed commercial blender for 10 min.
Samples of paper pretreated with base (sodium hydroxide) and dried as in Example 1 were wetted with the above emulsion and squeezed between rubber rollers. The samples thus treated were dried for 2 minutes at 120° C., washed twice with water and dried briefly at 50° C.
The effectiveness of the sizing reaction was determined as in Example 1.
Under the above conditions, a penetration time of 164 seconds was obtained.
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A method of sizing cellulose fibers with a sizing agent having the formula: ##STR1## Where: R 1 is an alkyl group having from 1 to 5 carbon atoms, and
R is an alkyl group having 12-24 carbons is disclosed.
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BACKGROUND OF THE INVENTION
To efficiently pack articles to be delivered people typically use packaging tape having a certain width to wrap around cartons housing these articles. Conventional wrapping apparatuses are operated manually and use metal buckles to fasten two ends of a strap. Such an apparatus must be manipulated by manual and is quite convenient. In addition, metal buckles do not have a strong grip so that it may allow a strap slides out of places. Besides, metal buckles may injure human body and so it is desirable to have an improvement made on this matter.
Currently there are electric wrapping apparatuses in the market, which use a motor to drive a tensioning mechanism and a hot sealing unit to perform wrapping. However, a typical deficiency is that the channel through which packaging tape passes must be curved to prevent tape from retreat during hot melting. Such a configuration results in poor tensioning. Moreover, frictional wheels are driven directly by a motor shaft and so it can not reach a high reduction ratio. Such a high rotation speed and quick rubbing will degrade the frictional wheels in a short time. Further, conventional apparatuses have an integrated construction and they can not be made as individual modules. Thus this design increases production costs and limits the application.
Accordingly, the object of the present invention is to provide an innovative portable electrical wrapping apparatus having an original construction that can quickly fold a strap around a package tightly.
Now the structural features and advantages of the invention will be described in detail with reference to the accompanying drawings.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
FIG. 1 is a perspective view schematically illustrating the entire structure of a portable electrical wrapping apparatus according to the invention.
FIG. 2 depicts the structure of the main body of the invention.
FIG. 3 shows the tensioning mechanism of the invention.
FIG. 4 is a schematic view indicating a sealing and cutting unit of the invention.
FIG. 5 is a cross-sectional view of the apparatus of FIG. 1 taken along a longitudinal direction.
FIG. 6 is a cross-sectional view of the apparatus of FIG. 1 taken along a transverse direction.
FIG. 7 is an exploded view of the tensioning mechanism of FIG. 3.
FIG. 8 is a schematic view showing a gear train of the invention.
FIG. 9 illustrates the movement of the tensioner of the invention.
FIG. 10 is a partial cross sectional side view of the tensioner of figure 9.
FIGS. 11 through 13 illustrate the movement of the sealing and cutting unit of the invention.
FIG. 14 shows a friction plate and the means adjusting the width of packing strip according to the invention.
FIGS. 15-16 illustrates the practice of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 through 5, the invention primarily includes a main body (1). The rear end of the main body (1) carries a motor (2) secured at a lower position. Above the motor (1) is a handle (11) and a lever (12) extending from the rear end of the main body (1). A transverse rod (3) is disposed above the main body (1). The lever (12) is pivotably attached by a pin (123) to the main body (1) and has a hook (121) at its lower end to grasp a pole (31) laterally extending from the transverse rod (3). A driven block (31) is pivotably disposed inside the main body (1), with the upper end mounted on the pole (31) and the lower end having a threaded hole (321). As shown in FIG. 2, the main body (1) can be made as a module and then combined with a tensioning mechanism (4) and a sealing and cutting unit (5) of FIGS. 3 and 4.
The shaft of the motor (2) extends into the main body (1), as shown in FIGS. 5 through 7, to drives a main shaft (21). The main shaft (21) is provided at its outer end with a pinion (211) to drive a worm (23). The tensioning mechanism (4) has a transmission shaft (42), to which a worm (23) is connected through a unidirectional bearing (41). Hence, through the worm (23) the main shaft (21) drives the transmission shaft (42) in one direction only. The transmission shaft (42) is provided with a gear (423) at its rear segment and connected to an internal support plate (45) at its outer end through a bearing (44). The internal support plate (43) has on one side surface thereof a protrusive driving shaft (431), which extends into a hollow pole (452) of an external support plate (45) to support the external support plate (45). The internal support plate (43) has an elliptical hole (432), through which a threaded bolt (49) passes. The threaded bolt (49) engages on its end with a threaded hole (321) of a driving plate (32). The gear (423) engages with a gear train consisting of three gears (46, 461, 462) as shown in FIG. 8. Two gears (461, 462) occupying lower positions individually have a cross-shaped axle (47) projecting toward the external support plate (45). The external support plate (45) includes on the corresponding side two frictional wheels (48) with a cross-shaped groove (482) formed thereof. The groove (482) is dimensioned to receive a cross-shaped axle (47) with clearance fit, as shown in FIGS. 3 and 7.
A unidirectional bearing (22), together with an eccentric wheel (51), mounts on the middle segment of the main shaft (21). Through the unidirectional bearing, the main shaft (21) drives a sealing and cutting unit (5) in one direction only as shown in FIG. 12. Outside the eccentric wheel (51) is a U-shaped connecting block (52) linked with a stationary block (53) on one end. A fusion block (54) is coupled with an adjustment wheel (55). The adjustment wheel (55) further engages with the stationary block (53) by screw threads. With reference to FIG. 9, a cutter (541) and an upper friction plate (542) are inserted into the lower portion of the fusion block (54). As can be seen from FIGS. 1, 2, and 11, a reversed U-shaped frame (56) pivotably mounts on the main body. Two raised blocks (561) on the top of the frame (56) locate near the transverse rod (3) having an oblique surface (33). Two hooks (562) configured to be caught by the inclined surface (543) of the fusion block (54) are respectively formed on two lower ends of the frame (56).
A tensioner (6) is by the sealing and cutting unit (5) as shown in FIGS. 9 and 10. The tensioner (6) comprises a round column (61) as well as a spring (62) therein. The top of the spring (62) is connected to a push rod (63). The push rod (63) is equipped with an upper and a lower oblique surface (631, 632), the upper oblique surface (631) being located in a central slot (71) of a movable block (7) and the lower oblique surface (632) being situated below a guide pin (34) at the end of the transverse rod (3). Referring to FIG. 2, the movable block (7) has a crooked portion (72) formed on the end thereof and abutting against a lock plate (563) disposed above the U-shaped frame (56). Further, a contact switch (73) is provided between the main body and the U-shaped frame (56).
In operation, the lever (12) along with a lock plate (8) is first moved upward. The lock plate (8) is pivotably attached to the handle (11) and provided with a locking edge (81) and a lock groove (82) at the front. The locking edge (81) forces against a locking pin (122) located on one side of the lever (12). As the locking edge (81) of the lock plate (8) slides and disengages from the locking pin (122), the lever (12) starts to rise as shown in FIG. 5. In the mean time, the hook (121) on the other end of the lever (12) urges the transverse rod (3) and the driving plate (32). The driving plate (32) further moves the internal support plate (43) around the transmission shaft (42) and turns the external support plate by the driving shaft (431) and the bearing (44) to displace a certain angle to expose the space below to the outside. Then, the lock groove (82) engages with the locking pin (122) to hold the lock plate (8) so as to allow packaging tape (9) to get in.
Below the main body (1) is a base (14) on which frictional plates (15) are disposed at positions corresponding to two functional wheels (48) and an upper frictional plate (542). Each frictional plate (15) has frictional surfaces (151, 152) respectively on the top and the bottom side and they are replaceable if worn out. Disposed between the lower frictional plates is a locating block (18) with a spring steel ball (181) as shown in FIG. 2, with which the apparatus can be adapted for different sizes of packaging tape.
When packaging tape (9) wrapping around a package is placed in position, release the lever (12) and the lock plate (8). Then the above components will return to their original positions due to spring forces and two frictional wheels (48) under the external support plate (45) can evenly apply forces against the packaging tape (9). That is because two frictional wheels (48) and driving cross shaped axles (47) are driven by the rotational motion of the driving shaft (431) to produce a uniform output. After the extension portion (16) is pushed forward and the start switch (13) is depressed, the motor (2) begins rotating the main shaft (21) in a forward direction, which in turn brings the pinion (211) and the worm (23) driven as well as the unidirectional bearing (41) to rotate. After that, the transmission shaft (42) starts to rotate. (If the main shaft (21) rotates in a reversed direction, the transmission shaft (42) can not be driven). Hence the transmission shaft (42) brings the gears (46, 461, 462) driven by the transmission shaft (42) also begin rotating. Gears (461, 462) rotate the two frictional wheels (48) through cross-shaped axles (47). As a result, the packaging tape (91) on the frictional wheels moves to the left to strain the tape gradually to a preset tightness.
As can be seen from FIGS. 9 through 11, when the packaging tape (9) is tightened, the stress will gradually lift the tensioner (6) and so the upper oblique surface (631) of the push rod (63) starts to force the movable block (7) moving toward the U-shaped frame (56). When the movable block (7) separates its crooked end (72) from the lock plate (563) of the reversed U-shaped frame (56), the frame (56) is free to move. Under the influence of the back spring (564), the frame (56) inclines forwards as shown in FIGS. 11,12 so that the hooks (562) of the frame (56) are disengaged with the oblique surfaces (543) of the fusion block (54). As a result the fusion block (54) is free to drop as shown in FIG. 12 and the upper frictional plate (542) presses against the packaging tape (9). At the same time, the reversed U-shaped frame (56) approaches the contact switch (73) and actuates it. Then, the motor (2) stops first and so the tensioning mechanism stops as well. Then the motor (2) starts to rotate in a reversed direction to drive the unidirectional bearing (22) and the eccentric wheel (51). With the movement of the eccentric wheel (51) and the U-shaped connecting block (52), the stationary block (53) and the fusion block (54) shown in FIG. 13 will quickly travel to and fro along a transverse direction. Consequently, the upper frictional plate (542), under the influence of the spring (551), presses against the upper packaging tape (91) to rub the lower packaging tape (92) with a high speed until they are molten and joined. The adjustment wheel (55) can be rotated to adjust the pressure applied on the upper frictional plate (542) by the spring (551) to adapt for different requirements. In addition, the cutter (541) under the fusion block (54) can be adjusted by means of the spring (544) to make it suitable for cutting the upper packaging tape (91). When a preset time elapses the motor (2) will automatically stop. Users can lift the lever (12) and the lock plate (8) to sideways remove the apparatus from the package wrapped with the packaging tape (9). The oblique surface (33) of the transverse rod (3) pushes the raised block (561) of the reversed U-shaped frame (56) and makes the frame (56) return to the original vertical position. The hooks (562) of the frame (56) lift the fusion block (54) when the frame rotates and finally disengages the fusion block from the packaging tape. Furthermore, the guide pin (34) at the end of the transverse rod (3) pushes the lower oblique surface (632) of the push rod (63) to make the push rod (63) downwards and the movable block (7) returns to its original position by use of the spring (70). The invention makes use of an extension portion (16) situated on the side of the handle (11) to urge the movable block (7) forward by manual operation as shown in FIG. 9. When the wrapping tape reaches a point that the user considers the strain is enough, he or she may stop tension and start welding and cutting or manually weld and cut tape without the use of automatic tension control in this fashion.
The invention has an eccentric knob (17) as shown in FIG. 5, which is situated near the lower corner of the internal support plate (43) and used to control the gap between the support plate (43) and the lower frictional plate (15). When the surface (433) of the plate (43) touches the peripherary of the knob body that has a smaller radius the gap becomes smaller. Contrarily, when it touches the peripherary of the knob body that has a larger radius the gap becomes larger. In this fashion, the apparatue can be adapted for packaging tape with different thickness and the support plate and the lower frictional plate can be kept a safe distance away from each other when no tape is loaded.
From the above description, the invention uses a single motor, cooperated with two unidirectional bearings, to drive a tensioning mechanism and a sealing and cutting unit in a forward direction. It can effectively perform packaging operation and thus it has a practical value in this industry. Besides, after loaded with packaging tape, the apparatus uses a unidirectional bearing (41) to provide convenience that users can manually align packaging tape with the fusion block and properly strain it in advance so as to reduce the tensioning time, promoting efficiency. The tensioning mechanism uses a combination of a pinion, a worm, and a gear train so that it can reach a high speed reduction ratio and facilitate tensioning operation. The invention further uses cross-shaped axles as transmission means between frictional wheels and driving gears. Thus it can control the level of two frictional wheels and the evenness of the application of forces on packaging tape. During tensioning, the invention employs securing a lock edge (81) of locking plates (8) to a lock pin (122) of a lever (12) to keep the support plate (45) pressing against packaging tape. Therefore, the restoring forces caused by tensioning will not cause the packaging tape sliding out of places.
As shown in FIG. 14, disposed under the support plate (45) is a screw (453), to which a stop plate (454) seated inside the apparatus is connected. By means of the screw (453), the position of the stop plate (454) can be adjusted to fit for packaging tapes with different widths. The stop plate functions as a guide of tape during packing. Besides, inside the base (14) there are provided with replaceable locating blocks (18) among frictional plates (15). With the spring steel balls (181) on the locating blocks (18) in cooperation with the adjustment of the stop plate (454), the apparatus of the invention has enhanced effects of positioning and guiding packaging tape. The frictional plates and the cutter can be replaceable. Thus they can be replaced when worn out, extending the service life of the apparatus. Further, as shown in FIG. 10, the tensioner (6) contains an adjustment wheel (64), by which users can control the stiffness of the spring (65) and in turn change the strain value that packaging tape (9) will reach after tensioning. That means users can adjust the tensile forces applied by packaging tape on packages. Along with a column (671) on a block (67) under the adjustment wheel (64), an indicator (66) placed on the outside of the apparatus shows the tension, facilitating the adjustment of tensile forces. Moreover, the tensioning mechanism of the invention is a module in construction and thus it can be designed to have different reduction ratios for various speed reductions. FIGS. 15, 16 show a variation application example in which gears of the gear train is aligned in a single row. It is therefore to be understood that other modifications may be made in the construction of preferred forms of the present invention without departing from the spirit and scope as defined by the appended claims.
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The present invention relates to a portable electric wrapping apparatus, comprising a motor to drive a main shaft, which moves a tensioning mechanism and a sealing and cutting unit. The tensioning mechanism and the sealing and cutting unit can be designed as individual modules and put together with the main body. The tensioning mechanism may be two frictional wheels each having cutting grooves or a single wheel aiming at the frictional plates to evenly apply pressure to the packaging tape therebetween and strain it for wrapping a package tightly. With the aid of a tension control rod, the tensioning mechanism can move the sealing and cutting unit downward to weld and cut the packaging tape automatically.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a continuation-in-part of PCT Patent Application No. PCT/IL06/00805, filed Jul. 12, 2006, which is based upon and claims the benefit of Israel Patent Application No. 170823, filed Sep. 12, 2005 entitled “Portable Charcoal Grill with Incorporated Fan,” both of which are incorporated herein by reference.
FIELD OF INVENTION
[0002] This invention relates generally to charcoal grills, and specifically to such devices that also have incorporated electric fans.
BACKGROUND OF THE INVENTION
[0003] Barbequing over charcoal grills is enormously popular the world over. To that end, consumers are able to choose from a seemingly endless array of charcoal grills that come in all shapes and sizes. In spite of great availability of charcoal grills and in spite of the bells and whistles that may accompany them, these grills universally face one great set back. Charcoal grills require approximately 30 minutes or more to heat the charcoal to a temperature suitable for safe and effective cooking.
[0004] Accelerants, like lighter fluid, may be used to decrease the igniting and heating time. However, such additives emit noxious fumes that contribute to ozone pollution. Because toxic chemicals may also enter the food and affect the flavor, one must take additional care to ensure that the additives are fully burned off before placing food on the grill.
[0005] Chimney starters are another option for decreasing charcoal heating time, wherein the charcoal is heated in a separate container and when sufficiently heated, is poured into the grill's cook box.
[0006] A safer and more practical option is to employ a fan. Traditionally, the tiring method of waving any available planar object, such as sheets of paper or a paper plate, is used. Using an electric fan is much less strenuous. Illustrative of such fans include U.S. Pat. No. 6,571,788 and German Patent 4423862, which disclose hand-held electric fans; German Patent 1245710, which discloses a fan that attaches to the bottom of a grill; U.S. Pat. No. 6,615,820, which discloses a fan through which air is blown from the upper side of the grill; and U.S. Pat. No. 3,933,145, which discloses a fan that is incorporated into the hood of a grill.
[0007] However, such devices, for reasons that will become apparent, do not provide a simple and easy to use device that generates an airflow that travels through the charcoals, allowing accelerated ignition and heating of the charcoal without creating potential contaminants or blowing ashes into the cooking food, in accordance with the principle of the present invention.
SUMMARY OF INVENTION
[0008] Presented herein is a portable charcoal grill with the added advantage of providing rapid ignition and heating of the charcoal, by means of an electric fan that is coupled to the body of the grill. The fan decreases the overall time required to heat the charcoal to proper cooking temperature by increasing the flow of air to the charcoal.
[0009] In accordance with exemplary embodiments of the present invention, the increased airflow created by the incorporated fan aids in heating and firing up the charcoal by channeling air up through the charcoal.
[0010] Because the fan blows the air into the cooking box below the level of the charcoal, thereby effectively providing additional air for the fire, while allowing the air to circulate naturally and uniformly up through the charcoal, ashes and charcoal dust are not blown up into the air or onto the food.
[0011] The decreased time required to heat the charcoal to a temperature suitable for cooking that results from the use of the present invention furthermore ensures more efficient use of the charcoal.
[0012] Another novel feature of some embodiments of the present invention is that charcoal can be placed on the entire surface of the cooking grid, without concern for providing entry for oxygen. This is because an attached air chamber allows air to enter from below the charcoal plate and flow up through the charcoals.
[0013] Yet another useful feature offered by the present invention relates to a protective screen that prevents charcoal and ashes from escaping from the grill area, onto the fan.
[0014] An additional unique feature disclosed in the present invention is providing an add-on air chamber that is incorporated within the grill box. The ability to disassemble the air chamber of the grill provides a new portability option and diversity to the charcoal grill.
BRIEF DESCRIPTION OF DRAWINGS
[0015] These and further features and advantages of the invention will become more clearly understood in light of the ensuing description of a preferred embodiment thereof, given by way of example only, with reference to the accompanying drawings, wherein—
[0016] FIG. 1 is a perspective view of an exemplary embodiment of the present invention;
[0017] FIG. 2 is a perspective view of the same embodiment, with the fan door open;
[0018] FIG. 3 is an exploded view of the same embodiment;
[0019] FIG. 4 is a cross-sectional view of an exemplary embodiment of the present invention with the ash catcher open;
[0020] FIG. 5 describes the- direction of airflow into and through the grill of the present invention;
[0021] FIG. 6 describes the direction of airflow through and out of the grill of the present invention.
[0022] FIGS. 7 a, b , and c illustrate two isometric views of an add-on air chamber in accordance with a preferred embodiment of the present invention as well as a cross sectional view of the air chamber.
[0023] FIG. 8 illustrates a grill partially installed with the add-on air chamber shown in FIG. 7 .
[0024] FIG. 9 illustrates a grill provided with the add-on air chamber in accordance with another preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] The description presented here relates to an exemplary embodiment of the present invention as shown in FIGS. 1 , 2 , and 3 , wherein a grill 10 substantially comprises a grill body 12 that houses the cooking components of the invention, an air chamber 24 that is attached at one end to body 12 , and an electric fan 30 that is set into the second end of air chamber 24 . When fan 30 of portable grill 10 is in the “ON” position, -the airflow generated by fan 30 causes the charcoal to heat more quickly and efficiently by providing additional oxygen to feed the flames.
[0026] Portable grill 10 can be used repeatedly and the components are made of any durable, heat-resistant materials that will stand up to repeated use.
[0027] Grill body 12 is the cook box that houses the cooking components of portable grill 10 . In an exemplary embodiment, grill body 12 is of a rectangular box shape. Other embodiments may have other shapes, for example, a square or circular container. In accordance with some embodiments of the present invention, there may be openings 58 scattered across the lateral surfaces of grill body 12 , an aesthetic feature that allows the flames to be viewed, a feature seen in FIG. 1 .
[0028] In some embodiments of the present invention, grill body 12 is constructed as two parts, an upper part and a lower part. In such embodiments, the upper part of grill body 12 may be separable from the lower part of grill body 12 and replaced. Preferably, the upper part includes grill plate 50 .
[0029] Portable grill 10 may be equipped with at least three legs 14 that extend down from grill body 12 . These legs 14 serve to provide added stability when grill 10 sits on the ground. Legs 14 may be rigidly affixed to grill body 12 and positioned on grill body 12 in any configuration that will allow grill 10 to rest soundly on a surface. There is the option of encasing one or all of legs 14 with rubber or other heat resistant material for increased handling comfort.
[0030] A pair of carry handles 16 allows the user to transport easily portable grill 10 from one location to another. In the exemplary embodiment, carry handles 16 are rigidly affixed to grill body 12 , on opposing short sides of grill body 12 . In alternative embodiments, carry handles 16 may be attached elsewhere in grill 10 . Furthermore, in alternative embodiments, carry handles 16 may be flexibly attached to grill body 12 . Carry handles 16 are heatproof and there is the option of encasing one or both carry handles 16 with rubber or other heat resistant material for increased handling comfort.
[0031] A protective screen 18 ensures that charcoal and ashes from portable grill 10 may not reach the area of fan 30 and also prevents the heat generated by portable grill 10 from adversely affecting the user while operating fan 30 , lever 38 , and heat vent 34 . In the exemplary embodiment, protective screen 18 is securely coupled to grill body 12 , between grill body 12 and air chamber 24 . Protective screen 18 may be constructed from any rigid planar material.
[0032] In some embodiments of the present invention, there is also an isolation layer 56 located between grill body 12 and air chamber 24 , seen in FIG. 1 . Isolation layer 56 may be constructed of wool surrounded by any rigid, planar material. Isolation layer 56 prevents the transfer of heat from grill body 12 to air chamber 24 , thus protecting fan 30 from heat damage, and also preventing lever 38 and heat vent cover 35 from getting too hot to be safely handled.
[0033] An ash catcher 20 provides both a convenient location to collect the ashes that accumulate during the course of using portable grill 10 and a simple disposal method. In the exemplary embodiment, ash catcher 20 is a removable drawer that is tapered at the bottom and is opened by means of a handle located on the exterior end of ash catcher 20 . In other embodiments, the drawer of ash catcher 20 may have other forms, for example, a flat or rounded bottom.
[0034] In alternative embodiments, ash catcher 20 may be an integral component of grill body 12 , wherein the ashes are accessed by alternative means. For example, a sliding panel or a door that is flexibly attached to grill body 12 and rotates away from grill body 12 may be located at the lowermost portion of one side of grill body 12 .
[0035] An air chamber 24 provides an enclosed area through which air may flow. Air chamber 24 is fixedly attached to one side of grill body 12 and houses the airflow regulating components of portable grill 10 .
[0036] An aperture 28 located at the side of grill body 12 is connecting the grill to air chamber 24 , and is positioned so that the upper edge of aperture 28 is parallel to or below the level of charcoal plate 50 . Air chamber 24 covers aperture 28 . Aperture 28 provides the opening necessary to allow air to flow between grill body 12 and air chamber 24 . There may also be a corresponding aperture 28 in ash catcher 20 .
[0037] A fan 30 is positioned at the second end of air chamber 24 , situated such that when the blades rotate and create an airflow, said air flows into grill body 12 . Fan 30 is comprised of a plurality of blades that extend from a central base and an electrical motor that is attached to the base to drive fan 30 .
[0038] Fan 30 expedites the heating process by increasing the flow of air to the igniting charcoal. The air is then able to flow up and circulate through the charcoal to efficiently stimulate the heating process. Because fan 30 causes air to flow under the charcoal rather than down or across, there is no need to place a cover, hood, or lid over portable grill 10 when igniting and heating the charcoal.
[0039] In the exemplary embodiment, fan 30 is firmly affixed to a fan door 32 , which is flexibly attached to air chamber 24 by means of a hinge or other connection device. Fan door 32 allows access to fan 30 for maintenance, repair, etc.
[0040] A unique feature of the present invention is an inner flap 36 , which is located within air chamber 24 , situated in front of fan 30 . The feature can be seen in FIG. 4 . Inner flap 36 is of the same shape as air chamber 24 , in order to completely close off the airflow from fan 30 . Inner flap 36 acts as a choke, providing the user with a means to adjust the amount of air flowing from fan 30 into grill body 12 , and thereby allowing the user to control the heat of the charcoal. This feature will be useful not only during the ignition phase, but also if the user wishes, for example, to re-ignite the charcoal or control the heat of the burning charcoal.
[0041] In the exemplary embodiment, a lever 38 is used to rotate inner flap 36 to the desired position. Lever 38 extends through air channel 24 and is fixedly attached to inner flap 36 . Inner flap 36 is moved to the opened position when the user wishes to ignite the charcoal. In the closed position, inner flap 36 completely blocks the airflow created by fan 30 .
[0042] Another unique feature of the present invention is a heat vent 34 located on the upper surface of air chamber 24 , between inner flap 36 and aperture 28 . Heat vent 34 provides an outlet for the heat from grill body 12 when inner flap 36 is partially or completely closed.
[0043] In an exemplary embodiment of the present invention, heat vent 34 is covered by a heat vent cover 35 that is flexibly connected to the top of air chamber 24 by any means. Heat vent cover 35 helps prevent ash or other contaminants from reaching fan 30 . In some embodiments of the present invention, heat vent 34 may by covered other methods, for example, a sliding panel.
[0044] In the exemplary embodiment, inner flap 36 and heat vent 34 may operate independently. In alternative embodiments, inner flap 36 and heat vent 34 may operate in tandem, wherein a single lever 38 operates both, such that when inner flap 36 is completely open, heat vent cover 35 is completely closed, when inner flap 36 is partially open, heat vent cover 35 is correspondingly partially open, and when inner flap 36 is completely closed, heat vent cover 35 is completely open. Yet other embodiments may allow for inner flap 36 and heat vent 34 to operate in other configurations.
[0045] A power cable 42 extends out from fan 30 and leads to a power source in order to provide power to fan 30 . In one embodiment, fan 30 may be powered by a replaceable battery. In other embodiments, the power may originate from other sources, including, for example, a car battery, an electrical wall outlet, or solar power. A power switch 44 of any kind allows the user to activate or turn off fan 30 . The rotation of the fan can be controlled.
[0046] Cooking grid 48 provides a cooking surface on which food can be placed. An added feature of the present invention is that the entire area of cooking grid 48 may be used, without having to leave gaps for air circulation, because air is provided by fan 30 from underneath cooking grid 48 .
[0047] A charcoal plate 50 equipped with a plurality of grid-like openings, is situated inside grill body 12 and below cooking grid 48 . Charcoal plate 50 holds the charcoal required for cooking and creates a partitioned area to separate the airflow area from the charcoal.
[0048] FIGS. 5 and 6 describe the airflow created by fan 30 , wherein the heavy arrows represent the direction of the airflow 54 through grill 10 .
[0049] During the ignition phase, shown in FIG. 5 , heat vent cover 35 is closed, and inner flap 36 is open. The charcoal is ignited in any suitable manner, and power switch 44 is moved to the “ON” position. When fan 30 is activated, ambient air is drawn in by fan 30 . The increased airflow created by fan 30 causes air to flow along air chamber 24 , through apertures 28 into grill body 12 . Once within grill body 12 , the air flows up and out through the plurality of openings in charcoal plate 50 , circulating air through the charcoal, and causing the charcoal to quickly reach a suitable cooking temperature.
[0050] Shown in FIG. 6 is an exemplary configuration of heat vent 34 , heat vent cover 35 , and inner flap 36 during the cooking phase, wherein the charcoal has reached cooking temperature. During this phase, heat vent cover 35 is opened and inner flap 36 is closed. The user may alternatively regulate the airflow by, for example, turning off fan 30 . In alternative embodiments, fan 30 may be equipped with a variable speed option. Heat vent 34 is provided to allow heat to escape from body 12 when fan 30 is not in use, without damaging fan 30 .
[0051] There is the option of adding openings 58 to grill body 12 or ash catcher 20 or both in order to allow the flames to be viewed. An example of an embodiment with such an option is seen in FIG. 1 .
[0052] While the exemplary embodiment of the present invention is of a portable size, there is also the option of manufacturing the present invention in other sizes. Additionally, the present invention may or may not include a cover that is flexibly attached to grill body 12 or elsewhere on grill 10 , or is completely removable.
[0053] FIGS. 7 a, b and c illustrate two isometric views of an add-on air chamber in accordance with a preferred embodiment of the present invention as well as a cross sectional view of the air chamber. Air chamber 100 provided with a fan 102 can be incorporated onto a grill in an add-on manner wherein the chamber 100 is provided with an opening 104 having lips 106 that are slidably inserted through a corresponding receiver 108 surrounding a corresponding opening 110 in grill 112 as shown in FIG. 8 . FIG. 8 illustrates a grill partially installed with the add-on air chamber 100 .
[0054] Basically, in the exemplary embodiment of the present invention, air chamber 100 is provided with similar features as the air chamber shown herein above in the other exemplary embodiments. In order to complete the portability feature of the grill, batteries 114 can be provided to the air chamber body wherein the batteries are activating fan 102 through switch 114 . Fan 102 can be connected to the air chamber through a hinge in a manner shown herein above.
[0055] Similarly to the above mentioned exemplary embodiment, air chamber 100 is provided with an outer flap 118 and an inner flap 120 that are movable using a lever 122 as shown herein before.
[0056] A bottom opening 124 is also provided in air chamber 100 so as to allow liquids from the cooking process or other liquids that may enter the air chamber to drain.
[0057] FIG. 9 illustrates a grill provided with the add-on air chamber in accordance with another preferred embodiment of the present invention. Grill 112 that is shown in FIG. 8 is provided with a cover 126 for covering the grill when it is not in use. In the exemplary embodiment, Grill 112 is provided with two openings 110 in both sides of the grill so as to allow the air chamber to be connected in one of the sides. When the opening is not used, a closure 130 is provided so as to block the opening that is not in use.
[0058] Optionally, a drawer 132 is provided in the bottom portion of grill 112 so as to allow cooked materials to be kept warm.
[0059] The fan can be operated in various ways such as mechanical or electrical and the means to operate the fan by no means limits the scope of the present invention.
[0060] While the invention has been described with respect to a limited number of embodiments, these should not be construed as limitations on the scope of the invention, but rather as exemplifications of some of the preferred embodiments. Those skilled in the art will envision other possible variations, modifications, and applications that are also within the scope of the invention. Accordingly, the scope of the invention should not be limited by what has thus far been described, but by the appended claims and their legal equivalents.
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A charcoal grill ( 10 ) providing a rapid ignition and heating of the charcoal, by means of an electric fan ( 30 ) that is coupled to the body ( 12 ) of the grill. The fan decreases the overall time required to heat the charcoal to proper cooking temperature by increasing the flow of air provided to the charcoal. The increased airflow created by the incorporated fan accelerates the firing-up and heating of the charcoal by channeling air across and through the charcoal. The decreased time required to heat the charcoal to a temperature suitable for cooking, further more ensures more efficient use of the charcoal.
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This is a continuation of application Ser. No. 07,783,863, filed Oct. 28, 1991, now abandoned.
FIELD OF THE INVENTION
The field is apparatus and method for transfer and application of offset heat release decals.
BACKGROUND OF THE INVENTION
Heat release decals customarily include a design layer supported on a substrate which is usually a paper sheet. An intermediate adhesive layer may be provided between the design layer and the paper sheet. That layer is solid at ambient temperature and softenable when heated. This permits separation of the design layer and the paper sheet, either during pickup of the decal or after its application to an article being decorated.
Heat release decals, as well as equipment for their application to ware, have been in use for many years. This is especially true for direct applied decals. There, the decal is brought into contact with the ware being decorated, and the design layer is applied by heat and contact pressure. Pressure may be applied by a rubber roller or pressure pad. Heat may be supplied by a heated pressure or print pad, for example, by an electrically heated pad. Alternatively, heat may be supplied by preheated ware.
Recently, an offset heat release decal process has been proposed where the decal is preheated on a platen. The design layer of the preheated decal is picked up from the decal paper substrate by a silicone print pad, The design layer is then transferred to the ware and applied by pressing the silicone print pad into contact with the ware. A feature of such a process is ability to design the print pad for use with curved or otherwise irregular surfaces.
Such a process holds forth much promise. However, certain problems limit its use. These involve primarily temperature control and material selection.
The design layer must separate from the carrier paper during pickup. This means that the temperature of the decal must be raised sufficiently to soften the adhesive layer. However, the adhesive must not become so hot that it becomes too fluid. It is evident that close temperature control must be exercised.
The transfer pad presents even more of a problem. The pad is normally of substantial size such that its temperature cannot be quickly changed. During decal pickup, the pad temperature must be sufficiently high so that the pad does not act as a heat sink and freeze the adhesive layer. However, some heat will be lost during transfer, and even more as the decal is applied to the ware. The ware, of course, will be at ambient temperature to freeze the adhesive on the surface of the ware, thereby permitting release of the decal from the pressure pad.
The net effect is that the transfer pad must be reheated between cycles. Because of its substantial size, this is relatively time consuming. This slows the rate at which the machine can be operated.
The material problem is one of selecting a suitable silicone material for the silicone transfer pad. On the one hand, the silicone must be relatively soft and deformable, that is, have a low durometer reading. This is necessary to avoid ware fracture when pressure is applied during decal application. However, most silicone materials of this nature do not have good release properties. In summary then, the problem is effecting a compromise between good chemical properties for decal release and good physical properties to avoid ware damage.
It is a basic purpose of my invention to provide a novel apparatus and process for offset heat release decal application that avoids the problems just discussed. Another purpose is to provide an apparatus and process where transfer of the decal is less dependent on the nature of the pressure pad.
SUMMARY OF THE INVENTION
The apparatus of my invention includes
a plurality of work positions,
a thin, silicone membrane carried by a support member,
means for indexing the membrane and support member throuqh successive work positions,
means for heating the membrane at a first work position,
means for presenting a decal for pickup by the heated membrane at a second work position,
means for bringing the membrane and decal into close proximity to an article at a third work position and
means for applying pressure through the membrane to print the decal on the surface of the article.
In one embodiment, the silicone membrane may be 0.040 to 0.100" (0.10-0.25 cm) thick. It may be heated by a heated platen, or by focused infra-red heating means. A single print head may be employed to apply pressure through the silicone membrane for the decal pickup and also for printing the decal on the ware. However, it is preferred to provide a separate print head for each operation and to heat each head.
The invention further resides in a method of applying an offset, heat release decal to an article surface which includes the steps of
supporting a thin, silicone membrane at the membrane periphery,
indexing the supported membrane through successive work positions,
heating the membrane to a predetermined temperature at a first position,
presenting a decal for pickup by the membrane at a second position,
heating the decal to a predetermined temperature,
bringing the membrane into contact with the heated decal to pick the decal up on the membrane,
bringing the decal on the membrane into contact with the article surface and
releasing the decal from the membrane onto the article surface.
Attention is directed to the following patents as illustrating the state of the art:
U.S. Pat. No. 2,077,790 (Hakogi) describes an offset printing apparatus in which a blanket carries an ink pattern, the blanket is pressed into a bowl to be decorated and air is evacuated between the blanket and the bowl.
U.S Pat. No. 4,392,905 (Boyd et al.) describes a laminate carried by a paper support, and application of the laminate to an article by a heated, silicone rubber transfer pad. The laminate support is heated to a temperature of 390°-420° F. to soften an adhesive layer, and the transfer pad is heated to a lower temperature of 300°-350° F.
U.S. Pat. No. 4,532,175 (Johnson et al.) describes a silicone membrane for use in collecting and transferring an ink design. The membrane is preferably 0.030 to 0.090" (0.075 to 0.225 cms) thick and has other defined release characteristics.
British No. 2,081,645 (Clare) describes a transfer apparatus that employs a vacuum pickup, and that heats a decal with an electric heating element for release.
British No. 2,193,158 (Pass) describes an apparatus including a heated platen to soften the adhesive layer in a decal for removal of the backing, and a deformable, heated transfer pad.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings,
FIG. 1 is a schematic top view of a four-position, indexing table in accordance with the invention.
FIG. 2a is a schematic view in cross-section taken at position A of FIG. 1.
FIG. 2b is a schematic view in cross-section that is similar to FIG. 2a, but illustrates an alternative heating system.
FIG. 3 is a schematic view in cross-section taken at position B of FIG. 1.
FIG. 4 is a schematic view in cross-section taken at position C of FIG. 1.
FIG. 5 is a schematic view in cross-section taken at position D of FIG. 1.
DESCRIPTION OF THE INVENTION
My invention resides in an apparatus for, and method of, applying an offset, heat release decal to an article. A key feature is the use of a thin, flexible, silicone membrane as a mechanism for picking up, transferring and printing a decal on an article. The silicone membrane is preferably in the range of 0.040 to 0.100" (0.10-0.25 cm) thick. Because of its thin nature, the durometer of the silicone is not critical, as it is in prior printing pads. Rather, the silicone for the membrane may be selected on the basis of optimum release characteristics.
A basic concept of the invention is physical separation of the thin, silicone membrane from a relatively bulky print or press pad. The print pad is still required in applying pressure through the membrane. However, the two members are physically separated so that critical temperature control is exercised in the membrane, not in the print pad. This will become more apparent as the invention is further described with reference to the accompanying drawings.
FIG. 1 is a schematic drawing showing a four-position, indexing membrane table. In this FIGURE, the membrane, in each of the four positions, is mounted with the print surface facing down. Position A is a membrane heater position. Position B is a decal pickup position. Position C is a decal print position where the decal is brought to, and printed on, the ware. Position D is optional, and is a position where additional membrane heating and/or cleaning may occur. The elements involved, and the functions carried out at positions A-D, are detailed in FIGS. 2-5, respectively.
FIGS. 2a and 2b are schematic views in cross-section. They illustrate alternative heating systems for membrane 10 in position A. Membrane 10 is a thin silicone member, usually circular in nature, which is mounted on member 12. Member 12 is shown as a metal ring that rests in an opening 14 in membrane table 16. Table 16 may have any suitable geometry, but is shown as a square, movable, flat sheet of any suitable material.
It is necessary to uniformly and rapidly heat the under surface of membrane 10 to a fixed, set-point temperature. The absolute value of that temperature will vary with, and depend on, the heat release decal construction and materials.
FIG. 2a illustrates a simple system employing a temperature-controlled platen 18. Platen 18 may, for example, be electrically heated. It may be controlled at a temperature determined to be adequate for quick reheating of the membrane after each cycle. Heated platen 18 is mounted close to the under surface of membrane 10, but with sufficient clearance to permit indexing of membrane table 16.
FIG. 2b shows an alternative heating system. Membrane 10 may be mounted as in FIG. 2a. However, heated platen 18 is replaced by infra-red heaters 20. Heaters 20 will also be controlled to bring membrane 10 to a fixed temperature at position A. The surface temperature of membrane 10 may be monitored by an optical pyrometer 22. In order to conserve and focus the heat generated, heaters 20 may be surrounded by a shroud-like enclosure 24.
Referring back to FIG. 1, membrane table 16 is indexed from position A to position B preparatory to picking up a decal for printing. At position B, a decal loader system 26 includes a decal magazine 28 from which a decal 30 is picked up by suction cups 32 and carried forward to a heated vacuum platen 34. The decal is released to platen 34 where it is held in place by vacuum means (not shown). Platen 34, carrying decal 30, then slides into position under membrane table assembly 16 and presshead assembly 36. This is shown in a schematic cross-section view in FIG. 3.
Presshead assembly 36 is a conventional component that has a cross arm construction, as shown, for vertical opera&.ion. Assembly 36 has a sheet 38 carried by vertical post 40 that serves as a carrier for presshead 42. The latter is composed of a deformable silicone. When presshead 42 is lowered against membrane 10, the membrane is depressed against decal 30 to pickup the decal.
Decal 30, in turn, is heated by platen 34 to soften an adhesive layer between the design layer and the decal backing. This permits separation to occur readily. Platen 34 may correspond to platen 18 in FIG. 2a. It operates at a set temperature. This temperature control, together with a controlled dwell time, ensures optimum conditions in decal 30 for its pickup by membrane 10.
As presshead 42 is lowered against membrane 10, the latter is deformed and pressed into contact with decal 30. The dwell time of presshead 42 is controlled, after which the presshead is retracted. This releases the pressure on membrane 10, thereby allowing it to regain its shape and lift the design layer of decal 30 away from its paper backing. Membrane table 16 then indexes to position C. Meanwhile, decal platen 34 retracts and the spent paper backing is removed preparatory to starting another cycle.
FIG. 4 is a schematic view in cross-section showing membrane table 16 indexed to position C with membrane 10 carrying decal 30. FIG. 4 also shows the arrangement for transfer of decal 30 to an article 44. In this arrangement, article 44, e.g., a dinner plate, is loaded in a vacuum chuck 46. Chuck 46 embodies a centering device 48 to hold article 44 in a fixed position. After article 44 is loaded in chuck 46, the assembly 50 is moved laterally on a track 52. This positions assembly 50 in alignment with a presshead assembly 54 and membrane 10.
Presshead assembly 54 is similar in structure and operation to assembly 36 of FIG. 3. The operative element is presshead 56 which, like presshead 42, is composed of a deformable silicone rubber. With article 44 in position, presshead assembly 54 is lowered to bring presshead 56 into contact with membrane 10. Further downward movement of assembly 54 deforms membrane 10 and presses decal 30 into contact with ware 44. A dwell timer operates to maintain contact pressure until the transfer of decal 30 is complete. Presshead assembly 54 then retracts to its inoperative position. At the same time, the ware assembly 50 moves back to its out position from unloading article 44 and loading of another article for another print cycle. Meanwhile membrane table 16 is indexed to position D.
As shown in FIG. 5, position D may be a combined preheat and cleaning station. A third presshead assembly 58, similar to previous assemblies 42 and 54, and a heated platen 60, similar to heated platens 18 and 34, are provided. Platen 60 serves to heat the membrane 10 for cleaning. It also reduces the heating time required in position A.
Presshead assembly 58 may be lowered to deform membrane 10. This presses membrane 10 against a cleaning material 62 which may be rolled over platen 60. A continuous roll of paper 62, passing between rolls 64, has been found successful to remove any decal residue from the membrane. After a fixed dwell time, presshead assembly 58 is retracted. Membrane table 16, with a clean and preheated membrane 10, is then indexed to position A to begin a new cycle.
An essential feature of my invention then is use of a thin silicone membrane as a pickup and print member. Necessarily, the membrane is used in conjunction with a means of applying pressure, such as the presshead assemblies shown. However, the membrane is a separate and distinct member that can be controlled independent of the presshead.
A primary significance of this distinction is that the characteristics of the presshead and the membrane may be optimized separately, that is, each for its inherent function. In choosing a membrane material, the primary concern will be release characteristics that are of a chemical nature. Because the membrane is so thin, physical properties, in particular the durometer of the material, are of secondary concern at most.
The physical properties are of significance in selecting the material for a presshead. To avoid crushing or breaking of thin ware, a soft, deformable material may be preferred for the presshead. By way of illustration, I have found that a preferred presshead material is a deformable silicone rubber with a durometer of about 30-40 on the Shore-00 scale. In contrast, I prefer a membrane material that has excellent release characteristics, but has a durometer of about 60-70.
A further feature of the invention is use of membrane and decal heating systems. In particular, the use of closely controllable heating systems permit determining and employing optimum temperature conditions for each stage of the operation. Thus, the decal is heated to a temperature where separation at the adhesive layer occurs most readily. Heating of the membrane means that it is at an optimum temperature for decal pickup. Also, heating of the presshead, while not so critical, does avoid it acting as a heat sink. The use of a thin membrane, controlled separately from the presshead, is significant with respect to temperature control. The membrane can be more quickly heated, or reheated, whereby the cycle is speeded up.
Within these basic considerations, numerous variations and modifications are contemplated. With the foregoing teaching as a guide, these will be readily evident to those conversant with the decal and decorating arts.
In particular, it is contemplated that a single presshead assembly might be used for all positions. It might be indexed in conjunction with the membrane table. The operation would, of course, be slower, but the apparatus would be simplified.
Also, as indicated earlier, position D is an optional operation. If cleaning and/or reheating of the membrane should prove unnecessary, this position might be omitted. A three-position table might then be used. However, the four-position table is preferred to speed up the cycle and increase the select rate of good ware.
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Apparatus and method for transfer and application of an offset, heat release decal to an article surface. A thin, supported, silicone membrane is indexed through successive work positions where the membrane is heated, picks up a heated decal and brings the decal into contact with the article surface for printing.
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BACKGROUND OF THE INVENTION
This invention relates to a product dispensing apparatus for dispensing a variety of pills at various times. More particularly, this invention relates to a tablet dispensing device which will assist the user in recalling whether he has or has not ingested tablets at appropriate times.
It is an object of the present invention to provide a self-loading device for use in chronologically dispensing tablets.
It is another object of the present invention to provide an apparatus for use in chronologically dispensing tablets for aiding the user in insuring that only certain tablets are ingested at certain times during certain days.
Yet another object of the present invention is to provide apparatus for use and chronologically dispensing tablets having a tablet receiving magazine including a plurality of axially spaced groups of radially outwardly opening tablet receiving pockets and a plurality of individually rotatable, tablet retaining and dispensing rings for retaining the tablets in the pockets and yet permitting tablets in selected pockets to be dispensed.
Another object of the present invention is to provide pill dispensing apparatus of the type described for use by individuals who have a plurality of different tablets, some of which are to be ingested at the same time and some of which are to be ingested at different times during various time periods during a week.
A still further object of the present invention is to provide tablet dispensing apparatus of the type described including a plurality of axially spaced groups of tablet receiving pockets which are axially aligned with the pockets of adjacent groups, and closure rings concentrically mounted on the magazine having tablet dispensing openings therein for registry with selected openings of the magazine.
Other objects and advantages of the present invention will become apparent to those who are unskilled in the art as the description thereof proceeds.
SUMMARY OF THE INVENTION
Apparatus for use in chronologically dispensing tablets comprising a tablet magazine including a plurality of axially disposed groups of annularly arranged radially outwardly opening, tablet receiving pockets; a plurality of axially disposed, closure rings mounted on a magazine in transverse alignment with the groups of pockets for retaining tablets in the pockets; a first plurality of axially disposed, time related indicia disposed on one of the plurality of rings or the magazine, generally in transverse alignment with the groups of pockets; a second plurality of annularly arranged, time related indicia disposed on the magazine, generally longitudinally aligned with the pockets; the rings being individually incrementally rotatable about the axis and including a tablet dispensing opening therein such that one of said openings can be moved into radial registry with any selected one of the pockets to allow a tablet in the selected pocket to be radially dispensed.
These and other objects of the present invention may more readily be understood by reference to the accompanying drawings in which:
FIG. 1 is the side elevational view of apparatus constructed according to the present invention;
FIG. 2 is a top plan view thereof taken along the line 2--2 of FIG. 1;
FIG. 3 is a sectional plan view, taken along the line 3--3 of FIG. 1;
FIG. 4 is a perspective view illustrating one of the tablet retaining rings; and
FIG. 5 is a sectional side view, taken along the line 5--5 of FIG. 3.
DESCRIPTION OF PREFERRED EMBODIMENT
Apparatus constructed according to the present invention, is generally designated 10, and includes a one-piece, tablet receiving magazine, generally designated 12, having a base 14 mounting an upstanding cylinder 16. The cylinder or column 16 includes a continuous pocket forming web or sheet 17 of thermoplastic material defining a plurality of axially spaced layers or groups 18 of circumferentially spaced, concentric, radially outwardly opening, tablet receiving pockets 20. More particularly, the groups 18 include seven axially spaced groups 18a-18g of pockets 20. Each group or set 18 includes four angularly spaced, tablet receiving pockets 20 which are vertically aligned with the pockets 20 of each of the other groups or sets 18 to form pocket rows R.
Each group 18 of the pocket forming sheet 17 includes four equi-angularly disposed pocket separating portions 24, 25, 26, and 27, spanned by upper and lower pocket defining portions 29 and 31 spanned by circumferentially curvilinear wall portions 33. Each of the pocket separating portions 24, 25, and 26 are substantially identical in top plan cross section, as illustrated in FIG. 3, and include radially outwardly diverging, confronting webs 28 spanned at the radially terminal ends thereof by curvilinear identical webs 30. The pockets separating portion 27 has a greater circumferential extent than the pockets separating members 24, 25, and 26, and includes radially outwardly diverging confronting webs 28a spanned at the radially terminal edges thereof by a curvilinear web 30a which has a circumferential length a which is substantially longer than the circumferential length b of the webs 30. The webb 22 thus defines pocket defining side walls 28 and 28a, terminating in curvilinear outer walls 30 and 30a respectively, and spanned by integral, upper and lower confronting wall sections 29 and 31 terminating in curvilinear walls 33.
The upper end of the column 12 includes an integral, hollow projection 34 removably mounting a retaining cover 36 which is cemented thereon. The retaining ring 36 includes an annular retaining lip 38 for a purpose to be immediately described.
A first plurality of indicia 40 is provided on the outer face of the curvilinear web 30a. The indicia 40 comprises axially spaced abbreviations "MON", "TUES", "WED", "THU", "FRI", "SAT", "SUN", which are abbreviations for the days of the week, Monday through Sunday, and lie in the planes P of the pockets 20 in each group 18a-18g.
A plurality of axially stacked, transparent, closure or tablet retaining rings 42 is mounted on the magazine 12 in vertically stacked, abutting relation between the base and the retaining lip 38. The rings 42 are individually rotatable and secure one or more tablets T in the pockets 20. Each of the closure rings 20 includes a tablet dispensing aperture 44 therein of sufficient size to permit a tablet T to be dispensed therethrough when the ring 42 is in radial registry with a pocket 20. The aperture 44 is molded into the upper edge 46 of the ring 42. The maximum circumferential width c of the dispensing opening 44 is greater than the circumferential length b of the web 30 and less than the circumferential length a of the web 30a.
The cylindrical column 16 includes a plurality of axially spaced radially outwardly projecting detents 48 projecting from the curvilinear walls 33, and each of the rings 42 includes a plurality of circumferentially spaced, radially inwardly relieved, detent receiving recesses 50 for releasably receiving the detents 48. When one of the detents 48 is received in one of the recesses 50, rotation of the ring 42 is inhibited. The web 22 is yieldable laterally inwardly when the ring 42 is rotated so that the detent 48 will move radially inwardly and escape the recess 50 when sufficient circumferential rotating force is applied to the ring 42. Five detent receiving recesses 50 are provided in each ring and are so located that when the detent 48 is received in a recess 50, the tablet dispensing opening 44 will either be aligned with one of the pockets 20 or with the indicia bearing face 30a.
A plurality of circumferentially spaced, indicia receiving paper blanks 51 are mounted on the end surface of retaining cover 36 via a layer of adhesive 53. The blanks 51 receive indicia 52, indicating different time periods through the day. More particularly, the indicia 52 comprises "MORN", "NOON", "EVNG", and "NITE", representing morning, noon, evening, and bedtime time periods respectively. Any other time increments may be utilized as desired. These indicia are marked by the user according to his requirements. The indicia receiving blanks 51 and the indicia 52 are in axial or longitudinal alignment with the pockets 20 of the vertically spaced pocket rows R.
THE OPERATION
In operation, it will be assumed that the user will be required to ingest a plurality of different tablets T, seven days per week. It will further be assumed that the user will be required to ingest the tablets at morning, noon, evening, and bedtime periods, however, not all of the different tablets are to be ingested at each time period throughout a given day. Some of the tablets are to be ingested at the same time, for example, noon, and others of the tablets are to be ingested at different times, for example, morning and evening.
The user will initially manually load the magazine by initially rotating the uppermost ring 40 adjacent the indicia "MON" into alignment with one of the pockets 20 in pocket group 18a underlying the indicia "MORN". At this time, the detent 48 adjacent the uppermost ring will be received by one of the recesses 50 in the uppermost ring 40. A suitable quantity and type of tablets T are inserted radially inwardly through the opening 44 to be received by the pocket 20. The operator will then index the ring 40 until the pocket 44 is in radial registry with the circumferentially adjacent pocket 20 underlying the indicia "NOON". He will then radially insert a suitable quantity and type of tablets T into this pocket. The operator will then rotate the ring 40 to remove the detent 48 from the recess 50 until the opening 44 in the uppermost ring is in radial registry with the pocket 20 underlying the indicia "EVNG". The user will then insert a suitable quantity and type of tablets T into this pocket. The operator will once again rotate the ring 40 to a position in which the aperture 44 is in radial alignment with a pocket 20 underlying the indicia "NITE". After suitable quantity and type of tablets T have been inserted into this pocket, the ring 40 will then be rotated to a position in which the aperture 44 is aligned with the indicia bearing wall 30a.
The user will then similarly successively index each successive ring 40 so that the apertures 40 are brought into alignment with the respective pockets so that suitable tablets can be placed in the remaining pockets. Some of the pockets may remain empty if no tablets are to be ingested at the time assigned to the pocket. When the loading is completed, the rings will be in the position illustrated in FIG. 1.
To dispense tablets, the user, for example, on Monday morning would rotate the ring 40 until the aperture 44 is in alignment with the pocket 20 of pocket group 18g, underlying the indicia "MORN". Any tablets in this pocket are then dispensed radially outwardly through the opening 44 by merely tipping the column 16 on its side, so that the tablets move therethrough by gravity forces. The opening 44 may remain in a position aligned with the empty pocket or returned to the start position to keep all pockets closed. At noon time, the user will then index the uppermost ring 40 until the aperture 44 therein is in radial registry with the pocket 20 underlying indicia "NOON". This sequence will be repeated at evening and night times for the remaining two pockets in the uppermost group 18. On Tuesday, the second uppermost ring 40 will be similarly successively indexed to each successive time period in the day. For each successive day of the week, the rings will be similarly rotated.
The apparatus will provide a ready visual indication as to whether or not the user has ingested the pills at the appointed times. In the event that the user inadvertently forgets to ingest the pills on Monday noon, for example, the user, on Monday afternoon, will be able to see through the uppermost transparent ring 20 to view the tablets T in the pocket 20 which is radially aligned with the indicia "MON" and axially aligned with the indicia "NOON". If the user views tablets in the pocket, he will know that he forgot to take the tablets and will ingest them accordingly.
It is to be understood that the drawings and descriptive matter are in all cases to be interpreted as merely illustrative of the principles of the invention, rather than as limiting the same in any way, since it is contemplated that various changes may be made in various elements to achieve like results without departing from the spirit of the invention or the scope of the appended claims.
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A product dispenser for dispensing products, such as tablets, on a time related schedule, or randomly as desired, comprising a generally cylindrical product receiving magazine having a plurality of axially spaced groups of circumferentially spaced, radially outwardly opening, product receiving pockets which are generally in axial alignment with the pockets of adjacent groups to form circumferentially spaced rows of pockets; a plurality of product retaining rotatable rings mounted on the magazine in radial alignment with the pockets for retaining the tablets in the pockets; each ring including a tablet dispensing aperture therethrough adapted to be moved into alignment with a selected one of the pockets; a plurality of axially spaced indicia, representing the days of the week, lying in the planes of the groups of pockets; and circumferentially spaced indicia, representing different time periods throughout the day, generally longitudinally aligned with the rows of pockets.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of application Ser. No. 10/230,085, filed Aug. 29, 2002, pending; which is a continuation-in-part of application Ser. No. 09/537,118, filed Mar. 29, 2000; which is a continuation-in-part of the U.S. national phase designation of PCT/US97/17899, filed Oct. 1, 1997, the disclosures of which are incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
[0002] It is known that certain biologically active compounds are better absorbed through the oral mucosa than through other routes of administration, such as through the stomach or intestine. However, formulations suitable for such administration by these latter routes present their own problems. For example, the biologically active compound must be compatible with the other components of the composition such as propellants, solvents, etc. Many such formulations have been proposed. For example, U.S. Pat. No. 4,689,233, Dvorsky et al., describes a soft gelatin capsule for the administration of the anti-coronary drug nifedipine dissolved in a mixture of polyether alcohols. U.S. Pat. No. 4,755,389, Jones et al., describes a hard gelatin chewable capsule containing nifedipine. A chewable gelatin capsule containing a solution or dispersion of a drug is described in U.S. Pat. No. 4,935,243, Borkan et al. U.S. Pat. No. 4,919,919, Aouda et al, and U.S. Pat. No. 5,370,862, Klokkers-Bethke, describe a nitroglycerin spray for administration to the oral mucosa comprising nitroglycerin, ethanol, and other components. An orally administered pump spray is described by Cholcha in U.S. Pat. No. 5,186,925. Aerosol compositions containing a hydrocarbon propellant and a drug for administration to a mucosal surface are described in U.K. 2,082,457, Su, U.S. Pat. No. 3,155,574, Silson et al., U.S. Pat. No. 5,011,678, Wang et al., and by Parnell in U.S. Pat. No. 5,128,132. It should be noted that these references discuss bioavailability of solutions by inhalation rather than through the membranes to which they are administered.
[0003] Atropine is a naturally occurring anticholinergic alkaloid found in the plant atropa belladona and has the structure depicted below:
[0004] Atropine is a competitive antagonist of muscarinic cholinergic receptors and blocks the effects of acetylcholine at muscarine receptors, including muscarine receptors in exocrine glands, smooth muscle, cardiac muscle, ganglia, and intramural neurons. Muscarinic receptor antagonists, such as atropine, have been employed to treat a wide variety of clinical conditions. Atropine can be administered intravenously, intramuscularly, or orally. When administered orally, atropine is absorbed from the gastrointestinal tract and is eventually excreted in the urine. Atropine undergoes hepatic metabolism and has a plasma half life of between 2 and 3 hours.
[0005] Atropine reduces secretion of gastric acid and, accordingly, has found use in the management of peptic ulcers. Atropine also reduces gastric motility and is therefore used to treat disorders resulting from excessive smooth muscle contraction in the gastrointestinal tract, such as irritable-bowel syndrome. Intestinal hypermotility and increased frequency of stools associated with antihypertensive agents, such as guanethidine, can also be controlled with atropine. Diarrhea associated with irritative conditions of the lower bowel, such as mild dysenteries and diverticulitis, also responds to atropine.
[0006] Atropine has also been used to treat parkinsonism.
[0007] Atropine has also found use in ophthamology, when locally administered to the eye, atropine, produces mydriasis and cycloplegia.
[0008] Atropine reduces secretions in the upper and lower respiratory tract. This effect in the nasopharynx can provide symptomatic relief of acute rhinitis such as associated with coryza or hay fever.
[0009] Atropine is used as a specific antidote for cardiovascular collapse that can result from administration of a choline ester or an inhibitor of cholinesterase. Atropine also antagonizes vagal cardiac slowing and can be used in the initial treatment of acute myocardial infarction where excessive vagal tone causes sinus or nodal bradycardia or atrioventricular block. When administered to treat bradycardias a dose of about 250-500 mcg is generally effective in adults and a dose of about 10-20 mcg/kg is generally effective in children.
[0010] Atropine is used as a pre-medication for anaesthesia since it decreases bronchial and salivary secretions; blocks bradycardia associated with various anesthetics, such as halothane, suxamethonium, and neostigmine; and prevents bradycardia from excessive vagal stimulation. When administered as a premedication for anaesthesia the typical dose for adults is about 500-600 mcg administered intramuscularly 30-60 minutes before surgery. Alternatively it may be given intravenously at induction of anaesthesia. Children should receive only about 20 mcg/kg.
[0011] Atropine is also effective at reducing excessive salivation, such as associated with heavy metal poisoning or parkinsonism, and for blocking salivation in patients unable to swallow from esophageal obstruction such as from tumors or stricture.
[0012] Atropine also acts as a muscle relaxant and finds application as an anti-spasmodic which may be used as a pretreatment before abdominal surgery.
[0013] Atropine has been administered in conjunction with an opioid for the treatment of renal colic. Atropine lowers intravesicular pressure, increases capacity, and reduces the frequency for urinary bladder contractions by antagonizing the parasympathetic control of the bladder. Atropine is used to treat enuresis in children, particularly when progressive increase in bladder capacity is the objective; to reduce urinary frequency in spastic paraplegia; and to increase the capacity of the bladder in conditions where irritation has led to hypertonicity.
[0014] Atropine is also used to treat intoxication from poisonous mushrooms where the toxic agent is a muscarine-like compound, such as Amanita nuscaria , and as an antidote for intoxication by anti-cholinesterase inhibitors such as the organophosphorous pesticides and “nerve gases.” Organophosphorous agents account for as much as 80% of pesticide related hospital admissions and is considered by the World Health Organization as a widespread global problem, particularly in developing countries. Goodman and Gilman's The Pharmacological Basis of Therapeutics, 9 th ed., pp. 141-154 and 169-170.
SUMMARY OF THE INVENTION
[0015] A buccal aerosol spray or soft bite gelatin capsule using a polar or non-polar solvent has now been developed which provides biologically active compounds for rapid absorption through the oral mucosa, resulting in fast onset of effect.
[0016] The buccal aerosol spray compositions of the present invention, for transmucosal administration of a pharmacologically active compound soluble in a pharmacologically acceptable non-polar solvent comprise in weight % of total composition: pharmaceutically acceptable propellant 5-80%, nonpolar solvent 19-85%, active compound 0.05-50%, suitably additionally comprising, by weight of total composition a taste mask and/or flavoring agent 0.01-10%. Preferably the composition comprises: propellant 10-70%, non-polar solvent 25-89.9%, active compound 0.01-40%, taste mask and/or flavoring agent 1-8%; most suitably propellant 20-70%, non-polar solvent 25-74.75%, active compound 0.25-35%, taste mask and/or flavoring agent 2-7.5%.
[0017] The buccal polar aerosol spray compositions of the present invention, for transmucosal administration of a pharmacologically active compound soluble in a pharmacologically acceptable polar solvent are also administrable in aerosol form driven by a propellant. In this case, the composition comprises in weight % of total composition: aqueous polar solvent 10-97%, active compound 0.1-25%, suitably additionally comprising, by weight of total composition a taste mask and/or flavoring agent 0.05-10% and propellant: 2-10%. Preferably the composition comprises: polar solvent 20-97%, active compound 0.1-15%, taste mask and/or flavoring agent 0.1-5% and propellant 2-5%; most suitably polar solvent 25-97%, active compound 0.2-25%, taste mask and/or flavoring agent 0.1-2.5% and propellant 2-4%.
[0018] In another embodiment, the buccal polar aerosol spray compositions of the present invention for transmucosal administration of a pharmacologically active compound (i.e., those administrable in aerosol form driven by a propellant) comprises a mixture of a polar and a non-polar solvent comprising in weight % of total composition: solvent 10-97%, active compound 0.05-50%, propellant 5-80%, and optionally a taste mask and/or flavoring agent 0.01-10%. Preferably the composition comprises: solvent 20-97%, active compound 0.1-40%, propellant 10-70%, and taste mask and/or flavoring agent 1-8%; most suitably solvent 25-97%, active compound 0.25-35%, propellant 20-70%, and taste mask and/or flavoring agent 2-7.5%. The ratio of the polar solvent to the non-polar solvent can range from about 1:99 to about 99:1, preferable from about 60:40 to about 40:60, and more preferably about 50:50.
[0019] The buccal pump spray composition of the present invention, i.e., the propellant free composition, for transmucosal administration of a pharmacologically active compound wherein said active compound is soluble in a pharmacologically acceptable non-polar solvent comprises in weight % of total composition: non-polar solvent 30-99.69%, active compound 0.005-55%, and suitably additionally, a taste mask and/or flavoring agent 0.1-10%.
[0020] The buccal polar pump spray compositions of the present invention, i.e., the propellant free composition, for transmucosal administration of a pharmacologically active compound soluble in a pharmacologically acceptable polar solvent comprises in weight % of total composition: aqueous polar solvent 30-99.69%, active compound 0.001-60%, suitably additionally comprising, by weight of total composition a taste mask and/or flavoring agent 0.1-10%. Preferably the composition comprises: polar solvent 37-98.58%, active compound 0.005-55%, taste mask and/or flavoring agent 0.5-8%; most suitably polar solvent 60.9-97.06%, active compound 0.01-40%, taste mask and/or flavoring agent 0.75-7.5%.
[0021] In another embodiment, the buccal pump spray composition (i.e., the propellant free composition) for transmucosal administration of a pharmacologically active compound comprises a mixture of a polar solvent and a non-polar solvent comprising in weight % of total composition solvent 30-99.69%, active compound 0.001-60%, and optionally a taste mask and/or flavoring agent 0.1-10%. Preferably the composition comprises: solvent 37-98.58%, active compound 0.005-55%, taste mask and/or flavoring agent 0.5-8%; more preferably the composition comprises solvent 60.9-97.06%, active compound 0.01-40%, and taste mask and/or flavoring agent 0.75-7.5%. The ratio of the polar solvent to the non-polar solvent can range from about 1:99 to about 99:1, preferable about 60:40 to about 40:60, and more preferably about 50:50.
[0022] The soft bite gelatin capsules of the present invention for transmucosal administration of a pharmacologically active compound, at least partially soluble in a pharmacologically acceptable non-polar solvent, having charged thereto a fill composition comprise in weight % of total composition: non-polar solvent 4-99.99%, emulsifier 0-20%, active compound 0.01-80%, provided that said fill composition contains less than 10% of water, suitably additionally comprising, by weight of the composition: taste mask and/or flavoring agent 0.01-10%. Preferably, the soft bite gelatin capsule comprises: non-polar solvent 21.5-99.975%, emulsifier 0-15%, active compound 0.025-70%, tatse mask and/or flavoring agent 1-8%; most suitably: nonpolar solvent 28.5-97.9%, emulsifier 0-10%, active compound 0.1-65.0%, taste mask and/or flavoring agent 2-6%.
[0023] The soft bite polar gelatin capsules of the present invention for transmucosal administration of a pharmacologically active compound, at least partially soluble in a pharmacologically acceptable polar solvent, having charged thereto a composition comprising in weight % of total composition: polar solvent 25-99.89%, emulsifier 0-20%, active compound 0.01-65%, provided that said composition contains less than 10% of water, suitably additionally comprising, by weight of the composition: taste mask and/or flavoring agent 01-10%. Preferably, the soft bite gelatin capsule comprises: polar solvent 37-99.95%, emulsifier 0-15%, active compound 0.025-55%, taste mask and/or flavoring agent 1-8%; most suitably: polar solvent 44-96.925%, emulsifier 0-10%, active compound 0.075-50%, taste mask and/or flavoring agent 2-6%.
[0024] It is an object of the invention to coat the mucosal membranes either with fine droplets of spray containing the active compounds or a solution or paste thereof from bite capsules.
[0025] It is also an object of the invention to administer to the oral mucosa of a mammalian in need of same, preferably man, by spray or bite capsule, a predetermined amount of a biologically active compound by this method or from a soft gelatin capsule.
[0026] A further object is a sealed aerosol spray container containing a composition of the non polar or polar aerosol spray formulation, and a metered valve suitable for releasing from said container a predetermined amount of said composition.
[0027] As the propellant evaporates after activation of the aerosol valve, a mist of fine droplets is formed which contains solvent and active compound.
[0028] The propellant is a non-Freon material, preferably a C 3-8 hydrocarbon of a linear or branched configuration. The propellant should be substantially non-aqueous. The propellant produces a pressure in the aerosol container such that under expected normal usage it will produce sufficient pressure to expel the solvent from the container when the valve is activated but not excessive pressure such as to damage the container or valve seals.
[0029] The non-polar solvent is a non-polar hydrocarbon, preferably a C 7-18 hydrocarbon of a linear or branched configuration, fatty acid esters, and triglycerides, such as miglyol. The solvent must dissolve the active compound and be miscible with the propellant, i.e., solvent and propellant must form a single phase at a temperature of 0-40° C. a pressure range of between 1-3 atm.
[0030] The polar and non-polar aerosol spray compositions of the invention are intended to be administered from a sealed, pressurized container. Unlike a pump spray, which allows the entry of air into the container after every activation, the aerosol container of the invention is sealed at the time of manufacture. The contents of the container are released by activation of a metered valve, which does not allow entry of atmospheric gasses with each activation. Such containers are commercially available.
[0031] A further object is a pump spray container containing a composition of the pump spray formulation, and a metered valve suitable for releasing from said container a predetermined amount of said composition.
[0032] A further object is a soft gelatin bite capsule containing a composition of as set forth above. The formulation may be in the form of a viscous solution or paste containing the active compounds. Although solutions are preferred, paste fills may also be used where the active compound is not soluble or only partially soluble in the solvent of choice. Where water is used to form part of the paste composition, it should not exceed 10% thereof. (All percentages herein are by weight unless otherwise indicated.)
[0033] The polar or non-polar solvent is chosen such that it is compatible with the gelatin shell and the active compound. The solvent preferably dissolves the active compound. However, other components wherein the active compound is not soluble or only slightly soluble may be used and will form a paste fill.
[0034] Soft gelatin capsules are well known in the art. See, for example, U.S. Pat. No. 4,935,243, Borkan et al., for its teaching of such capsules. The capsules of the present invention are intended to be bitten into to release the low viscosity solution or paste therein, which will then coat the buccal mucosa with the active compounds. Typical capsules, which are swallowed whole or bitten and then swallowed, deliver the active compounds to the stomach, which results in significant lag time before maximum blood levels can be achieved or subject the compound to a large first pass effect. Because of the enhanced absorption of the compounds through the oral mucosa and no chance of a first pass effect, use of the bite capsules of the invention will eliminate much of the lag time, resulting in hastened onset of biological effect. The shell of a soft gelatin capsule of the invention may comprise, for example: gelatin: 50-75%, glycerin 20-30%, colorants 0.5-1.5%, water 5-10%, and sorbitol 2-10%.
[0035] The active compound may include, biologically active peptides, central nervous system active amines, sulfonyl ureas, antibiotics, antifingals, antivirals, sleep inducers, antiasthmatics, bronchial dilators, antiemetics, histamine H-2 receptor antagonists, barbiturates, prostaglandins and neutraceuticals.
[0036] The active compounds may also include antihistamines, alkaloids, hormones, benzodiazepines and narcotic analgesics. While not limited thereto, these active compounds are particularly suitable for non-polar pump spray formulation and application.
[0037] The active compounds may also include anti-diuretics, anti-muscle spasm agents, anti-spasmodics, agents for treating urinary incontinence, anti-diarrheal agents, agents for treating nausea and/or vomiting, smooth muscle contractile agents, anti-secretory agents, enzymes, anti-diuretics, anti-ulcerants, bile acid replacement and/or gallstone solubilizing drugs, or mixtures thereof.
[0038] In one embodiment, the active compound is atropine or a pharmaceutically acceptable salt thereof.
BRIEF DESCRIPTION OF THE DRAWING
[0039] [0039]FIG. 1. is a schematic diagram showing routes of absorption and processing of pharmacologically active substances in a mammalian system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] The preferred active compounds of the present invention are in an ionized, salt form or as the free base of the pharmaceutically acceptable salts thereof (provided, for the aerosol or pump spray compositions, they are soluble in the spray solvent). These compounds are soluble in the non-polar solvents of the invention at useful concentrations or can be prepared as pastes at useful concentrations. These concentrations may be less than the standard accepted dose for these compounds since there is enhanced absorption of the compounds through the oral mucosa. This aspect of the invention is especially important when there is a large (40-99.99%) first pass effect.
[0041] As propellants for the non polar sprays, propane, N-butane, iso-butane, N-pentane, iso-pentane, and neo-pentane, and mixtures thereof may be used. N-butane and iso-butane, as single gases, are the preferred propellants. It is permissible for the propellant to have a water content of no more than 0.2%, typically 0.1-0.2%. All percentages herein are by weight unless otherwise indicated. It is also preferable that the propellant be synthetically produced to minimize the presence of contaminants which are harmful to the active compounds. These contaminants include oxidizing agents, reducing agents, Lewis acids or bases, and water. The concentration of each of these should be less than 0.1%, except that water may be as high as 0.2%.
[0042] Suitable non-polar solvents for the capsules and the non-polar sprays include (C 2 -C 24 ) fatty acid (C 2 -C 6 ) esters, C 7 -C 18 hydrocarbon, C 2 -C 6 alkanoyl esters, and the triglycerides of the corresponding acids. When the capsule fill is a paste, other liquid components may be used instead of the above low molecular weight solvents. These include soya oil, corn oil, other vegetable oils.
[0043] As solvents for the polar capsules or sprays there may be used low molecular weight polyethyleneglycols (PEG) of 400-1000 Mw (preferably 400-600), low molecular weight (C 2 -C 8 ) mono and polyols and alcohols of C 7 -C 18 linear or branch chain hydrocarbons, glycerin may also be present and water may also be used in the sprays, but only in limited amount in the capsules.
[0044] It is expected that some glycerin and water used to make the gelatin shell will migrate from the shell to the fill during the curing of the shell. Likewise, there may be some migration of components from the fill to the shell during curing and even throughout the shelf-life of the capsule.
[0045] Therefore, the values given herein are for the compositions as prepared, it being within the scope of the invention that minor variations will occur.
[0046] The preferred flavoring agents are synthetic or natural oil of peppermint, oil of spearmint, citrus oil, fruit flavors, sweeteners (sugars, aspartame, saccharin, etc.), and combinations thereof.
[0047] The compositions may further include a taste mask. The term “taste mask” as used herein means an agent that can hide or minimize an undesirable flavor such as a bitter or sour flavor. A representative taste masks is a combination of vanillin, ethyl vanillin, maltol, iso-amyl acetate, ethyl oxyhydrate, anisic aldehyde, and propylene glycol (commercially available as “PFC 9885 Bitter Mask” from Pharmaceutical Flavor Clinic of Camden, N.J.). A taste mask in combination with a flavoring agent is particularly advantageous when the active compound is an alkaloid since alkaloids often have a bitter taste.
[0048] The active substances include the active compounds selected from the group consisting of cyclosporine, sermorelin, octreotide acetate, calcitonin-salmon, insulin lispro, sumatriptan succinate, clozepine, cyclobenzaprine, dexfenfluramine hydrochloride, glyburide, zidovudine, erythromycin, ciprofloxacin, ondansetron hydrochloride, dimenhydrinate, cimetidine hydrochloride, famotidine, phenytoin sodium, phenytoin, carboprost thromethamine, carboprost, diphenhydramine hydrochloride, isoproterenol hydrochloride, terbutaline sulfate, terbutaline, theophylline, albuterol sulfate and neutraceuticals, that is to say nutrients with pharmacological action such as but not limited to carnitine, valerian, echinacea, and the like.
[0049] In another embodiment, the active compound is an anti-diuretic, anti-muscle spasm agent, anti-spasmodic, agent for treating urinary incontinence, anti-diarrheal agent, agent for treating nausea and/or vomiting, smooth muscle contractile agent, anti-secretory agent, enzyme, anti-diuretic, anti-ulcerant, bile acid replacement and/or gallstone solubilizing drug, or a mixture thereof
[0050] In one embodiment the active compound is an anti-diuretic. Suitable anti-diuretics for use in the buccal sprays of the invention include, but are not limited to, acetazolamide, benzthiazide, bendroflumethazide, bumetanide, chlorthalidone, chlorothiazide, ethacrynic acid, furosemide, hydrochlorothiazide, hydroflumethiazide, methyclothiazide, polythiazide, quinethazone, spironolactone, triamterene, torsemide, trichlomethiazide, and mixtures thereof.
[0051] In one embodiment the active compound is an anti-muscle spasm agent. Suitable anti-muscle spasm agents for use in the buccal sprays of the invention include, but are not limited to, baclofen, botulinum toxin, carisoprodol, chlorphenesin, chlorzoxazone, cyclobenzaprine, dantrolene, diazepam, metaxalone, methocarbamol, orphenadrine, tizanidine, and mixtures thereof.
[0052] In one embodiment the active compound is an anti-spasmodic. Suitable anti-spasmodics for use in the buccal sprays of the invention include, but are not limited to, atropine, baclofen, dicyclomine, hyoscine, propatheline, oxybutynin, S-oxybutynin, tizanidine, and mixtures thereof.
[0053] In one embodiment the active compound is an agent for treating urinary incontinence. Suitable agents for treating urinary incontinence for use in the buccal sprays of the invention include, but are not limited to, darifenacin, vamicamide, detrol, ditropan, imipramine, and mixtures thereof.
[0054] In one embodiment the active compound is an anti-diarrheal agent. Suitable anti-diarrheal agents for use in the buccal sprays of the invention include, but are not limited to, ondansetron, palnosetron, tropisetron, attapulgite, atropine, bismuth, diphenoxylate, loperamide, and mixtures thereof.
[0055] In one embodiment the active compound is an agent for treating nausea and/or vomiting. Suitable agents for treating nausea and/or vomiting for use in the buccal sprays of the invention include, but are not limited to, alosetron, dolasetron, granisetron, meclizine, metoclopramide, ondansetron, palnosetron, prochloperazine, promethazine, trimethobenzamiode, tropisetron, and mixtures thereof.
[0056] In one embodiment the active compound is a smooth muscle contractile agent. A suitable smooth muscle contractile agents for use in the buccal sprays of the invention includes, but is not limited to hyoscine.
[0057] In one embodiment the active compound is an anti-secretory agent. Suitable anti-secretory agents for use in the buccal sprays of the invention include, but are not limited to, esomeprazole, lansoprazole, omeprazole, pantoprazole, rabeprazole, tenetoprazole, ecabet, misoprostol, teprenone, and mixtures thereof.
[0058] In one embodiment the active compound is an enzyme. Suitable enzymes for use in the buccal sprays of the invention include, but are not limited to, alpha-galactosidase, alpha-L-iduronidase, imiglucerase/alglucerase, amylase, lipase, protease, pancreatin, olsalazine, and mixtures thereof.
[0059] In one embodiment the active compound is an anti-diuretic. Suitable anti-diuretics for use in the buccal sprays of the invention include, but are not limited to, desmopressin, oxytocin, and mixtures thereof.
[0060] In one embodiment the active compound is an anti-ulcerant. Suitable anti-ulcerants for use in the buccal sprays of the invention include, but are not limited to, cimetidine, ranitidine, famotidine, misoprostol, sucralfate, pantoprazole, lansoprazole, omeprazole, and mixtures thereof.
[0061] In one embodiment the active compound is a bile acid replacement and/or gallstone solubilizing drug. A suitable bile acid replacement and/or gallstone solubilizing drug for use in the buccal sprays of the invention includes, but is not limited to ursodiol.
[0062] In a another embodiment, the active compound is atropine or a pharmaceutically acceptable salt thereof. In one embodiment, the active compound is atropine sulfate.
[0063] Typically, when atropine is the active compound the buccal spray contains from about 0.2 to 20 weight/weight (w/w) percent atropine, more preferably 1 to 15 w/w percent atropine, and most preferably 2 to 10 w/w percent atropine.
[0064] The invention further relates to a method of blocking the effects of acetylcholine at muscarine receptors in a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof.
[0065] The invention further relates to a method of treating an ulcer in a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof.
[0066] The invention further relates to a method of treating a disorder resulting from excessive smooth muscle contraction in the gastrointestinal tract in a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof.
[0067] The invention further relates to a method of treating irritable-bowel syndrome in a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof.
[0068] The invention further relates to a method of treating intestinal hypermotility and increased frequency of stools associated with administration of an antihypertensive agent in a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof.
[0069] The invention further relates to a method of treating diarrhea associated with mild dysentery or diverticulitis in a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof.
[0070] The invention further relates to a method of reducing excessive salivation in a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof. In another embodiment, the excessive salivation is caused by heavy metal poisoning. In another embodiment, the excessive salivation is caused by parkinsonism.
[0071] The invention further relates to a method of reducing secretions in the upper and lower respiratory tract of a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof. In one embodiment, the secretions in the upper and lower respiratory tract are caused by acute rhinitis, such as is associated with coryza or hay fever.
[0072] The invention further relates to a method of treating parkinsonism in a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof.
[0073] The invention further relates to a method of treating cardiovascular collapse resulting from the administration of a choline ester or an inhibitor of cholinesterase in a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof.
[0074] The invention further relates to a method of antagonizing vagal cardiac slowing in a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof.
[0075] The invention further relates to a method of treating acute myocardial infarction where excessive vagal tone causes sinus or nodal bradycardia or atrioventricular block in a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof.
[0076] The invention further relates to a method of administering anaesthesia to a patient comprising pre-medicating the patient with atropine before administering the anaesthesia by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof. In one embodiment, pre-medicating the patient decreases bronchial and salivary secretions; blocks bradycardia associated with various anesthetics, such as halothane, suxamethonium, and neostigmine; or prevents bradycardia from excessive vagal stimulation.
[0077] The invention further relates to a method of relaxing muscles in the gastrointestinal tract of a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof.
[0078] The invention further relates to a method of treating renal colic in a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof. In one embodiment, the method for treating renal cholic further comprises administering an opioid.
[0079] The invention further relates to a method of treating intoxication from exposure to an anticholinesterase agent in a patient by spraying the oral mucosa of the patient with a therapeutically effective amount of a buccal spray comprising atropine or a pharmaceutically acceptable salt thereof.
[0080] The term “anticholinesterase agent” as used herein means any agent that inhibits cholinesterase, i.e., the enzyme responsible for terminating the action of acetylcholinesterase at the junction of various cholinergic nerve endings ( Goodman and Gilman's The Pharmacological Basis of Therapeutics, 9 th ed., pp. 161.)
[0081] Representative anticholinesterase agents include, but are not limited to tetraethylpyrophosphate (“TEPP”), diethoxyphosphinylthiocholine iodide (echothiophate, phospholine iodide), O,O-diethyl O-(4-nitrophenyl)-phosphorothioate (parathion), O,O-dimethyl S-(1, 2-dicarbethoxyethyl) phosphorodithioate (malathion), isopropyl methylphosphonofluoridate (sarin, GB), pinacolyl methylphosphonofluoridate (soman), ethyl N-dimethylphosphoramidocyanidate (tabun), O,O-diethyl2-isopropyl-6-methyl-4-pyrimidinyl phosphorothioate (dimpylate, diazinon), O,O, dimethyl O-4-methylthio-m-tolyl phosphorothioate (fenthion), O,O-diethyl O-(4-nitrophenyl)-phosphate (paraoxon, mintacol), diisopropyl phosphorofluoridate (diisopropyl fluorophosphate, DFP), 1-napthyl N-methylcarbamate (carbaril, carbaryl, sevin), and 2-isopropoxyphenyl N-methylcarbamate (Baygon).
[0082] Anticholinesterase agents are known to be used as nerve gases and bioterrorism agents. Buccal sprays containing atropine or a pharmaceutically acceptable salt thereof can be an effective antidote to nerve gases.
[0083] The formulations of the present invention comprise an active compound or a pharmaceutically acceptable salt thereof. The term “pharmaceutically acceptable salts” refers to salts prepared from pharmaceutically acceptable non-toxic acids or bases including organic and inorganic acids or bases.
[0084] When an active compound of the present invention is acidic, salts may be prepared from pharmaceutically acceptable non-toxic bases. Salts derived from all stable forms of inorganic bases include aluminum, ammonium, calcium, copper, iron, lithium, magnesium, manganese, potassium, sodium, zinc, etc. Particularly preferred are the ammonium, calcium, magnesium, potassium, and sodium salts. Salts derived from pharmaceutically acceptable organic non-toxic bases include salts of primary, secondary, and tertiary amines, substituted amines including naturally occurring substituted amines, cyclic amines and basic ion-exchange resins such as arginine, betaine, caffeine, choline, N,N dibenzylethylenediamine, diethylamine, 2-diethylaminoethanol, 2-dimethyl-aminoethanol, ethanolamine, ethylenediamine, N-ethylmorpholine, N-ethylpiperidine, glucamine, glucosamine, histidine, isopropylamine, lysine, methyl-glucosamine, morpholine, piperazine, piperidine, polyarnine resins, procaine, purine, theobromine, triethylamine, trimethylamine, tripropylamine, etc.
[0085] When an active compound of the present invention is basic, salts may be prepared from pharmaceutically acceptable non-toxic acids. Such acids include acetic, benzenesulfonic, benzoic, camphorsulfonic, citric, ethane-sulfonic, fumaric, gluconic, glutamic, hydrobromic, hydrochloric, isethionic, lactic, maleic, mandelic, methanesulfonic, mucic, nitric, pamoic, pantothenic, phosphoric, succinic, sulfuric, tartaric, p-toluenesulfonic, etc. Particularly preferred are citric, hydrobromic, maleic, phosphoric, sulfuric, and tartaric acids.
[0086] In the discussion of methods of treatment herein, reference to the active compounds is meant to also include the pharmaceutically acceptable salts thereof. While certain formulations are set forth herein, the actual amounts to be administered to the mammal or man in need of same are to be determined by the treating physician.
[0087] The invention is further defined by reference to the following examples, which are intended to be illustrative and not limiting.
[0088] The following are examples of certain classes. All values unless otherwise specified are in weight percent.
EXAMPLES
Example 1
Biologically Active Peptides Including Peptide Hormones
[0089] A. Cyclosporine Lingual Spray
most Amounts preferred amount preferred amount cyclosporine 5-50 10-35 15-25 water 5-20 7.5-50 9.5-12 ethanol 5-60 7.5-50 10-20 polyethylene glycol 20-60 30-45 35-40 flavors 0.1-5 1-4 2-3
[0090] B. Cyclosporine Non-Polar Lingual Spray
preferred most Amounts amount preferred amount cyclosporine 1-50 3-40 5-30 Migylol 20 25 30-40 Polyoxyethylated castor oil 20 25 30-40 Butane 25-80 30-70 33-50 flavors 0.1-5 1-4 2-3
[0091] C. Cyclosporine Non-Polar Bite Capsule
Amounts preferred amount most preferred amount cyclosporine 1-35 5-25 10-20 olive oil 25-60 35-55 30-45 polyoxyethylated 25-60 35-55 30-45 oleic glycerides flavors 0.1-5 1-4 2-3
[0092] D. Cyclosporine Bite Capsule
most Amounts preferred amount preferred amount cyclosporine 5-50 10-35 15-25 polyethylene glycol 20-60 30-45 35-40 glycerin 5-30 7.5-25 10-20 propylene glycol 5-30 7.5-25 10-20 flavors 0.1-10 1-8 3-6
[0093] E. Sermorelin (as the Acetate) Lingual Spray
preferred Amounts amount most preferred sermorelin (as the acetate) .01-5 .1-3 .2-1.0 mannitol 1-25 5-20 10-15 monobasic sodium phosphate, 0.1-5 1-31 .5-2.5 dibasic sodium phosphate water 0.01-5 .05-3 0.1-0.5 ethanol 5-30 7.5-25 9.5-15 polyethylene glycol 20-60 30-45 35-40 propylene glycol 5-25 10-20 12-17 flavors 0.1-5 1-4 2-3
[0094] F. Octreotide Acetate (Sandostatin) Lingual Spray
most Amounts preferred amount preferred amount octreotide acetate 0.001-0.5 0.005-0.250 0.01-0.10 acetic acid 1-10 2-8 4-6 sodium acetate 1-10 2-8 4-6 sodium chloride 3-30 .5-25 15-20 flavors 0.1-5 0.5-.4 2-3 ethanol 5-30 7.5-20 9.5-15 water 15-95 35-90 65-85 flavors 0.1-5 1-4 2-3
[0095] G. Calcitonin-Salmon Lingual Spray
most Amounts preferred amount preferred amount calcitonin-salmon 0.001-5 0.005-2 01-1.5 ethanol 2-15 3-10 7-9.5 water 30-95 50-90 60-80 polyethylene glycol 2-15 3-10 7-9.5 sodium chloride 2.5-20 5-15 10-12.5 flavors 0.1-5 1-4 2-3
[0096] H. Insulin Lispro, Lingual Spray
most preferred Amounts preferred amount amount insulin 20-60 4-55 5-50 glycerin 0.1-10 0.25-5 0.1-1.5 dibasic sodium 1-15 2.5-10 4-8 phosphate m-cresol, 1-25 5-25 7.5-12.5 zinc oxide 0.01-0.25 .05-0.15 0.075-0.10 m-cresol 0.1-1 0.2-0.8 0.4-0.6 phenol trace amounts trace amounts trace amounts ethanol 5-20 7.5-15 9-12 water 30-90 40-80 50-75 propylene glycol 5-20 7.5-15 9-12 flavors 0.1-5 0.5-3 0.75-2
Example 2
CNS Active Amines and their Salts: Including but not Limited to Tricyclic Amines, GABA Analogues, Thiazides, Phenothiazine Derivatives, Serotonin Antagonists and Serotonin Reuptake Inhibitors
[0097] A. Sumatriptan Succinate Lingual Spray
most Amounts preferred amount preferred amount sumatriptan succinate 0.5-30 1-20 10-15 ethanol 5-60 7.5-50 10-20 propylene glycol 5-30 7.5-20 10-15 polyethylene glycol 0-60 30-45 35-40 water 5-30 7.5-20 10-15 flavors 0.1-5 1-4 2-3
[0098] B. Sumatriptan Succinate Bite Capsule
most Amounts preferred amount preferred amount sumatriptan succinate 0.01-5 0.05-3.5 0.075-1.75 polyethylene glycol 25-70 30-60 35-50 glycerin 25-70 30-60 35-50 flavors 0.1-10 1-8 3-6
[0099] C. Clozepine Lingual Spray
most Amounts preferred amount preferred amount clozepine 0.5-30 1-20 10-15 ethanol 5-60 7.5-50 10-20 propylene glycol 5-30 7.5-20 10-15 polyethylene glycol 0-60 30-45 35-40 water 5-30 7.5-20 10-15 flavors 0.1-5 1-4 2-3
[0100] D. Clozepine Non-Polar Lingual Spray with Propellant
Amounts preferred amount most preferred amount clozepine 0.5-30 1-20 10-15 Migylol 20-85 25-70 30-40 Butanol 5-80 30-75 60-70 flavors 0.1-5 1-4 2-3
[0101] E. Clozepine Non-Polar Lingual Spray without Propellant
Amounts preferred amount most preferred amount clozepine 0.5-30 1-20 10-15 Migylol 70-99.5 80-99 85-90 flavors 0.1-5 1-4 2-3
[0102] F. Cyclobenzaprine Non-Polar Lingual Spray
most Amounts preferred amount preferred amount cyclobenzaprine (base) 0.5-30 1-20 10-15 Migylol 20-85 25-70 30-40 Iso-butane 15-80 30-75 60-70 flavors 0.1-5 1-4 2-3
[0103] G. Dexfenfluramine Hydrochloride Lingual Spray
most Amounts preferred amount preferred amount dexfenfluramine Hcl 5-30 7.5-20 10-15 ethanol 5-60 7.5-50 10-20 propylene glycol 5-30 7.5-20 10-15 polyethylene glycol 0-60 30-45 35-40 water 5-30 7.5-20 10-15 flavors 0.1-5 1-4 2-3
Example 3
Sulfonylureas
[0104] A. Glyburide Lingual Spray
most Amounts preferred amount preferred amount glyburide 0.25-25 0.5-20 0.75-15 ethanol 5-60 −7.5-50 10-20 propylene glycol 5-30 7.5-20 10-15 polyethylene glycol 0-60 30-45 35-40 water 2.5-30 5-20 6-15 flavors 0.1-5 1-4 2-3
[0105] B. Glyburide Non-Polar Bite Capsule
most Amounts preferred amount preferred amount glyburide 0.01-10 0.025-7.5 0.1-4 olive oil 30-60 35-55 30-50 polyoxyethylated oleic 30-60 35-55 30-50 glycerides flavors 0.1-5 1-4 2-3
Example 4
Antibiotics Anti-Fungals and Anti-Virals
[0106] A. Zidovudine [Formerly Called Azidothymidine (AZT) (Retrovir)] Non-Polar Lingual Spray
(AZT) (Retrovir)] non-polar lingual spray Amounts preferred amount most preferred amount zidovudine 10-50 15-40 25-35 Soya oil 20-85 25-70 30-40 Butane 15-80 30-75 60-70 flavors 0.1-5 1-4 2-3
[0107] B. Erythromycin Bite Capsule Bite Capsule
most preferred Amounts preferred amount amount erythromycin 25-65 30-50 35-45 polyoxyethylene glycol 5-70 30-60 45-55 glycerin 5-20 7.5-15 10-12.5 flavors 1-10 2-8 3-6
[0108] C. Ciprofloxacin Hydrochloride Bite Capsule
preferred most preferred Amounts amount amount ciprofloxacin hydrochloride 25-65 35-55 40-50 glycerin 5-20 7.5-15 10-12.5 polyethylene glycol 120-75 30-65 40-60 flavors 1-10 2-8 3-6
[0109] D. Zidovudine [Formerly Called Azidothymidine (AZT) (Retrovir)] Lingual Spray
most preferred preferred Amounts amount amount zidovudine 10-50 15-40 25-35 water 30-80 40-75 45-70 ethanol 5-20 7.5-15 9.5-12.5 polyethylene glycol 5-20 7.5-15 9.5-12.5 flavors 0.1-5 1-4 2-3
Example 5
Anti-Emetics
[0110] A. Ondansetron Hydrochloride Lingual Spray
most preferred preferred Amounts amount amount ondansetron hydrochloride 1-25 2-20 2.5-15 citric acid monohydrate 1-10 2-8 2.5-5 sodium citrate dihydrate 0.5-5 1-4 1.25-2.5 water 1-90 5-85 10-75 ethanol 5-30 7.5-20 9.5-15 propylene glycol 5-30 7.5-20 9.5-15 polyethylene glycol 5-30 7.5-20 9.5-15 flavors 1-10 3-8 5-7.5
[0111] B. Dimenhydrinate Bite Capsule
most preferred preferred Amounts amount amount dimenhydrinate 0.5-30 2-25 3-15 glycerin 5-20 7.5-15 10-12.5 polyethylene glycol 45-95 50-90 55-85 flavors 1-10 2-8 3-6
[0112] C. Dimenhydrinate Polar Lingual Spray
most preferred preferred Amounts amount amount dimenhydrinate 3-50 4-40 5-35 water 5-90 10-80 15-75 ethanol 1-80 3-50 5-10 polyethylene glycol 1-80 3-50 5-15 sorbitol 0.1-5 0.2-40 0.4-1.0 aspartame 0.01-0.5 0.02-0.4 0.04-0.1 flavors 0.1-5 1-4 2-3
Example 6
Histamine H-2 Receptor Antagonists
[0113] A. Cimetidine Hydrochloride Bite Capsule t, 0250
[0114] B. Famotidine Lingual Spray
most preferred preferred Amounts amount amount famotidine 1-35 5-30 7-20 water 2.5-25 3-20 5-10 L-aspartic acid 0.1-20 1-15 5-10 polyethylene glycol 20-97 30-95 50-85 flavors 0.1-10 1-7.5 2-5
[0115] C. Famotidine Non-Polar Lingual Spray
most preferred preferred Amounts amount amount famotidine 1-35 5-30 7-20 Soya oil 10-50 15-40 15-20 Butane 1 5-80 30-75 45-70 polyoxyethylated 10-50 15-40 15-20 oleic glycerides flavors 0.1-5 1-4 2-3
Example 7
Barbiturates
[0116] A. Phenytoin Sodium Lingual Spray
most preferred preferred Amounts amount amount phenytoin sodium 10-60 15-55 20-40 water 2.5-25 3-20 5-10 ethanol 5-30 7.5-20 9.5-15 propylene glycol 5-30 7.5-20 9.5-15 polyethylene glycol 5-30 7.5-20 9.5-15 flavors 1-10 3-8 5-7.5
[0117] B. Phenytoin Non-Polar Lingual Spray
most preferred preferred Amounts amount amount phenytoin 5-45 10-40 15-35 migylol 10-50 15-40 15-20 Butane 15-80 30-75 60-70 polyoxyethylated 10-50 15-40 15-20 oleic glycerides flavors 0.1-10 1-8 5-7.5
Example 8
Prostaglandins
[0118] A. Carboprost Thromethamine Lingual Spray
most preferred preferred Amounts amount amount carboprost thromethamine 0.05-5 0.1-3 0.25-2.5 water 50-95 60-80 65-75 ethanol 5-20 7.5-15 9.5-12.5 polyethylene glycol 5-20 7.5-15 9.5-12.5 sodium chloride 1-20 3-15 4-8 flavors 0.1-5 1-4 2-3
[0119] B. Carboprost Non-Polar Lingual Spray
Amounts preferred amount most preferred amount carboprost 0.05-5 0.1-3 0.25-2.5 migylol 25-50 30-45 35-40 Butane 5-60 10-50 20-35 polyoxyethylated 25-50 30-45 35-40 oleic glycerides flavors 0.1-10 1-8 5-7.5
Example 9
Neutraceuticals
[0120] A. Carnitine as Bite Capsule (Contents are a Paste)
Amounts preferred amount most preferred amount carnitine 6-80 30-70 45-65 fumarate soya oil 7.5-50 10-40 12.5-35 soya lecithin 0.001-1.0 0.005-0.5 .01-0.1 Soya fats 7.5-50 10-40 12.5-35 flavors 1-10 2-8 3-6
[0121] B. Valerian as Lingual Spray
Amounts preferred amount most preferred amount valerian extract 0.1-10 0.2-7 0.25-5 water 50-95 60-80 65-75 ethanol 5-20 7.5-15 9.5-12.5 polyethylene 5-20 7.5-15 9.5-12.5 glycol flavors 1-10 2-8 3-6
[0122] C. Echinacea as Bite Capsule
Amounts preferred amount most preferred amount echinacea 30-85 40-75 45-55 extract soya oil 7.5-50 10-40 12.5-35 soya lecithin 0.001-1.0 0.005-0.5 .01-0.1 Soya fats 7.5-50 10-40 12.5-35 flavors 1-10 2-8 3-6
[0123] D. Mixtures of Ingredients
Amounts preferred amount most preferred amount magnesium oxide 15-40 20-35 25-30 chromium 0.01-1.0 0.02-0.5 .025-0.75 picolinate folic acid .025-3.0 0.05-2.0 0.25-0.5 vitamin B-12 0.01-1.0 0.02-0.5 .025-0.75 vitamin E 15-40 20-35 25-30 Soya oil 10-40 12.5-35 15-20 soya lecithin 0.1-5 0.2-4 0.5-1.5 soya fat 10-40 15-35 17.5-20
Example 10
Sleep Inducers (Also CNS Active Amine)
[0124] A. Diphenhydramine Hydrochloride Lingual Spray
most preferred Amounts preferred amount amount diphenhydramine 3-50. 4-40 5-35 HCl water 5-90 10-80 50-75 ethanol 1-80 3-50 5-10 polyethylene 1-80 3-50 5-15 glycol Sorbitol 0.1-5 0.2-4 0.4-1.0 aspartame 0.01-0.5 0.02-0.4 0.04-0.1 flavors 0.1-5 1-4 2-3
Example 11
Anti-Asthmatics-Bronchodilators
[0125] A. Isoproterenol Hydrochloride as Polar Lingual Spray
Amounts preferred amount most preferred amount isoproterenol 0.1-10 0.2-7.5 0.5-6 Hydrochloride water 5-90 10-80 50-75 ethanol 1-80 3-50 5-10 polyethylene 1-80 3-50 5-15 glycol Sorbitol 0.1-5 0.2-4 0.4-1.0 aspartame 0.01-0.5 0.02-0.4 0.04-0.1 flavors 0.1-5 1-4 2-3
[0126] B. Terbutaline Sulfate as Polar Lingual Spray
Amounts preferred amount most preferred amount terbutaline sulfate 0.1-10 0.2-7.5 0.5-6 water 5-90 10-80 50-75 ethanol 1-10 2-8 2.5-5 Sorbitol 0.1-5 0.2-4 0.4-1.0 aspartame 0.01-0.5 0.02-0.4 0.04-0.1 flavors 0.1-5 1-4 2-3
[0127] C. Terbutaline as Non-Polar Lingual Spray
Amounts preferred amount most preferred amount terbutaline 0.1-10 0.2-7.5 0.5-6 migylol 25-50 30-45 35-40 isobutane 5-60 10-50 20-35 polyoxyethylated 25-50 30-45 35-40 oleic glycerides flavors 0.1-0.1 1-8 5-7.5
[0128] D. Theophylline Polar Bite Capsule
Amounts preferred amount most preferred amount theophylline 5-50 10-40 15-30 polyethylene 20-60 25-50 30-40 glycol glycerin 25-50 35-45 30-40 propylene glycol 25-50 35-45 30-40 flavors 0.1-5 1-4 2-3
[0129] E. Albuterol Sulfate as Polar Lingual Spray
most preferred preferred Amounts amount amount albuterol sulfate 0.1-10 0.2-7.5 0.5-6 water 5-90 10-80 50-75 ethanol 1-10 2-8 2.5-5 Sorbitol 0.1-5 0.2-4 0.4-1.0 aspartame 0.01-0.5 0.02-0.4 0.04-0.1 flavors 0.1-5 1-4 2-3
Example 12
Polar Solvent Formulations Using a Propellant
[0130] A. Sulfonylurea
Most- Preferred Preferred Amount Amount Amount glyburide 0.1-25% 0.5-15% 0.6-10% Ethanol 40-99% 60-97% 70-97% Water 0.01-5% 0.1-4% 0.2-2% Flavors 0.05-10% 0.1-5% 0.1-2.5% Propellant 2-10% 3-5% 3-4%
[0131] B. Prostaglandin E (Vasodilator)
Most- Preferred Preferred Amount Amount Amount prostaglandin E 1 0.01-10% 0.1-5% 0.2-3% Ethanol 10-90% 20-75% 25-50% Propylene glycol 1-90% 5-80% 10-75% Water 0.01-5% 0.1-4% 0.2-2% Flavors 0.05-10% 0.1-5% 0.1-2.5% Propellant 2-10% 3-5% 3-4%
[0132] C. Promethazine (Antiemetic, Sleep Inducer, and CNS Active Amine)
Most- Preferred Preferred Amount Amount Amount promethazine 1-25% 3-15% 5-12% Ethanol 10-90% 20-75% 25-50% Propylene glycol 1-90% 5-80% 10-75% Water 0.01-5% 0.1-4% 0.2-2% Flavors 0.05-10% 0.1-5% 0.1-2.5% Propellant 2-10% 3-5% 3-4%
[0133] D. Meclizine
Most- Preferred Preferred Amount Amount Amount meclizine 1-25% 3-15% 5-12% Ethanol 1-15% 2-10% 3-6 Propylene glycol 20-98% 5-90% 10-85% Water 0.01-5% 0.1-4% 0.2-2% Flavors 0.05-10% 0.1-5% 0.1-2.5% Propellant 2-10% 3-5% 3-4%
Example 13
Atropine Formulations
[0134] A. Propellant Free Atropine Formulations in a Polar Solvent:
Most- Preferred Preferred Amount Amount Amount % w/w % w/w % w/w Atropine sulfate 0.2-20 1-15 2-10 Propylene glycol 30-65 35-60 30-50 ethylenediamine- 0.005-0.1 0.0075-0.05 0.01-0.025 tetraacetate (EDTA) Benzalkonium chloride 0.005-0.1 0.0075-0.05 0.01-0.025 Flavoring agent 0-15 0.15-10 0.1-5 glycerol 0.1-2 0.2-1 0.3-0.6 Tween 80 0.1-2 0.2-1 0.3-0.6 water 0.5-10 0.8-5 1-3 ethanol Qs to 100 mL 100 mL 100 mL
[0135] B. A Propellant Free Atropine Formulation in a Polar Solvent has the Following Formula:
Amount % w/w Atropine sulfate 5 Propylene glycol 50 Ethylenediamine- 0.02 tetraacetate (EDTA) Benzalkonium chloride 0.02 Flavoring agent 0.1 Glycerol 0.5 Tween 80 0.5 Water 2 Ethanol Qs to 100 mL
[0136] C. An Atropine Formulation in a Non-Polar Solvent with a Propellant can be made According to the Following Formula:
Percent Component (w/w) Atropine 5% Miglyol 810 40% Flavoring agent 1% Butane to 100 g
[0137] D. An Atropine Formulation in a Polar Solvent with a Propellant has the Following Formula:
Percent Component (w/w) Atropine sulfate 5% Ethanol 40% Flavoring agent 1% Butane 54%
[0138] E. A Propellant Free Atropine Formulation in a Non-Polar Solvent can be made According to the Following Formula:
Percent Component (w/w) Atropine 5% Miglyol 46% Flavoring agent 1% Light liquid paraffin 48%
[0139] F. A Propellant Free Atropine Formulation in a Mixture of a Non-Polar Solvent and a Polar Solvent has the Following Formula:
Percent Component (w/w) Atropine 5 Miglyol 46 Flavor 1 Ethanol Qs to 100
[0140] G. Atropine Formulation in a Mixture of a Non-Polar Solvent and a Polar Solvent with a Propellant has the Following Formula:
Component Percent (w/w) Atropine Sulfate 5 Ethanol 30 Flavor 1 Miglyol 10 Butane 54
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Buccal aerosol sprays or capsules using polar and non-polar solvent have now been developed which provide atropine for rapid absorption through the oral mucosa, resulting in fast onset of effect. The buccal polar compositions of the invention comprise formulation I: aqueous polar solvent, atropine, and optional taste mask and/or flavoring agent; formulation II: aqueous polar solvent, atropine, optionally flavoring agent, and propellant; formulation III: non-polar solvent, atropine, and optional flavoring agent; and formulation IV: non-polar solvent, atropine, optional flavoring agent, and propellant; formulation V: a mixture of a polar and a non-polar solvent, atropine, and optional flavoring agent; formulation VI: a mixture of a polar and a non-polar solvent, atropine, optional flavoring agent, and propellant.
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[0001] This claims the benefit to U.S. Provisional Patent Application No. 61/862,707, filed on Aug. 6, 2013, which is hereby incorporated by reference herein.
[0002] The present disclosure relates generally to torque converters and more specifically to cover assemblies for torque converters.
BACKGROUND
[0003] U.S. Pat. No. 7,011,196 discloses a torque converter having a drive plate welded to a front cover at two radial locations.
SUMMARY OF THE INVENTION
[0004] A cover assembly for a torque converter is provided. The cover assembly includes a front cover and a drive plate connected to an outer surface of the front cover for coupling to the front cover to an engine crankshaft. The drive plate includes elastic preloading elements pressing against the outer surface of the front cover.
[0005] Embodiments of the cover assembly may also include one or more of the following advantageous features:
[0006] Each elastic preloading element may be formed in an interior of the drive plate. The elastic preloading elements may be formed by tabs formed into the interior of the drive plate and bent toward the front cover. The tabs may extend radially away from a center axis of the drive plate. The drive plate may include radial protrusions at an outer circumference thereof and the tabs may extend into the radial protrusions. The drive plate may be connected to the front cover by rivets. The rivets may be extruded from the front cover through holes in the drive plate. The elastic preloading elements may be radially outside of the rivets.
[0007] A method of forming a cover assembly is also provided. The method includes fixing a drive plate to an outer surface of a front cover of the torque converter such that elastic preloading elements of the drive plate press against the outer surface and are compressed.
[0008] Embodiments of the method may also include one or more of the following advantageous features:
[0009] The method may further include forming the elastic preloading elements within an interior of the drive plate. The forming the elastic preloading elements may include forming slots in the interior of the drive plate to form tabs and bending the tabs away from the interior of the drive plate. The drive plate may include radial protrusions at an outer circumference thereof and the slots may be formed to extend into the radial protrusions. The fixing the drive plate to the front cover may include riveting the drive plate to the front cover. The riveting the drive plate to front cover may include extruding the front cover through holes in the drive plate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention is described below by reference to the following drawings, in which:
[0011] FIG. 1 shows a half plan view of a cover assembly of a torque converter in accordance with an embodiment of the present invention; and
[0012] FIG. 2 shows a cross-sectional view of the cover assembly along A-A of FIG. 1 .
DETAILED DESCRIPTION
[0013] Embodiments of the present disclosure show a drive plate that is preloaded by elastic preloading elements when the drive plate is fixed to the front cover of a torque converter by for example riveting or welding. The elastic preloading element may limit the cyclic loading at the connection between the drive plate and the front cover (i.e., for example at the weld or rivets) to mostly when in compression.
[0014] FIG. 1 shows a half plan view of a cover assembly 10 of a torque converter 12 in accordance with an embodiment of the present invention. Cover assembly 10 includes a drive plate 14 , a front cover 16 and a pilot 18 . Cover assembly 10 is connectable to a crankshaft of an internal combustion engine via pilot 18 at a center axis 20 and lugs 22 circumferentially spaced about center axis 20 that are fixed to drive plate 14 . Front cover 16 is connectable to a rear cover is form a housing, which may house a lockup clutch, a damper, a turbine, an impeller and a shaft for connecting to a variable speed transmission. Drive plate 14 and front cover 16 are fixed together by a plurality of rivets 24 spaced circumferentially about center axis 20 .
[0015] In order to preload drive plate 14 when drive plate 14 is fixed to front cover 16 , drive plate 14 includes a plurality of elastic preloading elements 26 circumferentially spaced about center axis 20 . FIG. 1 shows two preloading elements circumferentially aligned with one of radial protrusions 28 , which extend radially outward at an outer circumference of drive plate 14 . While only two elastic preloading elements 26 are shown in FIG. 1 , preferred embodiments of the present invention include more than two preloading elements. For example, drive plate 14 may include two elastic preloading elements 26 circumferentially aligned with each of radial protrusions 28 , such that drive plate 14 , which include six radial protrusions 28 , includes twelve elastic preloading elements 26 .
[0016] In this embodiment, elastic preloading elements 26 are formed in an interior 30 of drive plate 14 . Drive plate 14 is formed by a metal plate processed to remove material therefrom to form slots 32 that define preload tabs 34 in drive plate 14 and provide preload tabs 34 with a flexible geometry. Preload tabs 34 each include a free end 36 connected to interior 30 of drive tab 14 by a base end 38 . A radially extending portion of each preload tab 34 extends radially from base end 38 away from center axis 20 such that each preload tab 34 is substantially finger-shaped. As shown in FIG. 1 , tabs 34 extend into radial protrusions 28 on opposite sides of the respective lug 22 in radial protrusion 28 . Drive plate 14 and front cover 16 are arranged such that radial protrusions 28 extend radially outward past an outer circumference of front cover 16 and lugs 22 are centered along the outer circumference of front cover 16 .
[0017] FIG. 2 shows a cross-sectional view of cover assembly 10 along A-A shown in FIG. 1 . As shown in FIG. 2 , front cover 16 is substantially cup shaped so as to include a first portion 40 extending radially and a second portion 42 extending axially from a radially outer end of first portion 40 . Pilot 18 is welded to first portion 40 by a weld 44 , In embodiment shown in FIG. 2 , drive plate 14 is riveted to front cover 16 by extruding front cover 16 with such a force that each rivet 24 is formed as an extruded rivet, installing the rivet into a respective hole 46 formed in drive plate, and expanding the rivet to form a head 48 . For each rivet 24 , a punch may be used to extrude a portion of front cover 16 , leaving an indentation 50 in an inner surface 52 of first portion 40 of front cover 16 . In alternative embodiments, instead of extruded rivets, rivets 24 may be conventional, cold headed rivets.
[0018] One elastic preloading element 26 is illustrated in FIG. 2 by dotted lines, as preloading element 26 is offset from A-A in FIG. 1 . As shown in FIG. 2 , preloading element 26 is formed by bending tab 34 away from interior 30 of drive plate 14 so that the bent tab 34 contacts and presses against outer surface 54 of first portion 40 of front cover 16 with free end 36 of tab 34 when drive plate 14 is fixed to front cover 16 . Tab 34 is compressed by the connection between drive plate 14 and front cover 16 and is urging front cover 16 away from drive plate 14 .
[0019] To form cover assembly 10 , elastic preloading element are formed in interior 30 of drive plate 14 by cutting slots 32 into interior 30 so as to define tabs 34 . Tabs 34 are then bent axially away from interior 30 . Drive plate 14 may then be fixed to outer surface 54 of front cover 16 such that elastic preloading elements 26 of drive plate 14 press against outer surface 54 and are compressed.
[0020] In alternative embodiments of the present invention, instead of being fixed together by rivets 24 , drive plate 14 and front cover 16 may be welded together.
[0021] In the preceding specification, the invention has been described with reference to specific exemplary embodiments and examples thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative manner rather than a restrictive sense.
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A cover assembly for a torque converter is also provided. The cover assembly includes a front cover and a drive plate connected to an outer surface of the front cover for coupling to the front cover to an engine crankshaft. The drive plate includes elastic preloading elements pressing against the outer surface of the front cover. A method of forming a cover assembly for a torque converter is also provided.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and claims the priority of U.S. Provisional Patent Application Nos. 60/958,317, 60/958,313, and 60/958,311, each of which was filed Jul. 3, 2007, and each of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This application discloses a novel process for the preparation of 1,2-substituted 3,4-dioxo-1-cyclobutene compounds, which have utility, for example, in the treatment of CXC chemokine-mediated diseases, and intermediates useful in the synthesis thereof.
BACKGROUND OF THE INVENTION
[0003] Identification of any publication, patent, or patent application in this section or any section of this application is not an admission that such publication is prior art to the present invention.
[0004] The preparation of 1,2-substituted 3,4-dioxo-1-cyclobutene compounds, for example, 2-Hydroxy-N,N-dimethyl-3-[[2-[[1(R)-(5-methyl-2-furanyl)propyl]amino]-3,4-dioxo-1-cyclobuten-1-yl]amino]benzamide (compound of formula I):
[0000]
[0000] has been described in U.S. Pat. Nos. 7,123,445 (the '445 patent), issued Nov. 7, 2006, and 7,071,342 (the '342 patent), issued Jul. 4, 2006, the disclosure of each of which is incorporated herein in its entirety by reference. For examples of the preparation of the compound of Formula I, see the '455 patent at cols. 491 to 492, cols. 196 to 197, and cols. 251 to 256, and see the '342 patent, for example, at cols. 22 through 24.
[0005] Another example of the preparation of a 1,2-substituted 3,4-dioxo-1-cyclobutene compound, the preparation the 2-hydroxy-N,N-dimethyl-3-[[2-[[1(R)-[5-methyl-4-(1-methylethyl)-2-furanyl]propyl]amino)-3,4-dioxo-1-cyclobuten-1-yl]amino]-benzamide (the compound of Formula II),
[0000]
[0000] is described in U.S. provisional patent application 60/819,541 (the '541 application) filed Jul. 7, 2006, the disclosure of which is incorporated by reference in its entirety. An example of the preparation of the compound of Formula II can be found in Example 2 of the '541 application. The aforementioned preparation schemes for the compounds of Formulae I and II are incorporated herein by reference in their entirety.
[0006] The synthesis method for preparing 1,2-substituted 3,4-dioxo-1-cyclobutene compounds described in the '342 patent generally follows Scheme I (which exemplifies the preparation of 2-Hydroxy-N,N-dimethyl-3-[[2-[[1(R)-(5-methyl-2-furanyl)propyl]amino]-3,4-dioxo-1-cyclobuten-1-yl]amino]benzamide, the compound of Formula I).
[0000]
[0007] The process for the preparation of the compound of Formula I shown in Scheme I is carried out by first preparing intermediate compound 2C from a dialkyl squarate, a strong skin sensitizer and irritant which is difficult to handle. Additionally, the conditions described in the aforementioned publications under which compounds 2C and 2Da are coupled in the second step of Scheme I produce an undesirable level of impurities admixed with the final product.
[0008] Moreover, the process for the preparation of the compound of Formula I shown in Scheme I requires in the first step a reaction between squarate compound 2A1 and intermediate compound IV(i), a 3-amino-2-hydroxy-benzamide compound which is unstable. The stability of the compound of Formula IV(i) makes it difficult to handle, store, and ship. Accordingly, this makes impracticable a process in which the compound of Formula IV(i) is made remotely from the process for making the compound of Formula 2C, or in which the process of making the compound of Formula 2C is not carried out contemporaneously with the preparation of the compound of Formula IV(i). Additionally, the product of Formula 2C provided using commercially available dialkylsquarate has a relatively large amount of impurities necessitating a product purification step prior to utilization in a synthesis of a compound of Formula Ia.
[0009] Additionally, as shown in step II of Scheme I, the compound of Formula I shown is prepared from coupling an aminofuran intermediate of Formula 2Da with intermediate compound 2C. The preparation of intermediate compound 2Da is described in U.S. Pat. No. 7,071,342 (the '342 patent) in cols. 35, line 1 to 39, line 20. The '342 patent describes a six step process for preparing the compound of Formula 2DA starting with the commercially available compound of Formula III. In the course of carrying out this process several changes of solvent are required, which leads to diminished isolated yields in the individual steps.
[0000]
OBJECTIVES AND SUMMARY OF THE INVENTION
[0010] In view of the foregoing, what is needed are synthetic processes for the preparation of intermediate 2C and the aminofuran salt intermediate of Formula 2Da having fewer steps and which can be carried out with starting materials that are easier to handle and obtain. What is needed also is a reaction scheme which can provide intermediates 2C and 2Da in a “one-pot reaction”
[0011] Additionally, what is needed is a process for preparing 1,2-substituted 3,4-dioxo-1-cyclobutene compounds using the intermediate compound of Formula IV(i) in which the compound of Formula IV(i) can be prepared in a physical location remote from the site in which the other process steps are carried out. Moreover, what is needed is a process which enables the preparation of 1,2-substituted 3,4-dioxo-1-cyclobutene compounds using a source of the compound of Formula IV(i) without a requirement that the source compound be utilized contemporaneously with its initial formation. What is needed also is a reaction scheme utilizing a source of the compound of Formula IV(i) in the preparation of 1,2-substituted 3,4-dioxo-1-cyclobutene compounds which affords practical scale up to a batch size suitable for commercial scale preparation, provides a product with less impurities, and better utilizes dialkylsquarate. What is needed also is a reaction scheme which affords practical scale up to a batch size suitable for commercial scale preparation of 1,2-substituted 3,4-dioxo-1-cyclobutene compounds.
[0012] These and other objectives are advantageously provided by the present invention, which in one aspect is a process for preparing 1,2-disubstituted-3,4-dioxo-1-cyclobutene compounds of Formula Ia in accordance with Scheme II.
[0000]
[0000] The process of Scheme II comprises:
(a) forming dialkyl-squarate in situ (compound “2A1” of scheme I) by reacting (R 3 O) 3 CH (trialkylorthoformate) with squaric acid (2A), wherein R 3 is a linear or branched alkyl of 6 carbon atoms or less; (b) reacting amino-hydroxybenzamide compound 2B with the dialkylsquarate formed in step “a” to form compound 2C; (c) forming in situ a free base amino-furan from the amino-furan salt compound of the formula 2Da wherein, R 1 is selected from hydrogen and a substituent comprising from 1 carbon atom to about 10 carbon atoms selected from linear, branched, and cyclic alkyl moieties and substituted linear, branched, and cyclic alkyl moieties and “R-Anion” represents a monovalent anionic moiety, and reacting said free base amino-furan compound with compound 2C formed in step “b” to provide the compound of Formula Ia; and (d) optionally precipitating the compound of Formula Ia by:
(i) successive cycles of concentrating the reaction mixture formed in step “c” by distillation followed by the addition of an aliquot of an alcohol, preferably, when R 1 is H, the alcohol is n-propanol and preferably, when R 1 is isopropyl, the alcohol is isopropanol; (ii) adding an aliquot of the alcohol used in step “i” and acetic acid to the concentrate formed in step “i”; (iii) heating the solution formed in step “ii”; (iv) adding an aliquot of water and seed crystals comprising the compound of Formula Ia to the hot solution from step “iii”; (v) cycling the temperature of the seeded solution prepared in step “iv” until a slurry comprising crystals of a desired size is formed; and (vi) optionally isolating the crystals from the slurry prepared in step “v”.
[0023] In some embodiments of the inventive process it is preferred to carry out step “a”, formation of dialkylsquarate from squaric acid, in the presence of an additional acid, preferably trifluoroacetic acid.
[0024] In some embodiments of the inventive process it is preferred to carry out step “a”, the in situ formation of dialkyl squarate using triethylorthoformate ((CH 3 CH 2 O) 3 CH), thus the compound of 2A1 formed is diethyl squarate, the compound of Formula 2A3.
[0000]
[0025] In some embodiments of the inventive process it is preferred to carry out step “a”, the in situ formation of dialkyl squarate using trimethylorthoformate ((CH 3 O) 3 CH), thus the compound of 2A1 formed is dimethyl squarate, the compound of Formula 2A2.
[0000]
[0026] In some embodiments of the invention in which dimethyl squarate is prepared in situ, it is preferred to carry out the formation of dimethyl squarate in a refluxing alcohol of the Structure R 3 OH, wherein R 3 is a linear or branched alkyl moiety of 6 carbon atoms or less, more preferably R 3 is H 3 C—, thus R 3 OH is methanol. In some embodiments, with reference to Scheme II, Step “a”, it is preferred to select the R 3 substituent in both the trialkylorthoformate reagent (structure (R 3 O) 3 CH) and the alcohol in which the reaction is carried out (structure R 3 OH) to be the same. Thus, if the trialkylorthoformate reagent is trimethylorthoformate ((H 3 CO) 3 CH), the reaction solvent will be methanol. In some embodiments of the invention in which dimethyl squarate is prepared in situ, it is preferred to concentrate the reaction mixture following the formation of dimethyl squarate prior to reacting with the compound of Formula 2B in subsequent step “b”. In some embodiments, subsequent Step “b” preferably uses methanol as the alcohol in which triethylamine is dissolved.
[0027] In some embodiments of the inventive process, in Step “c” it is preferred for R 1 in the compound amino-furan salt compound of Formula 2Da to be hydrogen or an isopropyl moiety, more preferably, R 1 is hydrogen, thus the compound of Formula Ia is a compound of Formula I. In some embodiments, preferably the anion represented by “R-Anion − ” in the compound of Formula 2Da is a monobasic D-tartarate anion (HOC(O)[CH 2 (OH)] 2 C(O)O − ) or tartaric acid derivative anion.
[0028] In some embodiments of the invention, preferably the compound of Formula 2Da is the compound of formula 2D,
[0000]
[0000] thus, with reference to the compound of Formula 2Da, “anion − ” is a monobasic tartarate anion and R 1 is hydrogen.
[0029] In some embodiments it is preferred to carry out step “b” of the process (formation of the compound of Formula 2C) at a temperature of from about (−5° C.) to about (+5° C.) and to add triethylamine to the reaction mixture over a portion of the reaction period. In some embodiments it is preferred to seed the reaction mixture used to prepare the compound of Formula 2C with aliquots of solid 2C during the reaction period. In some embodiments it is preferred to work up the reaction mixture of step “b” of the inventive process (preparation of the compound of formula 2C) by heating the reaction mixture with acetic acid and then cooling the reaction mixture to precipitate solid 2C.
[0030] In some embodiments of the inventive process, it is preferred to carry out step “c” (formation of the compound of Formula I by reacting compound 2C with the free base formed in situ from compound 2Da) by heating the reaction mixture to reflux and refluxing for a period of time, concentrating the reaction mixture by distillation, and then reflux the concentrated reaction mixture for a second period of time.
[0031] In some embodiments it is preferred to carry out optional step “d” of the inventive reaction by adding an aliquot of an alcohol which is i-propanol or n-propanol, concentrating the reaction mixture by distillation, adding a second aliquot of alcohol, concentrating the mixture a second time by distillation, adding a third aliquot of alcohol and acetic acid, filtering the reaction mixture, adding additional alcohol and heating the mixture, then adding water, seeding the mixture with crystals of the compound of Formula I and cooling the mixture. In some embodiments, the mixture is cycled between ambient temperature and a temperature of from about 45° C. to about 60° C. until crystals of desired size are formed.
[0032] Another aspect of the present invention is a process for the preparation of intermediate compound (2Ca) useful in the provision of compounds of Formula Ia,
[0000]
[0000] the process comprising:
(a) forming dimethyl-squarate in situ by reacting (CH 3 O) 3 CH with squaric acid and optionally additionally trifluoroacetic acid; and (b) reacting the amino-hydroxide benzamide salt compound of Formula 2B,
[0000]
[0035] with the dimethylsquarate formed in step “a” to form compound 2Ca.;
[0036] In some embodiments forming intermediate compound (2Ca) it is preferred to carry out step “a” of the process in methanol. In some embodiments for the preparation of compound (2Ca) it is preferred to perform an optional isolation step in which the reaction mixture containing the compound of Formula (2Ca) is worked up by adding acetic acid, heating the reaction for a period of time, seeding the reaction mixture with a solid form of the compound of Formula (2Ca), and cooling the resulting mixture to precipitate a solid form of product (2Ca).
[0037] In another aspect, the present invention provides a process for preparing carbamoyl benzamine salts of Formula 2B1 in accordance with Scheme III, which illustrates also the optional conversion of the compound of Formula 2B1 into squarate intermediates of Formula 2C.
[0000]
[0000] The process of Scheme III comprises:
(a) providing a 3-amino-2-hydroxy-N,N-dimethyl-benzamide compound of Formula IV(i)) and subsequently reacting it with an acid of the Formula H + Anion − , wherein “Anion − ” is a monovalent anionic moiety, to form the compound of Formula 2B1; (b) optionally, precipitating the compound of Formula 2B1 and collecting the precipitate; and (c) optionally reacting the compound of Formula 2B1 with a dialkyl squarate compound of Formula 2A1 to form the compound of Formula 2C.
[0041] In some embodiments of the inventive process it is preferred to carry out the reaction of step “a”, formation of the salt compound of Formula 2B1, in a mixed solvent comprising methyl tertiarybutyl ether (MTBE) and ethanol. In some embodiments it is preferred to carry out reaction step “a” using an acid selected from mineral acids, for example, but not limited to H 2 SO 4 , H 3 PO 4 , HBr, and HCl, and organic acids, for example, but not limited to, maleic acid, fumaric acid, malic acid, sulfonic acids, oxalic acid, and tartaric acids and derivatives thereof. When a mineral acid is used, preferably the acid is HCl (thus “A − ” is Cl − ). When an organic acid is used, preferably the acid is selected from p-tolysulfonic acid (thus “A − ” is p-tolysulfonate), oxalic acid (thus “A − ” is oxalate), and tartaric acid (thus “A − ” is monobasic tartarate (HO—C(O)—(HOCH) 2 C(O)O − ), more preferably tartaric acid acid is used. In some embodiments it is preferred to use a concentrated aqueous acid solution to carry out reaction step “a”. In some embodiments it is preferred to carry out step “a” by treating the reaction mixture containing the compound of Formula IV with a solid acid.
[0042] In some embodiments, step “c”, the preparation of the compound of the Formula 2C, additionally includes the steps of seeding the reaction mixture with a solid form of the compound of Formula 2C, heating the reaction mixture in the presence of acetic acid and cooling the reaction mixture to precipitate a solid form of the compound of Formula 2C. In some embodiments of the invention it is preferred to seed the reaction mixture provided in step “a” with a solid portion of the compound of Formula 2B1 selected from compound 2B1 prepared in accordance with the '342 patent and compound 2B1 sourced from an earlier batch of material prepared in accordance with the process of the present invention.
[0043] In some embodiments of the invention it is preferred to carry out step “a” of the process in a place and time remote from carrying out step “b” of the process. In some embodiments of the invention it is preferred to precipitate and collect a solid form of the compound of the Formula of 2B1 prepared in step “a” and store it for later use in carrying out step “b” of the process.
[0044] In some embodiments of the process it is preferred to provide the compound of Formula VI(i) in accordance with Scheme IIIa.
[0000]
[0045] Thus, the compound of Formula IV(i) is provided by reducing the compound of Formula IV using a hydrogenation catalyst, preferably a palladium catalyst, more preferably palladium on carbon black. In some embodiments it is preferred to use the reaction mixture produced after the reduction of the compound of Formula IV as a source of the compound of Formula VI(i) in the preparation of the compound of Formula 2B1.
[0046] In another aspect, the present invention provides compounds of Formula Ia in accordance with the process of Scheme II, wherein, in Step “c” of the process, the salt compound of Formula 2Da (from which the corresponding free-base amino-furan is prepared) is itself provided by the process of Scheme IV:
[0000]
[0000] the process comprising:
a. reductively aminating the compound of Formula (2Dd) by treatment with formamide in the presence of formic acid to provide the intermediate compound (2Dc), preferably. R 1 is hydrogen or a substituent comprising from 1 carbon atom to about 10 carbon atoms selected from linear, branched, and cyclic alkyl moieties and substituted linear, branched, and cyclic alkyl moieties; b. hydrolyzing, preferably in situ, the compound of Formula (2Dc) prepared in Step “a”, preferably by the addition of aqueous base to the reaction mixture, yielding the freebase racemic mixture of Formula (2Db); and c. treating the reaction mixture comprising the freebase racemate (2 Db) with an acid of the formula H + [R-Anion − ] in the presence of an alcohol of the formula R 3 OH, and optionally in the presence of a coacid, wherein “R-Anion” represents an optically active monovalent anionic moiety, preferably capable of preferentially forming a salt of the R-isomer of the compound of Formula 2D, and R 3 is selected from linear, branched, and cyclic alkyl of 6 carbon atoms or less, thereby yielding a salt of the desired isomer.
[0050] In some embodiments of the process of Scheme IV it is preferred for R 1 in the compounds of the Formulae (2Da) through (2Dd) to be hydrogen or isopropyl. In some embodiments, it is preferred for the alcohol of Formula R 3 OH in step “c” to be methanol or ethanol. In some embodiments using a coacid in resolution step “c”, the coacid is preferably HCl, malonic acid, acetic acid, formic acid, chloroacetic acid, or trifluoroacetic acid, or mixtures thereof, more preferably, the coacid is trifluoroacetic acid.
[0051] In some embodiments of the process of Scheme IV it is preferred to carry out Step “a”, using 5-methyl-2-propionylfuran as the compound of Formula 2Dd (thus R 1 is hydrogen).
[0052] In some embodiments of the inventive process, R 1 in the amino-furan salt compound of Formula 2Da is hydrogen (thus providing the compound of Formula I) or an isopropyl moiety (thus providing the compound of Formula II). In some embodiments, preferably, the anion represented by “R-Anion − ” in the compound of Formula 2Da is an optically active monovalent anionic moiety capable of preferentially forming a salt of the R-isomer of the compound of Formula 2D. Examples of suitable anions include, but are not limited to, monobasic D-tartarate anion (HOC(O)[CH 2 (OH)] 2 C(O)O − ) and tartarate anion derivatives, for example DDTA.
[0053] In some embodiments of the invention, the compound of Formula 2Da is preferably the compound of formula 2Da1
[0000]
[0000] (thus, “Anion” in the compound of Formula 2Da is a monobasic tartarate anion and R 1 is hydrogen).
[0054] In some embodiments of the inventive process illustrated in Scheme IV step “c” (formation of the compound of Formula I by reacting compound 2C with the free base formed in situ from compound 2Da) is preferably carried out by heating the reaction mixture to reflux and refluxing the reaction mixture for a period of time, concentrating the reaction mixture by distillation, and then refluxing the concentrated reaction mixture for a second period of time.
[0055] In some embodiments it is preferred to carry out optional step “d” of the inventive process illustrated in Scheme IV by adding an aliquot of n-propanol, concentrating the reaction mixture by distillation, adding a second aliquot of n-propanol, concentrating the mixture a second time by distillation, adding a third aliquot of n-propanol and acetic acid, filtering the reaction mixture, adding additional n-propanol and heating the mixture, then adding water, seeding the mixture with crystals of the compound of Formula I and cooling the mixture. In some embodiments, the mixture is cycled between ambient temperature and a temperature of from about 55° C. to about 70° C. until crystals of desired size are formed.
[0056] Other aspects and advantages of the invention will become apparent from following Detailed Description.
DETAILED DESCRIPTION OF THE INVENTION
[0057] Terms used in the general schemes herein, in the examples, and throughout the specification, include the following abbreviations, together with their meaning, unless defined otherwise at the point of their use hereinafter: Me (methyl); Bu (butyl); t-Bu (tertiary butyl); Et (ethyl); Ac (acetyl); t-Boc or t-BOC (t-butoxycarbonyl); DMF (dimethylformamide); THF (tetrahydrofuran); DIPEA (diisopropylethylamine); MTBE (methyltertiarybutyl ether); 2-Me-THF (2-methyl tetrahydrofuran
[0000]
[0000] n-propyl, n-prop (CH 3 CH 2 CH 2 —); RT (room temperature, ambient temperature, generally 25° C.); TFA (trifluoroacetic acid); TEA (triethyl amine), i-propanol means isopropanol, n-propanol means normal propyl alcohol.
[0058] As used herein, the following terms, unless otherwise indicated, are understood to have the following meanings:
[0059] The term “substituted” means that one or more hydrogens on the designated atom or group of atoms in a structure is replaced with a selection from the indicated group, provided that the designated atom's normal valency under the existing circumstances is not exceeded, and that the substitution results in a stable compound. Combinations of substituents and/or variables are indicated when such combinations result in stable compounds. By “stable compound” or “stable structure” is meant a compound that is sufficiently robust to survive isolation to a useful degree of purity from a reaction mixture, and formulation into an efficacious therapeutic agent.
[0060] The term “optionally substituted” means optional substitution with the specified groups, radicals or moieties.
[0061] “Patient” includes both humans and animals.
[0062] “Mammal” means humans and other mammalian animals.
[0063] “Alkyl” means an aliphatic hydrocarbon group which may be linear straight or branched and comprising about 1 to about 10 carbon atoms in the chain. Branched means that one or more lower alkyl groups such as methyl, ethyl or propyl, are attached to a linear alkyl chain. Non-limiting examples of suitable alkyl groups include methyl, ethyl, n-propyl, isopropyl, n-butyl, t-butyl and n-pentyl.
[0064] “Alkenyl” means an aliphatic hydrocarbon group containing at least one carbon-carbon double bond and which may be straight or branched and comprising about 2 to about 10 carbon atoms in the chain. Branched means that one or more lower alkyl groups such as methyl, ethyl or propyl, are attached to a linear alkenyl chain. Non-limiting examples of suitable alkenyl groups include ethenyl, propenyl, n-butenyl, 3-methylbut-2-enyl and n-pentenyl.
[0065] “Alkylene” means a difunctional group obtained by removal of an additional hydrogen atom from an alkyl group, as “alkyl” is defined above. Non-limiting examples of alkylene include methylene (i.e., —CH 2 —), ethylene (i.e., —CH 2 —CH 2 —) and branched chains, for example, —CH(CH 3 )—CH 2 —.
[0066] “Aryl” means an aromatic monocyclic or multicyclic ring system comprising about 6 to about 14 carbon atoms, preferably about 6 to about 10 carbon atoms. The aryl group can be optionally substituted with one or more “ring system substituents” which may be the same or different, and are as defined herein. Non-limiting examples of suitable aryl groups include phenyl and naphthyl.
[0067] “Cycloalkyl” means a non-aromatic mono- or multicyclic ring system comprising about 3 to about 10 carbon atoms, preferably about 3 to about 6 carbon atoms. Non-limiting examples of suitable monocyclic cycloalkyls include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl and the like. Non-limiting examples of multicyclic cycloalkyls include, but are not limited to 1-decalin, norbornyl and cognitors, adamantyl and cognitors.
[0068] “Halo” means a halogen selected from fluoro, chloro, bromo, or iodo groups.
[0069] “Aminoalkyl” means an alkyl as defined above having at least one hydrogen atom on the alkyl moiety replaced by an amino functional (i.e., —NH 2 ) group. Alkylamino means an amino functional group having one or both hydrogens replaced by an alkyl functional group, as “alkyl” is defined above.
[0070] With reference to the number of moieties (e.g., substituents, groups or rings) in a compound, unless otherwise defined, the phrases “one or more” and “at least one” mean that there can be as many moieties as chemically permitted, and the determination of the maximum number of such moieties is well within the knowledge of those skilled in the art.
[0071] A wavy line appearing on a structure and joining a functional group to the structure in the position of a bond generally indicates a mixture of, or either of, the possible isomers, e.g., containing (R)- and (S)-stereochemistry. For example,
[0000]
[0000] means containing either, or both of
[0000]
[0000] A wavy line which terminates a bond indicates that the portion of the structure depicted is attached to a larger structure at the indicated bond, for example,
[0000]
[0000] implies that the nitrogen of the substituted piperidyl group depicted is bonded to an undepicted structure on which it is a substituent.
[0072] Lines drawn into ring systems, for example the substituted aryl group:
[0000]
[0000] indicates that a substituent (R 1 ) may replace a hydrogen atom of any of the ring carbons otherwise bonded to a hydrogen atom. Thus, as illustrated, R 1 can be bonded to any of carbon atoms 2, 4, 5, or 6, but not 3, which is bonded to a methyl substituent, or 1, through which the substituted aryl group is bonded.
[0073] As well known in the art, a bond drawn from a particular atom wherein no moiety is depicted at the terminal end of the bond indicates a methyl group bound through that bond to the atom, unless stated otherwise. For example:
[0000]
[0000] represents
[0000]
[0000] However, in some structures shown herein, the CH 3 moiety is explicitly included in a structure. Herein, the use of either convention for depicting methyl groups is meant to be equivalent and these conventions are used herein interchangeably for convenience and without intending to alter thereby the meaning which is conventionally understood using either depiction.
[0074] The term “isolated” or “in isolated form” for a compound refers to the physical state of said compound after being isolated from a process. The term “purified” or “in purified form” for a compound refers to the physical state of said compound after being obtained from a purification process or processes described herein or well known to the skilled artisan, in sufficient purity to be characterizable by standard analytical techniques described herein or well known to the skilled artisan.
[0075] When any variable (e.g., aryl, heterocycle, R 2 , etc.) occurs more than one time in any constituent or in a formula, its definition on each occurrence is independent of its definition at every other occurrence.
[0076] As mentioned above, a process for preparing each of the compounds of Formula I and Formula II have been described U.S. Pat. No. 7,123,455 (the '455 patent, both compounds) and U.S. Pat. No. 7,071,342 (the '342 patent, the compound of Formula I). The present invention utilizes the processes depicted in Schemes I, II, II(a and b) and IV to prepare the compounds of Formula Ia, for example, the compounds of Formulae I and II. Aspects of the preparation and purification of the compounds of Formulae I and II are also discussed in U.S. provisional application Ser. Nos. 60/958,313, 60/958,317, and 60/958,311, each of which was filed on Jul. 3, 2007, and the disclosure of each of which is incorporated herein by reference in its entirety.
[0077] Scheme V presents a coupling reaction between a salt of an amino-furate (2Da) and an amino-substituted hydroxyl-benzamide (2C) which is carried out in 2-methyl-tetrahydrofuran (2-MeTHF) and the product is optionally extracted into isopropyl alcohol, and wherein, optionally, the freebase amino-furan intermediate is generated from the corresponding salt.
[0000]
[0000] The coupling reaction depicted in Scheme V is a process comprising:
(a) forming a free base amino-furan compound 2Da from the amino-furan salt compound of the formula 2D wherein, R 1 is selected from hydrogen and a substituent comprising from 1 carbon atom to about 10 carbon atoms selected from linear, branched, and cyclic alkyl moieties and substituted linear, branched, and cyclic alkyl moieties and “A-Anion” represents a monovalent anionic moiety which is preferably an optically active monovalent anionic moiety capable of preferentially forming a salt of the R-isomer of the compound of Formula 2D; (b) reacting said free base amino-furan compound 2Da with a hydroxyaminobenzamide compound of Formula 2C to provide the compound of Formula Ia; and (c) optionally precipitating the compound of Formula Ia by:
(i) successive cycles of concentrating the reaction mixture formed in step “c” by distillation followed by the addition of an aliquot of an alcohol; (ii) adding an aliquot of acetic acid and the alcohol used in Step “i” to the concentrate formed in step “i”; (iii) heating the solution formed in step “ii”; (iv) adding an aliquot of water and seed crystals comprising the compound of Formula Ia to the hot solution from step “iii”; (v) cycling the temperature of the seeded solution prepared in step “iv” until a slurry comprising crystals of a desired size is formed; and (vi) optionally isolating the crystals from the slurry prepared in step “v”.
Although Step “a” of Scheme V can be carried out in a various solvents, the inventors have surprisingly found that the coupling reaction between the hydroxyamino-benzamide and aminofuran shown in Step “a” occurs with an improved impurity profile if the coupling reaction is conducted in a solvent of 2-methyltetrahydrofuran. Conveniently, the aminofuran used in the coupling reaction shown in Scheme V can be provided by liberating the free base form of the aminofuran to be reacted from its corresponding salt. Accordingly, the aminofuran salt can be prepared at a time and place remote from the synthesis of a compound of Formula I, and shipped or stored for use as desired in providing the freebase aminofuran precursor used in the preparation of a compound of Formula I. It will be appreciated that Step “a” of Scheme V can be carried out using any amino-furan salt, for example, where “R-Anion − ” is any monovalent ionic moiety, for example, but not limited to the anion from a mineral acid, for example, H 2 SO 4 , H 3 PO 4 , HBr, and HCl, and the anion from an organic acid, for example, but not limited to, maleic acid, fumaric acid, malic acid, sulfonic acids, oxalic acid, and tartaric acids and derivatives thereof. However, preferably, the compound of Formula 2D comprises an “R-Anion − ” where “R-Anion − ” is a monovalent anion which preferentially forms a salt with the R-isomer of the aminofuran, for example, but not limited, to monovalent D-tartarate ion. Conveniently, in selecting a salt made with an “R-Anion − ” which preferentially forms a salt with the R-isomer of the amino-furan, an aminofuran salt useful in the inventive process can be precipitated from a mixture of isomers without the need for complex procedures to isolate the desired isomer prior to forming the salt.
[0087] Thus, as shown in Step “a” of Scheme V, a 2-methyltetrahydrofuran solution of the aminofuran free base is provided by treatment of a 2-methyl-tetrahydrofuran suspension of the corresponding salt with a strong aqueous base. Upon reaction with the aqueous base, the freebase form of the aminofuran is liberated and dissolves in the 2-methyltetrahydrofuran in which the precursor salt was suspended. The organic layer of the reaction mixture is then easily obtained in isolation from the reaction mixture using physical means, for example, separation and decantation. The hydroxyaminobenzamide (2C) to be coupled with the aminofuran is added to the 2-methyltetrahydrofuran solution containing the aminofuran freebase, and heated to initiate the coupling reaction. The reaction can be carried out at temperatures above 0° C., preferably a temperature of at least 40° C., and more preferably the reaction is carried out at a temperature of about 70° C.
[0088] In some embodiments it is preferred to select hydroxyaminobenzamide (compound of Formula 2C) as the limiting reagent. In some embodiments, preferably after a substantial portion of the limiting reagent has been consumed, aliquots of an alcohol which is normal propanol or isopropanol are added to the reaction mixture with subsequent distillation to concentrate the reaction mixture. In some embodiments it is preferred to carry out several cycles of adding the alcohol and subsequently distilling volatiles from the reaction mixture until the reaction mixture comprises substantially the added alcohol, thus facilitating the separation of the product compound of Formula Ia from the reaction mixture by crystallization. In some embodiments, when R 1 of the compound of Formula Ia is hydrogen, preferably n-propanol is employed, and when R 1 of the compound of Formula Ia is an isopropyl substituent, preferably the alcohol is isopropanol. To this end a final aliquot of the selected alcohol and a small amount of acetic acid is added to neutralize any residual base, thereby maximizing yield. The mixture is subsequently filtered and the filtrate is diluted with additional alcohol and heated to at least 70° C. Water is added to the heated mixture as an antisolvent while maintaining the temperature. The mixture is then cooled to about 60° C. and seed crystals of the compound of Formula Ia are added and the mixture is subjected to controlled cooling to facilitate crystallization of the compound of Formula Ia.
[0089] The inventors have found that in some embodiments, for example, when the compound of Formula Ia is the compound of Formula I, cycling the temperature of the seeded mixture between ambient temperature and a temperature of from about 50° C. to about 60° C. permits control of the size of the crystals formed.
[0090] For use in carrying out the synthesis shown in Scheme V, above, the aminohydroxybenzamide intermediate compounds of Formula 2C are conveniently prepared by reacting a dialkyl squarate, for example, dimethyl squarate and diethyl squarate, preferably, dimethyl squarate, and the compound of 2B in accordance with Scheme VI, shown below.
[0000]
[0000] Scheme VI illustrates a process comprising:
(a) forming dialkyl-squarate compounds of Formula 2A1 in situ by reacting (R 3 O) 3 CH (trialkylorthoformate) with squaric acid (2A), wherein R 3 is a linear or branched alkyl of 6 carbon atoms or less; and (b) reacting the compound of Formula 2A1 prepared in step “a” with a salt of a 2-hydroxy-2-amino-benzamide compound of Formula 2B, wherein [Anion − ] is a monovaient anionic moiety defined below.
[0093] Surprisingly, the inventors have found that the coupling reaction shown in Scheme VI can be carried out by generating the dialkyl squarate in situ from a reaction between squaric acid (compound 2A) and a trialkylorthoformate [(R 3 O) 3 CH]. Preferably the trialkylorthoformate is selected from trimethyl orthoformate and triethylorthoformate, more preferably trimethylorthoformate. In some embodiments it is preferred to use a slight excess of trialkylorthoformate in comparison to the amount of squaric acid employed. In some embodiments it is preferred to use about 1 equivalent of squaric acid and about 2.1 equivalents of trialkylorthoformate.
[0094] Optionally, the esterification reaction providing dialkyl squarate of Formula 2A1 is catalyzed with a small amount of acid, preferably trifluoroacetic acid. In some embodiments of the inventive process using trifluoroacetic acid to catalyze the reaction between trimethylorthoformate and squaric acid it is preferred to use about 1 mole % of trifluoroacetic acid relative to the amount of trimethylorthoformate employed.
[0095] Squaric acid is an article of commerce available, for example, from Aldrich. The inventors have surprisingly found that generating dialkylsquarate (2A1) in situ from squaric acid (2A) permits the process to be run without requiring isolation and handling a dialkyl squarate in the preparation of the intermediate compound (2C). Dialkylsquarates are known to be irritants and skin sensitizers. By generating the dialkylsquarate in situ for use in preparing intermediate 2C the present process eliminates the necessity of handling dialkyl squarate and thereby improves the safety and scalability of the process.
[0096] Any trialkyl orthoformate of the formula [(R 3 O) 3 CH], wherein R 3 is linear or branched alkyl having 6 carbon atoms or less is suitable for carrying out step 1 of dialkylsquarate synthesis reaction shown in Scheme VI, preferably, the trialkylorthoformate is triethylorthoformate (yielding diethyl squarate as the compound of Formula 2A1) or trimethyl orthoformate (yielding dimethyl squarate as the compound of Formula 2A1), more preferably the reaction is carried out with trimethyl orthoformate. It will be appreciated that other methods of generating dialkylsquarates in situ can also be employed without departing from the scope of the present inventive reaction.
[0097] In some embodiments, Scheme VI, Step “a”, in situ generation of dialkyl squarate, is preferably carried out in a refluxing alcohol having the structure (R 3 OH), wherein “—R 3 ” is selected to be the same as the alkyl moiety present in the trialkylorthoformate [(R 3 O) 3 CH] used in the provision of dialkyl squarate from squaric acid. Thus, for example, when diethyl squarate is prepared (by reaction with triethylorthoformate) the reaction is preferably carried out in ethanol. When dimethyl squarate is prepared (by reaction with trimethylorthoformate) the reaction is preferably carried out in methanol. In some embodiments it is preferred to prepare dimethylsquarate by reacting squaric acid with trimethylorthoformate in methanol. In some embodiments, at the end of the refluxing period for preparing a dialkylsquarate, it is preferred to concentrate the reaction mixture by distilling volatiles from the reaction mixture. In some embodiments using methanol as the reaction solvent, it is preferred to concentrate the solution containing the dialkylsquarate prepared in situ by refluxing the reaction mixture until it reaches a temperature of about 70° C. and to distill off volatiles while maintaining the temperature at about 70° C. until distillation ceases.
[0098] After obtaining an alcohol solution of dialkylsquarate (preferably a methanol solution of dimethyl squarate) in accordance with Step “a” of Scheme VI, the solution can be employed directly in Step “b” of Scheme VI, (the formation of the compound of Formula 2C). In some embodiments of the process shown in Scheme VI it is preferred to concentrate the alcohol solution comprising dialkylsquarate obtained in Step “a” prior to using it in Step “b”. In some embodiments of the process illustrated in Scheme VI the concentrated the alcohol solution comprising dialkylsquarate from Step “a” is diluted by adding additional amounts of the alcohol solvent before it is used in Step “b” of the process. In some embodiments it is preferred to dilute the concentrated solution of dialkylsquarate from Step “a” to 6× the volume by adding additional aliquots of the same alcohol comprising the concentrated solution of dialkylsquarate in preparation to carry out Step “b” of Scheme Vi (the coupling reaction forming the compound of the Formula 2C). In some embodiments it is preferred to carry out the coupling reaction at a temperature of mess than about 30° C., more preferably at a temperature of from about [−10° C.] to about [+10° C.], and more preferably at a temperature of from about [−5° C.] to about [+5° C.].
[0099] In some embodiments of the process illustrated in Scheme VI, Step “b” is carried out after cooling the solution of dialkyl squarate by adding amino-hydroxybenzamide salt of Formula 2B to the alcoholic solution of dialkylsquarate in an amount that provides from about 0.5 equivalents to about 1.0 equivalents of the benzamide salt in comparison with the dialkylsquarate present in solution, preferably about 0.7 equivalent of the benzamide salt is employed. In some embodiments it is preferred for the salt compound of Formula 2B to be the hydrochloride salt compound of Formula 2B1.
[0000]
[0100] In some embodiments it is preferred to mediate the coupling reaction (Scheme VI, Step “b”) with an organic base, for example, but not limited to pyridine, pyridine derivatives, and tertiary amines, for example, but not limited to, triethyl amine. Preferably the base is a tertiary amine, more preferably it is selected from diisopropylethylamine and triethyl amine, more preferably the base is triethylamine. When used, it is preferred to employ at least about one equivalents of the base in comparison with the amount of benzamide salt employed, preferably about 1.8 equivalents.
[0101] In some embodiments using triethylamine to mediate the coupling reaction, it is preferred to add the triethylamine over a period of the reaction time, preferably about two thirds of the reaction period, while maintaining the reaction mixture temperature from about [−5° C.] to about [+5° C.]. In some embodiments utilizing triethylamine, it is preferred to work up the reaction after the reaction period by seeding the reaction mixture with the solid amounts of the compound of formula 2C to nucleate crystal growth, then add acetic acid to insure that any base still present is neutralized, thus maximizing yields of the coupled product. When used, it is preferable to add an amount of acetic acid equivalent to twice the mole amount of triethylamine added. In some embodiments employing acetic acid, following acid addition it is preferred to heat the reaction mixture, preferably to at least 60° C., more preferably to a temperature of from about 60° C. to about 70° C., then lower the temperature in controlled stages, preferably, first to a temperature of less than about 35° C., more preferably to a temperature of from about 25° C. to about 35° C., followed by a period of time in which the reaction mixture is cooled, preferably to a temperature of from about [−5° C.] to about [+5° C.], to precipitate crystals of the intermendiate compound of Formula 2C.
[0102] The aminofuran salt compounds of Formula 2D used in the process of Scheme V (above) are preferably prepared in accordance with Scheme VII (below).
[0000]
[0103] Scheme VII utilizes as a starting material a 4-substituted-5-methyl-2-propionylfuran (2Dd), wherein R 1 is hydrogen or a substituent comprising from 1 carbon atom to about 10 carbon atoms selected from linear, branched, and cyclic alkyl moieties and substituted linear, branched, and cyclic alkyl moieties. The process of Scheme VII comprises reductively aminating the compound of Formula (2Dd) by treatment with formamide in the presence of formic acid to provide an intermediate compound of the Formula (2Dc), hydrolyzing intermediate (2Dc) in situ by the addition of aqueous base to the reaction mixture yielding the freebase racemic compound (2 Db); and precipitating a salt form of the compound 2 Db by treating it with an acid of the Formula H + [R-Anion − ], wherein “R-Anion − ” represents a monovalent anionic moiety. Preferably, the acid used to precipitate 2 Db comprises an “R-Anion − ” which is an optically active anionic moiety capable of preferentially forming a salt of the R-isomer of the compound of Formula 2D, thereby resolving the racemic reaction mixture by selective precipitation of the compound of the Formula (2Da). When R 1 is an isopropyl substituent ((CH 3 ) 2 CH—), the compound of Formula 2Da is named (R) 1-(4-Isopropyl-5-methyl-furan-2-yl)-propylamine, also termed herein for convenience, (R)-ethyl-5-methyl-2-furanmethanamine. Examples of “R-Anion − ” which are suitable for resolving the reaction mixture containing the freebase racemate (2 Db) according to the foregoing include, but are not limited to, tartaric acid and derivatives thereof. Preferably the acid used for resolving the reaction mixture is dissolved in an alcohol, which is preferably methanol or ethanol.
[0104] The inventors have surprisingly found that using the process illustrated in Scheme VII with an optically active “R-Anion − ” can provide precipitation yields of over 80% of the desired R-isomer present in the racemic solution and yield a precipitate having an optical purity in excess of about 94% ee. In some embodiments it is preferred to add a coacid along with the acid supplying “[R-Anion − ]” to decrease the amount of the optically active acid needed to achieve resolution of the target compound and may increase the optical purity of the precipitated solids. The inventors have surprisingly found that the use of a coacid can provide an optically active product having more than about 99% ee. In some embodiments using a coacid, the coacid is preferably HCl, malonic acid, acetic acid, formic acid, chloroacetic acid, or trifluoroacetic acid, more preferably the coacid is trifluoroacetic acid.
[0105] In some embodiments, optionally, preceding the resolution step in Scheme VII, wherein the desired isomer of the compound of Formula 2 Db is precipitated as a salt, the reaction mixture is treated with an acid having an anion which preferentially forms an insoluble complex with the unwanted isomer of the compound of the Formula 2 Db, thereby preferentially precipitating the unwanted isomer and increasing the ratio of desired isomer to unwanted isomer in solution. It will be appreciated that when such a step precedes the resolution step shown in Scheme VII, prior to treatment with an optically active acid to precipitate the desired isomer the reaction mixture is filtered to remove precipitate solids comprising the unwanted isomer. Without wanting to be bound by theory, it is believed that in most cases precipitation of the unwanted isomer prior to precipitating the desired isomer will provide an increase in the enantiomeric purity of the product produced in the resolution step.
[0106] Preferably, R 1 in the compound of Formula (2Dd) is hydrogen or isopropyl (—CH(CH 3 ) 2 ). When R 1 is hydrogen, the compound of Formula 2Dd is 2-methyl-5-propionyl furan and is commercially available. In some embodiments where R 1 is hydrogen, preferably the solvent R 3 —OH used in the resolution step is methanol. In some embodiments where R 1 is isopropyl, preferably solvent R 3 —OH used in the resolution step is ethanol.
[0107] In some embodiments, preferably the process of providing aminofuran salt compound of Formula (2Da) is carried out with the formamide starting compound of Formula (2Dd) dissolved in formamide and add the required amount of formic acid thereto. In some embodiments it is preferred to heat the reaction mixture after the addition of formic acid to a temperature of at least about 100° C., preferably to a temperature of from about 140° C. to about 150° C.
[0108] In some embodiments, after reductive amination and hydrolysis, it is preferred to extract the crude racemic aminofuran of Formula (2 Db) from the reaction mixture with an alcohol of the Formula R 3 —OH, and carry out the resolution step “c” using the resulting alcohol solution of crude aminofuran, where R 3 — is a linear or branched alkyl of 6 carbon atoms or less.
[0109] As mentioned above, with reference to Scheme I and Scheme IIIa, the preparation of the compound of Formula IV(i) [3-amino-2-hydroxy-benzamide] and its use in the synthesis of compounds of Formula; is described in U.S. Pat. No. 7,071,342 (the '342 patent), see for example, col. 23, lines 3 to 30.
[0000]
[0110] However the inventors have found that the compound of Formula IV(i) is unstable, making isolating, storing, and shipping the free-base compound problematic. Surprisingly, the inventors have found that treatment of the compound of Formula IV(i) with an acid to form the salt compound of Formula 2B (Scheme VI), for example, the compound of Formula 2B1,
[0000]
[0000] yields sufficiently stable intermediate compounds that they can be made remotely, then isolated, shipped and stored for use at a time and in a place which is convenient to carry out further reactions, for example, as illustrated in Scheme VI using the compound of Formula 2B to prepare compounds of Formula Ia. Moreover, with reference to Scheme VI, the inventors have found that the benzamide/dialkyl squarate coupling reaction leading to the compound of Formula 2C proceeds more readily when the benzamide salt of Formula 2B1 is used in the coupling step in place of the compound of Formula IV(i) and the reaction is carried out in a polar solvent in the presence of a tertiary amine base, for example, triethylamine.
[0111] In some embodiments the compound of Formula 2B is prepared starting with a compound of Formula IV(i)a,
[0000]
[0000] wherein “X” is selected from hydrogen and a halogen selected from F, Cl, Br, and I.
[0112] Although it will be appreciated that the compound of Formula 2B1 can be prepared in many different ways, in some embodiments of the present invention process it is preferred to prepare a compound of Formula IV(i) by reducing the compound of Formula IV as shown in step 1 of Scheme III. The preparation of the compound of Formula IV and its reduction to the compound of Formula VI(i) has been described in the '342 patent, see for example, cols. 31 to 34, which is incorporated by reference herein. In some embodiments it is preferred to reduce the compound of Formula IV using hydrogen and Pd/C (palladium dispersed on carbon black) hydrogenation catalyst in some embodiments it is preferred to carry out the reduction with the compound of Formula IV dissolved in a mixed solvent comprising t-butyl-methyl ether and ethanol, preferably used in a 1:1 volumetric ratio. In some embodiments, following the reduction of the compound of Formula IV, it is preferred to collect the solution containing the compound of Formula VI(i), filter it, and treat the filtrate with aqueous acid to form the compound of Formula 2B1. In some embodiments it is preferred to collect the compound of Formula 2B1 thus formed by crystallizing it from the reaction mixture with the addition of an anti-solvent, for example, heptane. In some embodiments when the compound is precipitated it is preferred to add solid compound of the Formula 2B1 to seed the solution and aid precipitation. In some embodiments the “seed” material is prepared in accordance with the procedures described in the '342 patent. In some embodiments the “seed” material is prepared in a process carried out in accordance with the present invention either without seeding or with seeding using material prepared in an earlier process batch.
[0113] In some embodiments it is preferred to select the acid reacted with the compound of Formula VI(i) from mineral acids, for example, but not limited to H 2 SO 4 , H 3 PO 4 , HBr, and HCl, and organic acids, for example, but not limited to, maleic acid, fumaric acid, malic acid, sulfonic acids, oxalic acid, and tartaric acids and derivatives thereof. In some embodiments, when hydrochloric acid is selected, it is used as a 37N (concentrated) aqueous solution. In some embodiments, when the acid is selected from p-tolysulfonic acid, oxalic acid, and tartaric acid, it is preferred to treat the reaction mixture directly with the solid acid. It will be appreciated that the manner of precipitating the salt form of the 3-amino-2-hydroxy-benzylamide (compound of Formula 2B1) is not critical, and other methods can be employed to precipitate the salt, and other acids can be employed to precipitate their respective salts, and still be within the scope of the present invention.
[0114] Conveniently, formation of the compound of Formula 2B1 can be carried out at ambient temperature, although it will be appreciated that other temperature regimes can be employed and remain within the scope of the present invention.
[0115] Accordingly, when reacted with an acid, for example, hydrochloric acid, the compound of Formula IV(i) can be used to provide the amino-hydroxybenzamide salt compound of Formula 2B1. In some embodiments it is preferred to produce the compound of Formula 2B1 from the compound of Formula IV(i) by treating a methyl-t-butyl ether/ethanol solution of the compound of Formula IV(i) with concentrated HCl. In some embodiments it is preferred to precipitate the salt product from an isopropanol/methyl-t-butyl ether solution by adding heptane antisolvent. It will be appreciated that other acid salts, produced using the same procedure can also be employed in the reaction of Scheme III. Suitable salts include, but are not limited to, oxalate, p-tolysulfonate, monobasic tartarate, and tartarate.
[0116] There follows non-limiting examples illustrative of the present invention but not limiting the present invention.
EXAMPLES
[0117] Unless otherwise specified, all reagents are articles of commerce, food grade or pharmaceutical grade, and used as received.
[0118] Example Ia
In Situ Preparation of Dimethyl Squarate (2A2) and Reaction With Compound (2B) to Form Compound (2Ca)
[0119]
[0120] Into a 50 gallon glass reactor equipped with a thermocouple, N 2 inlet and feed tank was charged 9.5 kg of the compound of Formula 2A. The reactor was then charged with 65 liters dry methanol (Karl Fischer titration “KF” indicates water present at <0.1%) followed by 20 liters trimethylorthoformate and 0.2 kg trifluororacetic acid. The reaction mixture was heated to reflux and maintained for about one hour. The reaction mixture was concentrated at one atmosphere until the internal temperature exceeded 70° C. The reaction mixture was maintained at reflux for about four hours then the temperature was adjusted to a temperature between 40° C. and 50° C. The reactor was charged with 26 liters dry methanol and the reaction mixture temperature was adjusted to about 20° C. to 30° C. The reactor was charged with 78 liters of dry methanol and the reaction mixture temperature was adjusted to a temperature between −5° C. and 5° C. The reactor was charged with 13.0 kg of the compound of Formula 2B. Triethylamine (TEA), 11.1 kg, was charged into the reactor over 4 hours while maintaining the batch at a temperature between −5 and 5° C. About one and a half hours after the start of the TEA charge, the reaction mixture was seeded with 130 grams of the compound 2C. After the addition of TEA was completed the reaction mixture was agitated for about 30 minutes maintaining the batch temperature between −5 and 5° C. Acetic acid, 12 liters was charged into the reactor while maintaining the batch at a temperature between −5 and 5° C. The reaction mixture was heated to a temperature between 60 and 70° C. and maintained in this temperature range for about 1 hour. After about 1 hour the temperature was adjusted to a temperature in the range of 25° C. to 35° C. and maintained at that temperature range for about 1 hour, then the temperature was readjusted to a temperature in the range of [−5° C.] to [+5° C.] over about 1 hour. The reaction mixture was filtered and the filter cake washed with 65 liters methanol. The solids collected were dried in a vacuum oven for about 24 hours with the oven temperature maintained at 60° C. to 70° C. Yield was 14.5 kg, about 81% based on the amount of the compound of Formula 2C employed.
[0121] 1 HNMR(CD 3 CN)
[0122] 8.07 (1H, s); 7.56 (1H, d) 7.28 (1H, d); 6.99 (1H, t); 4.35 (3H, s); 3.10 (6H, s)
Example Ib
Preparation of the Compound of Formula (2Ca) from Commercial Dimethyl Squarate (2A2)
[0123] Charge 6.3 grams of the compound of Formula 2A1 (Aldrich, used as received) and 5.0 grams of the compound of Formula I to 250 ml round bottom flask equipped with a thermocouple, N 2 inlet and addition funnel. Charge 41 ml dry methanol (KF<0.1%). Adjust the batch to temperature between −5 and 5° C. Over about 5 hours, charge 4.9 ml (0.98×) triethylamine (TEA) to the batch while maintaining the batch at a temperature between −5 and 5° C. After the addition of TEA is complete, agitate the batch for about one hour at a temperature between [−5° C.] and [+5° C.]. Charge 2.8 ml acetic acid while maintaining the batch at a temperature between [−5° C.] and [+5° C.]. Adjust the batch volume to 63 ml by adding dry methanol. Heat the batch to reflux and maintain for about 15 minutes. Adjust the temperature to about [−5° C.] and [+5° C.] over about 1 hour. Filter the batch and wash the filter cake with 25 ml methanol. Dry the batch in a vacuum oven for at least 24 hours at 60 to 70° C. Yield 7.5 g, 88%.
Example Ic
Preparation of the Compound of Formula (2Ca) from Commercial Diethyl Squarate (2A3)
[0124]
[0125] Charged 44.0 kg of the compound of Formula I, 225 kg dry ethanol and 41.8 kg of the compound of formula II to a 300 gallon glass lined reactor equipped with a thermocouple. N 2 inlet and feed bottle. Adjusted the batch to temperature between 0 and 10° C. Over about 1 hour, charged 17.1 kg triethylamine (TEA) to the batch while maintaining the batch at a temperature between 0° C. and 10° C. After the addition of TEA was complete, agitated the batch for about three hours at a temperature between 0° C. and 10° C. Over about 3 hours, charged additional 8.2 kg triethylamine (TEA) to the batch while maintaining the batch at a temperature between 0° C. and 10° C. After the addition of TEA was complete, agitated the batch for about three hours at a temperature between 0° C. and 10° C. Charged 19 liters acetic acid while maintaining the batch at a temperature between 0° C. and 10° C. Adjusted the batch volume to 440 liters by adding dry ethanol. Heated the batch to reflux and maintain for about 15 minutes. Adjusted the temperature to about 0° C. and 10° C. over about 2 hours. Filtered the batch and washed the filter cake with 220 liters 50% v/v ethanol in water. Dried the batch in a vacuum oven for at least 12 hours at 50 to 60° C. Yield 52 kg, 88%.
[0126] 1 HNMR (CD 3 CN)
[0127] 7.61 (1H, d); 7.28 (1H, d); 6.96 (1H, t); 4.69 (2H, q); 3.10 (6H, s), 1.44 (3H, t).
Example IIa
Preparation of 2-Hydroxy-N,N-dimethyl-3-[[2-[[1(R)-(5-methyl-2-furanyl)propyl]amino]-3,4-dioxo-1-cyclobuten-1-yl]amino]benzamide Monohydrate (Form 4)
[0128]
[0129] To a suspension of 10.1 g (2D1) (1.06 eq.) in 30 ml of water and 40 ml of 2-methyltetrahydrofuran was added 6.5 ml 32% of sodium hydroxide solution. The resulting aqueous layer was tested by pH paper. Additional small amount of caustic solution was added if pH was lower than 13. The organic was separated and the aqueous was extracted with 20 ml of 2-methyltetrahydrofuran. The combined organic layers was mixed with 10.0 g (1.0 eq.) of (2C) and the suspension was heated at 70° C. for 5 hours until the remaining starting material was below 1.0%. N-Propanol (50 ml) was added. The volume of the reaction mixture was reduced by distillation under partial vacuum to 40 ml (4×), followed by addition of 50 ml of n-propanol. The volume of the solution was reduced again under partial vacuum to 60 ml. The mixture was diluted to 90 ml with n-propanol and 0.3 ml of acetic acid was charged. The solution was then filtered. The filtrate was then diluted to 140 ml with n-propanol and the solution was heated to 70° C. Water (125 ml) was added while the batch temperature was maintained above 70° C. The solution was cooled to 62° C. and 200 mg (0.02×) seeds of the compound of Formula I (Form 4, previously prepared) were added. The mixture was stirred at 62° C. for 2 hours before it was cooled to 20° C. over about 5 hours. The suspension was then warmed up to 55° C. over 30 minutes before slowly cooling to 20° C. over 4 hours. The heating and cooling operation was repeated several times to grow crystals of the desired particle size. The suspension was finally cooled to 20° C. before filtration. The wet cake was washed with 80 ml solvent mixture of n-propanol and water (1:1). The cake was dried at 50° C. for 12 hours or until KF analysis showed the water content was below 4.7%, to give 11.5 g (85%) white needles, m.p. 83° C. XRD analysis showed the crystal form of the solids was form 4 monohydrate. 1 H NMR (DMSO-D6) δ, 0.91 (t, 3H, 1.84 (m, 1H), 1.94 (m, 1H), 2.25 (s, 3H), 2.92 (S, 6H), 5.13 (m, 1H), 6.01 (d, 1H, J=3.1), 6.25 (d, 1H, J=3.1), 6.85 (m, 2H), 7.78 (d, 1H, J=7.3), 8.65 (d, 1H, J=8.9), 9.29 (br, 1H), 9.99 (br, 1H). 13 C NMR (DMSO-D6): 10.26, 13.32, 27.18, 52.78, 106.42, 107.52, 119.77, 120.76, 122.18, 124.42, 128.64, 143.25, 151.31, 152.06, 163.41, 168.27, 168.52, 180.17, 183.95, 184.71. Anal. calcd. for C 12 H 25 N 3 O 6 (monohydrate 415.4): C, 60.71; H, 6.07; N, 10.11. Found: C, 60.65; H, 5.93; N, 9.91.
Example IIb
Preparation of 2-Hydroxy-N,N-dimethyl-3-[[2-[[1(R)-(5-methyl-2-furanyl)propyl]amino]-3,4-dioxo-1-cyclobuten-1-yl]amino]benzamide Monohydrate (Form 4)
[0130]
[0131] Following the same procedure used in Example IIa, 40.2 kg of 2D1 was treated with the base to make 2D1a, which was subsequently reacted with 39.8 kg of 2Cb (made previously from diethylsquarate), to give 43.8 kg (81%) of the title compound.
Example III
Preparation of 2-Hydroxy-N,N-dimethyl-3-amino-benzamide Salts (2B1)
[0132] There follows four examples of the preparation of the hydrochloride, oxalate, p-tolysulfonate, and tartarate salts of 3-amino-2-hydroxy-benzamide in accordance with Scheme V, below.
[0000]
Example III a
Preparation of Compound 2B (HCl salt of 3-amino-2-hydroxy-benzamide (compound (IV(i)))
[0133] To a suspension of 10 g (34.6 mmol) of (IV) in a mixture of 21 ml of methyl t-butylether and 49 ml of ethanol was added 13.7 ml of KOEt (24%) in ethanol, followed by addition of 0.8 g of 5% Pd/C (50% wet). The mixture was then agitated under 120-150 psi hydrogen pressure for about 6 hours. Upon completion of the reaction, the batch was filtered through a Celite pad and the cake was washed with 80 ml of solvent mixture of methyl t-butylether and ethanol (1:1). The filtrate was treated with 3.7 ml of concentrated HCl solution. The batch was then concentrated under reduced pressure to about 50 ml. Isopropanol (100 ml) was added and the resulting solution was concentrated under vacuum to about 40 ml. Methyl t-butylether (50 ml) was added, followed by a slow addition of 110 ml of heptane. Finally, the mixture was cooled to 0° C. The solids were collected by filtration and the cake was washed with 20 ml solvent mixture of 1:1 methyl t-butylether/EtOH. The cake was dried at 60° C. for 10 hours in a vacuum oven, to give 7.24 g (96%) off-white solids of the compound of Formula 2B. 1 H NMR (DMSO-D6): 7.50 (d, 1H), 6.96 (dd, 1H), 7.17 (d, 1H), 2.9 (br, 6H), 10.2 (br, 4H), 13 C NMR (DMSO-D6): 147.7, 121.4, 125.9, 120.6, 128.5, 127.1, 167.8.
Example IIIb
Preparation of 3-amino-2-hydroxy-benzamide Oxalate Salt (2B2),
[0134] Following the procedure described for preparing the HCl salt (2B) in Preparative Example 1, 10 g (34.6 mmol) of compound (IV) was hydrogenated under the same condition and the filtered solution was treated with 3.3 g of oxalic acid. Following the same procedure as above resulted in 8.5 g (90%) off-white solids, 1 H NMR (DMSO-D6): 6.45 (m, 2H), 6.17 (dd, 1H), 2.70 (s, 6H). 5.5 (very broad, 4H).
Example IIIc
Preparation of 3-amino-2-hydroxy-benzamide p-Tolysulfonate Salt (2B3)
[0135] Following the procedure described for preparing the HCl salt (2B) in Preparative Example 1, the compound of Formula 2B3 was prepared by placing 10 g of compound (IV) was hydrogenated under the same condition and the filtrate was treated with 7.9 g (41.1 mmol) p-toluenesulfonic acid monohydrate. The resulting mixture was concentrated as above and the mixture after heptane addition was stirred over night at room temperature, to give 11.4 g (94%) off-white solids. 1 H NMR (DMSO-D6): 7.49 (d, 2H), 7.29 (d, 1H), 7.15 (m, 3H), 6.93 (dd, 1H), 2.90 (s, 6H), 2.31 (s, 3H),
Example IIId
Preparation of 3-amino-2-hydroxy-benzamide tartarate Salt
[0136] Following the procedure described for preparing the HCl salt (2B) in Preparative Example 1, the compound of Formula 2B4 was prepared by placing 10 g of compound (IV) was hydrogenated under the same condition and the filtrate was treated with 5.47 g (36.5 mmol) of tartaric acid. Following the same procedure as described in 527123-PS preparation resulted in 9.1 g (80%) of off-white solids. 1 H NMR (DMSO-D6): 8.5 (br, 3H), 6.6 (dd, 2H), 6.38 (d, 1H), 4.26 (s, 2H), 3.6 (b, 2H), 2.96 (s, 6H).
Example IV
Preparation of Amino-Furan Salt Intermediates (2Da)
[0137] There follows three examples of preparing various salt compounds of the Formula 2Da
Example IVa
Preparation of tartarate salt of α-(R)-Ethyl-5-methyl-2-furanmethanamine D-tartrate (2Da1)
[0138]
[0139] To a stirred solution of 100 g 2-methyl-5-propionylfuran (1.0 equiv., 0.724 mol) and 115 mL formamide (2.90 mol, 4.0 equiv.) at 25° C. was added 30.0 mL formic acid (0.796 mol, 1.1 equiv.). A small exotherm was observed. The resulting solution was heated to 140-150° C. over 1 hour, held at this temperature for 12 hours, and then cooled to 20-30° C. over 1 hour. To the stirred solution of crude intermediate amide product was added 641 mL 25% w/w aq. NaOH (5.07 mol NaOH, 7.0 equiv.). An exotherm was observed. The heterogeneous solution was vigorously agitated to achieve a homogeneous mixture. The solution was heated to 65-70° C. over 30 min., held at this temperature for 10 hours, then cooled to 20-30° C. over 1 hour. The phases were allowed to separate, drained the aqueous layer, then washed the organic layer of crude racemic amine twice with 10% aq. NaCl (100 mL). The crude racemic amine was taken up in 350 mL methanol and 28 ml water. The solution was heated to 50-60° C. and to it was added 73.5 g D-tartaric acid (0.502 mol, 1.0 equiv.) as a solution in 210 mL, methanol and 14 mL water over 30 minutes. The reaction was held at 60° C. for 15 min, then cooled to 15-35° C. over 2 hours. The suspension was then filtered under vacuum and washed twice with 70 mL methanol. The wet cake was dried in a vacuum oven at 50-60° C. for at least 8 hours to afford 60.1 g (28.7% yield, 99% se) of a white crystalline solid; mp=191-194° C.; 1 H NMR (DMSO-D6): δ 0.81 (t, 3H, J=7.4 Hz), 1.79-1.95 (m, 2H), 2.26 (s, 3H), 3.99 (s, 2H), 4.18 (dd, 1H, J=8.9, 5.7 Hz), 6.07 (dd, 1H, J=3.1, 1.1 Hz), 6.38 (d, 1H, J=3.1 Hz), and 8.16 (brs, 6H). 13 C NMR (DMSO-D6): 10.31, 13.63, 25.46, 49.40, 72.31, 107.03, 109.98, 149.46, 152.01, 175.01 ppm.
Example IVa
Alternative Preparation of tartarate salt of α-(R)-Ethyl-5-methyl-2-furanmethanamine D-tartrate (2Da1)
[0140]
[0141] To a stirred solution of 60 g 2-methyl-5-propionylfuran (1.0 equiv., 0.434 mol) and 69 mL formamide (1.74 mot, 4.0 equiv.) at 25° C. was added 16.4 mL formic acid (0.434 mol, 1.0 equiv.). The resulting solution was heated to 140-150° C. over 1 hour, held at this temperature for 16 hours, and then cooled to 20-30° C. over 1 hour. To the stirred solution of crude intermediate amide product was added 377 mL 25% w/w aq. NaOH (2.89 mol NaOH, 7.0 equiv.). The heterogeneous solution was vigorously agitated to achieve a homogeneous mixture. The solution was heated to 80-90° C. over 30 min., held at this temperature for 6 hours, then cooled to 20-30° C. over 1 hour. The phases were allowed to separate, and the aqueous layer was drained. The crude racemic amine was distilled under vacuum (20-25 mmHg) to afford 50.1 g (82% yield) of a pale yellow oil; bp=60-65° C. (40-45 mmHg): 1 H NMR (DMSO-D6) δ 0.84 (3H, t, J=7.4 Hz), 1.49-1.58 (1H, m), 1.81-1.71 (1H, m), 1.61 (2H, brs), 2.21 (3H, s), 3.63 (1H, t, J=6.54 Hz), 5.93 (1H, dd, J=2.98, 1.00 Hz), 6.00 (1H, d, J=1.0 Hz); 13 C NMR (DMSO-D6): 10.6, 13.6, 29.7, 51.1, 105.2, 106.1, 149.8, 158.5 ppm. To a solution of the racemic amine in 250 mL methanol was added 50.5 g D-tartaric acid (336.5 mmole) as a solution in 150 mL methanol over 30 minutes. The solution was heated to 40-50° C. and held at this temperature for 20 minutes. The reaction was slowly cooled to 0-10° C. over 2 hours. The suspension was then filtered under vacuum and washed with methanol (100 mL). The wet cake was dried in a vacuum oven at 50-60° C. for at least 8 hours to afford 44.1 g (42.3% yield from racemic amine, 94% ee) of a white crystalline solid; characterized as above.
Example IVa
Preparation Using a Coacid in Resolution of tartarate salt of α-(R)-Ethyl-5-methyl-2-furanmethanamine D-tartrate (2Da1)
[0142]
[0143] To a solution of racemic amine (5.0 g, 35.9 mmole, prepared as described above) in methanol (25 mL) and water (1.8 mL) was added an acid (0.5 equiv., 18.0 mmole, see table below). The solution was warmed to 60° C. A solution of D-tartaric acid (3.23 g, 21.6 mmole, 0.6 equiv.) in methanol (15 mL) was added dropwise over 10 min. The reaction was held at 60° C. for 20 min., cooled to 25° C. over 90 minutes, and seeded with a small amount of product. After product precipitated the suspension was cooled to 0-10° C. over 30 minutes, held 30 minutes, then filtered under vacuum and washed with methanol (10 mL). The wet cake was dried in a vacuum oven for 12 hours to afford a white crystalline solid (see table below for yield).
[0000]
Acid
Yieid (%)
Ee (%)
none
19.3
96.5
acetic acid
34.2
98.9
formic acid
39.1
97.3
malonic acid
44.7
98.5
hydrochloric acid
43.2
99.0
chloroacetic acid
44.9
98.4
trifluoroacetic acid
44.8
99.4
Example V
Preparation of 2-hydroxy-N,N-dimethyl-3-[[2-[[1(R)-[5-methyl-4-(1-methylethyl)-2-furanyl]propyl]-amino]-3,4-dioxo-1-cyclo-buten-1-YL]amino]-benzamide (the compound of Formula II)
[0144] There follows two examples of the preparation of a compound of Formula II according to the following scheme:
[0000]
[0145] Example Va utilizes a methyl-THF workup to isolate the final product, example Vb utilizes an isopropyl alcohol workup to isolate the final product.
Example Va
Step 1: 1-(4-Isopropyl-5-methyl-2-furyl)propan-1-one (206)
[0146] Under nitrogen, 2-methyl-5-propionylfurane (100 g, 0.72 moles) was added dropwise at 0-30° C. to aluminium chloride (131 g, 0.96 moles). The resulting suspension was stirred for further 30 minutes at room temperature and then cooled to 0-5° C. Within one hour isopropyl chloride (76 g, 0.96 moles) was added dropwise at 0-10° C. and the mixture stirred until complete conversion was achieved (HPLC). The mixture was hydrolyzed on 2 L of water/ice. The pH was adjusted to 1 by addition of sodium hydroxide solution (60 mL) and the product was extracted into 500 mL TBME. The aqueous layer was separated and reextracted with 200 mL TBME. The combined organic layers were washed with 500 mL brine and evaporated to minimum volume. Yield: 132.5 g (102%) of a yellow-brown liquid.
[0147] Assay (HPLC: YMC Pack Pro C18 150×4.6 mm, 5 μm; 220 nm; ACN/0.05% TFA: water/0.05% TFA 20:80 to 95:5 within 23 min): 60% pure by area, RT 17.2 min.
Step 2: [1-(4-Isopropyl-5-methyl-2-furyl)propyl]amine (207)
[0148] Under nitrogen, a mixture of crude 1-(4-Isopropyl-5-methyl-2-furyl)propan-1-one (100 g), formamide (100 g, 2.22 moles) and formic acid (28.7 g, 0.61 moles) was heated to 140° C. for about two days until complete conversion to intermediate N-(1-(4-isopropyl-5-methylfuran-2-yl)propyl)formamide was achieved. The mixture was cooled to 20-25° C. and diluted with 400 mL methanol and 400 mL diisopropylether. Aqueous sodium hydroxide (1.2 kg, 25% in water) was added and the mixture was heated to reflux (55-60° C.) for about one day until complete conversion to [1-(4-Isopropyl-5-methyl-2-furyl)propyl]amine was achieved. The mixture was cooled down to 20-25° C. and the phases were separated. The organic layer was washed with 400 mL brine (5% in water). The combined aqueous layers were reextracted with 200 mL diisopropylether. The combined organic layers were evaporated to minimum volume. Yield: 94.6 g (45% abs (absolute), from 2-methyl-5-propionylfurane) of a yellow-brown liquid.
[0149] Assay (HPLC: YMC Pack Pro C18 150×4.6 mm, 5 μm; 220 nm; ACN/0.05% TFA: water/0.05% TFA 20:80 to 95:5 within 23 min): 48.5% pure vs. standard, RT 9.2 min.
Step 3: (R)-1-(4-Isopropyl-5-methylfuran-2-yl)propan-1-amine (2S,3S)-2,3-dihydroxysuccinate (208)
[0150] Under nitrogen, crude [1-(4-isopropyl-5-methyl-2-furyl)propyl]amine (51 g, 135 mmol active) was dissolved in 204 mL dry ethanol at 60° C. 20% of a solution of D-(−)-tartaric acid (20.3 g, 135 mmol) in a mixture of 102 mL ethanol/water (15:1) was added at 55° C. The solution was seeded. The residual solution of tartaric acid was added within 10 minutes. The suspension was cooled to 20° C. and stirred at room temperature over night. The salt was filtered off and washed with dry ethanol until a colorless mother liquor was obtained. The product was dried in vacuum at 50° C. to constant weight. Yield: 16.9 g (38% abs.) of white crystals.
[0151] Assay (HPLC: YMC Pack Pro C18 150×4.6 mm, 5 μm; 220 nm; ACN:0.01M KH 2 PO 4 pH=2.5 (H 3 PO 4 ) 15:85 to 80:20 within 25 min): 95.8% by area, RT 8.8 min.
[0152] Optical Purity (HPLC: Chiralcel OD-R 250×4.6 mm; 226 nm; ACN:0.5M NaClO 4 40:60): dr 98:2, RT 12.6 min (R), 16.3 min (S). Wherein “dr” represents diastereomeric ratio.
Step 4: 2-Hydroxy-3-[(2-{[(1R)-1-(4-isopropyl-5-methyl-2-furyl)propyl]amino}-3,4-dioxocyclobut-1-en-1-yl)amino]-N,N-dimethylbenzamide (Compound II)
[0153] Under nitrogen, (R)-1-(4-Isopropyl-5-methylfuran-2-yl)propan-1-amine (2S,3S)-2,3-dihydroxy-succinate (208)(2.0 g, 6 mmol) was suspended in 6 ml water and 8 mL 2-methyl tetrahydrofurane (MeTHF) at 20-25° C. 1.3 mL aqueous sodium hydroxide (30%) were added and the organic layer was separated after 5 minutes. The aqueous layer was extracted with 4 mL MeTHF. The combined organic layers were added to (209B) (1.74 g, 5.7 mmol) and 4 mL MeTHF were added. The mixture was heated to 65° C. for 4.5 hours and was then cooled to 20-25° C. After 16 hours at 20-25° C. the product crystallized and was isolated by filtration. The product was washed with MeTHF and dried in vacuum at 50° C. to constant weight. Yield: 1.25 g (47%) as off-white solid. Assay (NMR): 95% pure.
[0154] If one were to use compound (209A) in place of compound (209B) in Step 4 of Example IV, one would also obtain compound (II) using this same procedure.
Example Vb
Step 1 1-(4-Isopropyl-5-methyl-2-furyl)propan-1-one (206)
[0155] Under nitrogen, 2-methyl-5-propionylfurane (120 g, 0.87 moles) was added dropwise at 0-35° C. to aluminium chloride (158 g, 1.18 moles) in dichloromethane (60 mL). The resulting solution was stirred for further 30 minutes at room temperature and then cooled to 0-5° C. Within one hour isopropyl chloride (96 g, 1.21 moles) was added dropwise at 0-10° C. and the mixture was stirred at 0-5° C. until complete conversion was achieved. The mixture was hydrolyzed on 2 L of water/ice and TBME (480 mL) was added. The pH was adjusted to 1 by addition of sodium hydroxide solution 30% (50 mL) and the phases were split. The aqueous layer was reextracted into 240 mL TBME. The combined organic layers were washed with 300 mL brine twice and evaporated to minimum volume. Yield: 168 g (107%) of a yellow-brown liquid.
[0156] Assay (HPLC: YMC J'sphere ODS-H80 150×4.6 mm, 4 μm; 220 nm; ACN/0.01M KH 2 PO 4 pH 2.5 (H 3 PO 4 ) 55:45 to 80:20 within 15 min): 55% pure by area, RT 6.6 min.
Step 2 [1-(4-Isopropyl-5-methyl-2-furyl)propyl]amine (207)
[0157] Under nitrogen, a mixture of crude 1-(4-Isopropyl-5-methyl-2-furyl)propan-1-one (206) (164 g), formamide (158 g, 3.5 moles) and formic acid (46 g, 0.98 moles) was heated to 140° C. for about two days until complete conversion to intermediate N-(1-(4-isopropyl-5-methylfuran-2® yl)propyl)formamide was achieved. The mixture was cooled to 20-25° C. and diluted with 624 mL, methanol and 624 mL, diisopropylether. Aqueous sodium hydroxide (1.9 kg, 25% in water) was added and the mixture was heated to reflux (55-60° C.) for about one day until complete conversion to [1-(4-Isopropyl-5-methyl-2-furyl)propyl]amine (207) was achieved. The mixture was cooled down to 20-25° C. and the phases were separated. The organic layer was washed with 624 mL brine (5% in water). The combined aqueous layers were reextracted with 312 mL diisopropylether. The combined organic layers were evaporated to minimum volume. Yield: 149 g (37% abs. from 2-methyl-5-propionylfurane) of a brown liquid.
[0158] Assay (HPLC: YMC Pack Pro C18 150×4.6 mm, 5 μm; 220 nm; ACN/0.01M KH 2 PO 4 pH 2.5 (H 3 PO 4 ) 15:85 to 80:20 within 25 min): 56% pure by area, RT 8.7 min.
Step 3 (R)-1-(4-Isopropyl-5-methylfuran-2-yl)propan-1-amine (2S,3S)-2,3-dihydroxysuccinate (208)
[0159] Under nitrogen, crude [1-(4-isopropyl-5-methyl-2-furyl)propyl]amine (207) (151 g, 0.35 mol active) was dissolved in 440 mL, ethanol at 40° C. 55% of a solution of D-(−)-tartaric acid (60.6 g, 0.40 mol) in 337 mL ethanol was added at 40° C. The solution was seeded and the residual tartaric acid solution was added slowly. The suspension was cooled to 20° C. and stirred at room temperature for additional two hours. The salt was filtered off and washed with ethanol until a colorless product was obtained. The product was dried in vacuum at 40 to 50° C. to constant weight. Yield: 50 g (42% abs.) of white crystals.
[0160] Assay (HPLC: YMC Pack Pro C18 150×4.6 mm, 5 μm; 220 nm; ACN:0.01M KH 2 PO 4 pH=2.5 (H 3 PO 4 ) 15:85 to 80:20 within 25 min): 96.5% by area, RT 8.6 min. Optical Purity (HPLC: Chiralcel OD-R 250×4.6 mm; 226 nm; ACN:0.5M NaClO 4 40:60): dr 98:2 R:S, RT 11.4 min (R), 14.8 min (S)
Step 4 2-Hydroxy-3-[(2-{[(1R)-1-(4-isopropyl-5-methyl-2-furyl)propyl]amino}-3,4-dioxocyclobut-1-en-1-yl)amino]-N,N-dimethylbenzamide (Compound II)
[0161] Under nitrogen, (R)-1-(4-Isopropyl-5-methylfuran-2-yl)propan-1-amine (2S,3S)-2,3-dihydroxy-succinate (208) (60 g, 0.18 mmol) was suspended if 180 mL water and 240 mL 2-methyl tetrahydrofurane (MeTHF) at 20-25° C. 51 g aqueous sodium hydroxide (30%) was added dropwise and the organic layer was separated. The aqueous layer was reextracted with 120 ml. MeTHF. The combined organic layers were added to (209B) (51.8 g, 0.17 mol active) and the mixture was heated to 65° C. for 4.5 hours. After complete conversion was obtained the mixture was evaporated to a volume of about 175 mL. To the concentrated reaction mixture was added 2-Propanol (450 mL) and the mixture was concentrated to about 250 mL. Another 100 mL of 2-propanol were added and removed again. The mixture was filtered and washed with 180 mL hot 2-propanol. At 40° C. water (5 mL) and seeds (0.5 g) were added followed by dropwise addition of a mixture of water (25 mL) and 2-propanol (50 mL). At 40° C. further 450 mL water were added and the suspension was cooled to 20-25° C. The product was filtered off and washed 4 times with 100 mL of a mixture of water/2-propanol (1:1) each. The product was dried under vacuum at 35-40° C. to constant weight. Yield: 67.6 g as monohydrate (83% abs.).
[0162] Assay (HPLC: YMC Pack Pro C18 150×4.6 mm, 5 μm; 220 nm; ACN:0.01M KH 2 PO 4 pH=2.5 (H 3 PO 4 ) 20:80 to 70:30 within 10 min): 96.3% by area, RT 12.5 min. Optical Purity (HPLC: Astec, Cyclobond I 2000 RN, 250×4.6 mm, 5 μm; 293 nm): dr 99:1 R:S, RT 12.9 min (R), 10.9 min (S)
[0163] 1 H-NMR (CDCl 3 , 300 MHz): 7.65 (d, 1H, Ph), 6.75 (d, 1H, Ph), 6.65 (dd, 1H, Ph), 6.03 (s, 1H, fur), 5.1 (m, 1H, CHEt), 3.00 (s, 6H, NMe 2 ), 2.6 (sept, 1H, iPr), 2.07 (s, 3H, Me), 1.8 (m, 2H, Et), 1.02 (d, 6H, iPr), 0.85 (t, 3H, Et) ppm.
[0164] The above description of the invention is intended to be illustrative and not limiting. Various changes or modifications in the embodiments described herein may occur to those skilled in the art. These changes can be made without departing from the scope or spirit of the invention
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This application discloses a novel process for the preparation of 1,2-substituted 3,4-dioxo-1-cyclobutene compounds, which have utility, for example, in the treatment of CXC chemokine-mediated diseases, and intermediates useful in the synthesis thereof.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application incorporates by reference and claims priority to U.S. Provisional Application 61/786,352 filed on Mar. 15, 2013.
BACKGROUND OF THE INVENTION
The present subject matter relates generally to a garage door stop and seal system. Specifically, the present invention relates to a garage door stop and seal system including a door stop that conceals fasteners used to attach the system to a door jamb.
Seals that are currently on the market do not have concealed fasteners, removable or replaceable seals, and do not allow for expansion and contraction of the door stop. Exposed fasteners detract from the appearance of the home and allow the elements to directly effect the fasteners causing them to rust or discolor. The seals wear out eventually requiring the entire door stop and seal to be replaced. Not allowing for expansion and contraction causes the seals to buckle and warp when the materials expand and contract due to fluctuations in temperature.
Accordingly, there is a need for a garage door stop and seal system that allows for expansion and contraction of the door stop and seal. In addition, there is a need for a door stop that conceals fasteners, and enables the replacement of door seals.
BRIEF SUMMARY OF THE INVENTION
To meet the needs described above and others, the present disclosure provides a garage door stop system that allows for expansion and contraction of the door stop, enables replacement of the seal, and provides hidden, or concealed, fasteners.
The present disclosure provides a snap lock garage door stop and seal system that includes a replaceable seal, which is removable within a door stop. The door stop attaches to a receiver, wherein the door stop conceals fasteners that are used to secure the system to the door jamb. The door stop and the receiver may be extruded from any number of materials including, but not limited to, aluminum, polyvinyl chloride, and polypropylene, among others. In addition, the door stop may include a slot to receive the seal. The receiver and the door stop are designed to allow each to expand and contract independently of each other during, for example, during installation as well as over time due to climate changes.
In an embodiment, the garage door stop and seal system includes a receiver that mates with a door stop. The receiver includes a receiver body including a receiver inner surface, a receiver outer surface, a receiver first end, and a receiver second end. The receiver further includes a first receiver tab extending from the receiver first end, and a second receiver tab extending from the second end.
The door stop includes a stop body having an stop inner surface, a stop outer surface, a stop first end, and a stop second end. The stop first end includes a slot forming a receiving space, wherein a cross-sectional length of the receiving space is parallel to a cross-sectional length of the stop body.
The stop first end includes a first seat configured to removeably receive the first receiver tab, wherein the stop second end includes a second seat configured to removeably receive the second receiver tab.
The door stop further includes at least one spacer extending perpendicular from the stop inner surface of the stop body. For example, when the first receiver tab is engaged with the first seat and the second receiver tab is engaged with the second seat, the spacer creates a space between the stop inner surface and the receiver outer surface.
In an example, the first receiver tab removeably snaps into the first seat and the second receiver tab removeably snaps into the second seat. In another example, the first receiver tab and the second receiver tab are different shapes.
In yet another example, the second stop end includes an incline adjacent to the second seat, wherein the second seat is an angular notch to receive the second receiver tab.
The system may further include a seal, wherein a portion of the seal is removeably positioned in the receiving space of the slot. In an example, the slot may be an alligator retainer slot.
The receiver may include a receiver opening through the receiver body to receive a fastener. In an example, the system may further include a fastener, wherein at least a portion of the fastener is positioned in the receiver opening, wherein the fastener secures the receiver to a door jamb. When the first receiver tab is engaged with the first seat and the second receiver tab is engaged with the second seat, at least a portion of the fastener may be positioned within a portion of the space between the receiver outer surface and the stop inner surface.
In another embodiment, the system may include a door stop and a removable seal, wherein the door stop may not hide the fasteners. In such example, the removable seal may be replaced when needed and is free to expand and contract independently of the snap lock stop.
For example, the system may include a garage door stop including a stop body having an stop inner surface and stop outer surface, wherein a stop first end of the stop body includes a slot forming a receiving space, wherein a cross-sectional length of the receiving space is parallel to a cross-sectional length of the stop body. The door stop includes a stop opening through the stop body to receive a fastener. In an example, the door stop includes at least one spacer extending perpendicular from the stop inner surface of the stop body. For example, when the garage door stop is fastened to a door jamb, the spacer creates a space between the stop inner surface and the door jamb.
In an example, the receiving space is positioned between the stop inner surface and the stop outer surface of the stop body. The door stop may further include a seal that is removeably positioned in the receiving space of the slot. The door stop may further include a fastener, wherein at least a portion of the fastener is positioned in the stop opening, wherein the fastener secures the stop body to a door jamb.
An advantage of the present system is that it is easy to install and aesthetically pleasing. Specifically, the system conceals the seal behind the door stop, which results in the seal being less visible when the garage door is closed.
A further advantage of the present system is providing a snap lock receiver and snap lock door stop that may independently expand and contract, which improves the resiliency of the system during various weather conditions.
Another advantage of the present system is a configuration that conceals the fasteners used during installation, which allows for an improved seal between the system and the garage door.
Yet another advantage of the present system is providing a replaceable seal that may be replaced when the seal is worn without having to replace the entire door stop. Conventional systems typically have a seal integrated into the door stop itself. As a result, in conventional systems the entire door stop must be replaced when the seal has been worn out due to contact with the garage door.
Another advantage of the system disclosed herein includes providing an improved appearance of door stops by concealing fasteners, therefore, preventing the fasteners from rusting and discoloration.
Additional objects, advantages and novel features of the examples 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 description and the accompanying drawings or may be learned by production or operation of the examples. The objects and advantages of the concepts may be realized and attained by means of the methodologies, instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.
FIG. 1 is a cross-sectional view of the installed snap lock garage door stop and seal system.
FIG. 2 is a cross-sectional side views of the individual parts of the snap lock garage door stop and seal system shown in FIG. 1 .
FIG. 3 is a cross-sectional view of an installed alternative version of the snap lock garage door stop and seal system.
FIG. 4 is a cross-sectional side views of the individual parts of the alternative version of the snap lock garage door stop and seal system shown in FIG. 3 .
FIG. 5 is a cross-sectional view of an example of a seal disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1 , in an embodiment, the garage door stop and seal system 10 disclosed herein includes a receiver 12 that mates with a door stop 14 , wherein the receiver 12 is configured to attach to a door jamb.
FIG. 2 is an exploded view of an embodiment of the system 10 . As shown, the receiver 12 includes a receiver body 16 including a receiver inner surface 18 , a receiver outer surface 20 , a receiver first end 22 , and a receiver second end 24 . The receiver body 16 may be a generally linear structure that fits flush against a door jamb.
The receiver 12 further includes a first receiver tab 26 extending from the receiver first end 22 , and a second receiver tab 28 extending from the second end 24 . The first receiver tab 26 and the second receiver tab 28 may be different shapes. As shown, the first receiver tab 26 may have a shape of an annular knob. The second receiver tab 28 may be in the shape of an angular point. Of course, various shapes may be used for the first receiver tab 26 and the second receiver tab 28 .
The door stop 14 includes a stop body 30 having an stop inner surface 32 , a stop outer surface 34 , a stop first end 36 , and a stop second end 38 . The door stop 14 may further include at least one spacer 40 extending perpendicular from the stop inner surface 32 of the stop body 30 . The stop first end 36 and stop second end 38 may also include spacers 40 extending from the stop inner surface 32 . The spacers 40 are configured to enhance the structural integrity of the system 10 . However, even in examples lacking the spacers 40 , the structural integrity of the system is maintained. In addition, when the receiver 12 and the door stop 14 are connected, the spacers 40 maintain a space 62 or void between the receiver outer surface 20 and the stop inner surface 32 . The space 62 created may partially house an end of a fastener 58 , such that the fastener 58 is concealed from the environment and visually from an outside observer. It should be understood that the space 62 exists in examples that do not include the spacers 40 .
The stop first end 36 includes a slot 46 forming a receiving space 48 , wherein a cross-sectional length of the receiving space 48 is parallel to a cross-sectional length of the stop body 30 . In an example, the receiving space 48 is positioned between the stop inner surface 32 and the stop outer surface 34 of the stop body 30 . The receiving space 48 is configured to accept at least a portion of a seal 50 . For example, a portion of the seal 50 may be removeably positioned in the receiving space 48 of the slot 46 . In an example, the slot 46 may be an alligator retainer slot.
The stop first end 36 includes a first seat 42 configured to removeably receive the first receiver tab 26 . The first seat 42 may be any shape that is suitable to receive the first receiver tab 26 . For example, the first seat 42 is configured to receive the first receiver tab 26 that may have an annular or round knob shape.
Similarly, the stop second end 38 includes a second seat 44 configured to removeably receive the second receiver tab 28 . The first seat 42 and the second seat 44 may be different shapes. For example, the second seat 44 may be angular notch 54 to receive the second receiver tab 28 that may have an angular point shape. The stop second end 38 may also an incline 52 adjacent to the second seat 44 . The incline 52 may aid a user in engaging the second receiver tab 28 with the second seat 44 once the first receiver tab 26 has been engaged with the first seat 42 . For example, if a user first engages the first receiver tab 26 with the first seat 42 , a user may guide the second receiver tab 28 over the incline 52 , after which the second receiver tab 28 may slip into the angular notch 54 to secure the receiver 12 to the door stop 14 .
The first receiver tab 26 temporarily locks into the first seat 42 and the second receiver tab 28 temporarily locks into the second seat 44 . In an example, the first receiver tab 26 removeably snaps into the first seat 42 and the second receiver tab 28 removeably snaps into the second seat 44 .
The receiver 12 may include a receiver opening 56 through the receiver body 16 to receive a fastener 58 . The fastener 58 may be any suitable fastener 58 that secures the receiver 12 to a door jamb. For example, the fastener 58 may be a screw, nail, adhesive, or combinations thereof, among others. At least a portion of a fastener 58 may be positioned in the receiver opening 56 , wherein the fastener 58 secures the receiver 12 to a door jamb. As mentioned above, when the first receiver tab 26 is engaged with the first seat 42 and the second receiver tab 28 is engaged with the second seat 44 , the spacer 40 creates a space 62 between the stop inner surface 32 and the receiver outer surface 20 . At least a portion of the fastener 58 may positioned within a portion of the space 62 between the receiver outer surface 20 and the stop inner surface 32 . For example, when the fastener 58 is a screw, the head of the screw may be positioned within space 62 . As a result the fastener 58 is concealed from the environment and from view.
In another embodiment, the system 10 may include a door stop 14 and a removable seal 50 , wherein the door stop 14 may not hide the fasteners 58 . In such example, the removable seal 50 may be replaced when needed and is free to expand and contract independently of the door stop 14 .
For example, the system 10 may include a door stop 14 including a stop body 30 having an stop inner surface 32 and stop outer surface 34 , wherein a stop first end 36 of the stop body 30 includes a slot 46 forming a receiving space 48 . A cross-sectional length of the receiving space 48 is parallel to a cross-sectional length of the stop body 30 .
The door stop 14 may also include at least one spacer 40 extending perpendicular from the stop inner surface 32 of the stop body 30 . When the garage door stop 14 is fastened to a door jamb, the spacer 40 creates a space 62 between the stop inner surface 32 and the door jamb.
The door stop includes a stop opening 60 through the stop body 30 to receive a fastener 58 . The door stop 14 may further include a fastener 58 , wherein at least a portion of the fastener 58 is positioned in the stop opening 60 , wherein the fastener 58 secures the stop body 30 to a door jamb. The fastener 58 may be any suitable fastener 58 that secures the door stop 12 to a door jamb. For example, the fastener 58 may be a screw, nail, adhesive, or combinations thereof, among others.
In an example, the receiving space 48 is positioned between the stop inner surface 32 and the stop outer surface 34 of the stop body 30 . The door stop 14 may further include a seal 50 that is removeably positioned in the receiving space 48 of the slot 46 . The removable or replaceable seal 50 creates a seal against a garage door. In an example, the seal 50 may include a vinyl covered foam that allows for fluctuations in the distance between the door stop 14 and the garage door while maintaining an appropriate seal.
As shown in FIG. 5 , the seal 50 may include a folded portion 64 and an installation tab 66 , wherein the installation tab 66 is configured to fit into the receiving space 48 . The seal 50 may be secured in the receiving space 48 by a pressure fit, screw mechanism, or any other suitable removeable connection that allows the seal 50 to be replaced independent of the door stop 14 . As a result, the seal 50 is free to expand and contract independently of the door stop 14 .
It should be noted that various changes and modifications to the embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. For example, various embodiments of the method and portable electronic device may be provided based on various combinations of the features and functions from the subject matter provided herein.
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The present disclosure provides a garage door stop and seal system that allows for expansion and contraction, enables replacement of the seal, and provides hidden, or concealed, fasteners. The system includes a door stop that removeably snaps into a receiver, wherein the door stop conceals the fasteners used to connect the receiver to a door jamb. In addition, the door stop includes a receiving space for a replaceable seal.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of U.S. Ser. No. 11/195,055, filed Aug. 2, 2005 (D0932-00514), which in turn is a continuation-in part of U.S. application Ser. No. 10/869,994, filed Jun. 17, 2004 (D0932-00440).
FIELD OF THE INVENTION
[0002] The present invention relates to insulation products, and more specifically to loose fill insulation, batts and board products such as duct liner and duct boards, and methods of making the same.
BACKGROUND OF THE INVENTION
[0003] Thermal insulation for buildings and other structures is available in the form of mats, batts, blankets and loose fill. Mats, batts and blankets are flexible products containing randomly oriented fibers bound together with a binder, and are generally prefabricated before being brought to a construction site and installed. In contrast, loose fill thermal insulation includes a large number of discrete fibers, flakes, powders, granules and/or nodules of various materials.
[0004] Efforts have been made to reduce the thermal conductivity of insulation. See for example U.S. Pat. App. No. 2005/0025952, directed to heat resistant insulation composites and methods of preparing them; U.S. Pat. App. No. 2005/0079352, directed to expandable microspheres for foam insulation and methods for preparing same; U.S. Pat. No. 6,864,297, directed to composite foam materials made from polymer microspheres reinforced with long fibers; U.S. Pat. No. 6,638,984, directed to microcellular foams, their method of production and uses thereof; U.S. Pat. No. 5,418,257, directed to modified low-density polyurethane foam bodies; U.S. Patent Application Nos. 2003/0087576 and 2003/0040239, directed to infrared radiation absorbing and scattering material dispersed on insulation material
SUMMARY OF THE INVENTION
[0005] The present invention is directed to a fiber glass thermal insulation comprising randomly distributed inorganic fibers and about 5-500 wt. % (based on the weight of the inorganic fibers) expandable microspheres, comprising a polymeric shell having disposed therein a blowing agent or gas, said expandable microspheres increasing in size when heated.
[0006] The present invention uses expandable microspheres that are small spherical, preferably, plastic particles. The microspheres consist of a polymer shell encapsulating a blowing agent or gas, such as a hydrocarbon, and in particular, a paraffinic hydrocarbon, isobutane or isopentane. When the gas inside the shell is heated, it increases its pressure and the thermoplastic shell softens. This causes the shell to stretch and expand in much the same way as a balloon. There is a difference, in that, when the heat is removed, the shell stiffens, and the microsphere remains in its new expanded form. When fully expanded, the volume of the microspheres can increase to more than 40 times its original volume.
[0007] The shell can be made of a polymeric material, such as a co-polymer, e.g., vinylidene chloride, acrylonitrile and methylmethacrylate. The microspheres can be expanded anywhere between about 100° and about 200° C., depending on the grade.
[0008] In a further embodiment of the present invention, a method of making a thermal insulation product is provided in which inorganic fibers, such as glass fibers, and about 5-500 wt. % (based on the weight of the inorganic fibers) unexpanded hollow microspheres comprising a polymeric shell having disposed therein a blowing agent or gas. This material is disposed on a receiving surface to form a thermal insulation product precursor. The thermal insulation product precursor is then heated to expand a significant portion of the unexpanded hollow microspheres to increase their size. The precursor is then permitted to cool, to form the final thermal insulation product, whereby the now expanded microspheres improve the thermal insulation properties of the thermal insulation product.
[0009] In certain embodiments of the present invention, the insulation product can include rotary fibers, i.e., the fine glass fibers used in batt insulation and blowing wool or “loose fill” products, and adhesive, such as phenolic adhesive binder. The insulation product can be produced by an air laid process with textile fibers and powdered adhesive, or a rotary process in which a liquid adhesive is sprayed onto the fibers as they are accumulated onto a receiving belt, for example.
[0010] In one embodiment of the present invention, the expandable microspheres are disposed within a slurry which is deposited onto a thermal insulation product, or disposed onto the fibers of the insulation product prior to heating the insulation product in a curing oven, for example. The preferred slurry is designed to be absorbed into the thermal insulation product readily, so as to disperse the unexpanded microspheres uniformly throughout the product. Upon heating, the unexpanded microspheres expand into their final form while, optionally, also curing the thermosetting phenolic binder. Naturally, the carrier liquid of the slurry, e.g., water, evaporates in the curing oven to leave a dry product.
[0011] In another embodiment of the invention, a thermal insulation comprising randomly distributed inorganic fibers bound together with an adhesive binder is provided. The thermal insulation comprises about 5-500 wt. % (based on the weight of the inorganic fibers), expanded hollow microspheres having a diameter of about 20-150 microns. The expanded microspheres reduce the thermal conductivity of the thermal insulation by at least about 5%. Preferably, they are uniformly mixed or distributed among the inorganic fibers, and can be adhered to the inorganic fibers by an adhesive binder.
[0012] In a further embodiment of the present invention, an attic insulation is provided comprising a roof supported by a plurality of rafters. An attic floor containing a plurality of joists, adjacent ones of said joists forming the side of the cavity with a room ceiling forming a bottom of the cavity. The cavity is at least partially filled by a thermal insulation comprising randomly distributed glass fibers. At least about 5 wt. % hollow expanded microspheres having a diameter of about 20-150 microns is provided. These microspheres have been expanded from a diameter of about 6-40 microns. The hollow expanded microspheres reduce the thermal conductivity of the thermal insulation by at least about 5% and, more preferably, about 6.8-19.4%.
[0013] In a further embodiment of the present invention, a fiber glass thermal insulation batt or board comprising a fiber glass layer containing randomly distributed glass fibers bound by a resinous binder is provided. The batt or board further comprises about 5-500 wt. % expanded microspheres, and a facing layer applied to the fiber glass insulation layer. The microspheres of this embodiment can be uniformly dispersed within the randomly distributed inorganic fibers, adhered to the facing layer, or mixed within the adhesive binder, for example. They can also be disposed within a bituminous mastic employed to join the facing layer to the fiber glass thermal insulation layer.
[0014] In still a further embodiment of the present invention, a fiber glass thermal insulation is provided comprising randomly distributed glass fibers bound by an adhesive material and at least about 5-500 wt. % hollow expanded microspheres containing a gas. The hollow expanded microspheres reduce the thermal conductivity of the fiber glass thermal insulation by at least about 5%. The hollow microspheres have a diameter of about 20-120 microns, and are mixed uniformly throughout the randomly distributed glass fibers. The hollow expanded microspheres can be expanded at a temperature of about 80-200° C. (176-392° F.).
[0015] In still a further embodiment of the present invention, a method of making a thermal insulation product is provided in which randomly distributed inorganic fibers and about 5-500 wt. % unexpanded hollow microspheres are provided. The unexpanded hollow microspheres comprise a polymeric shell having disposed therein a blowing agent or gas. The mixture is disposed onto a receiving surface to form a thermal insulation product precursor. The precursor is heated to expand a significant portion of the unexpanded hollow microspheres to increase their size, and then permitted to cool to form a thermal insulation product, whereby the now expanded hollow microspheres improve the thermal insulation properties. This method can employ, as the disposing step, a rotary spinning process in which glass is produced into a plurality of fibers and adhesively bonded together to form a thermal insulation product. Similarly, the disposing step can include air laying the glass-containing inorganic fibers and mixing the air laid glass containing inorganic fibers with a powdered adhesive. The heating step can include expanding a significant portion of the unexpanded hollow microspheres while also causing the powdered and/or liquid adhesive to cure.
[0016] In a still further embodiment of the invention, a thermal insulation is provided including randomly distributed inorganic fibers and about 5-500 wt. % (based on the weight of inorganic fibers), expanded microspheres, 5-500 wt. % calcium acetate, 5-500 wt. % cupric carbonate or 5-500 wt. % of a combination of these ingredients, for reducing the thermal conductivity (K-value, BTU-in/hr-ft 2 -F) of the thermal insulation by at least about 1%.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The accompanying drawings illustrate preferred embodiments of the invention, as well as other information pertinent to the disclosure, in which:
[0018] FIG. 1 illustrates loose fill insulation, including expanded microspheres, blown in an attic between a pair of joists; and
[0019] FIG. 2 illustrates an insulation batt having expanded microspheres in three different locations.
DETAILED DESCRIPTION
[0000] Loose Fill
[0020] With reference to FIG. 1 , a loose fill insulation product 10 having expanded microspheres 11 dispersed therein is provided. As used herein, the term “microspheres” applies to microspheres such as those made from glass and polymers, and expandable or expanded microspheres. The loose fill insulation 10 can be in the form of fibers, flakes, powders, granules and/or nodules of various materials. The loose fill insulation 10 is of the type for insulating an interior of a hollow or open space in a building structure, e.g., a house, office, or other building structure. Preferably, the loose fill can be compressed during storage to save space, and then expanded or “fluffed-up” with air or another gas when poured or blown into a hollow wall or other empty space of a structure. The loose fill insulation 10 can include organic materials, inorganic materials or both. Examples of organic loose fill materials include animal fibers, such as wool; cellulose-containing vegetable fibers, such as cotton, rayon, granulated cork (bark of the cork tree), redwood wool (fiberized bark of the redwood tree), and recycled, shredded or ground newspaper fibers; and thermoplastic polymer fibers, such as polyester; and expanded plastic beads. Examples of inorganic and organic loose fill materials include diatomaceous silica (fossilized skeletons of microscopic organisms), perlite, fibrous potassium titanate, alumina-silica fibers, microquartz fibers, opacified colloidal alumina, zirconia fibers, alumina bubbles, zirconia bubbles, carbon fibers, granulated charcoal, paper, graphite fibers, rock fibers, slag fibers, glass wool and rock wool. The loose fill can include one or more varieties of loose fill material. In an exemplary embodiment, the loose fill insulation includes OPTIMA® fiberglass loose fill insulation available from CertainTeed Corporation, Valley Forge, Pa.
[0021] When manufactured and compressed during storage, the loose fill particles forming the compressed loose fill are dimensioned so as to have an equivalent sphere with a diameter generally smaller than 3 cm, preferably from 0.1 to 1 cm. In one embodiment, after the compressed loose fill is decompressed, expanded and processed through a blowing hose, the loose fill particles forming the expanded loose fill are each dimensioned so as to just fit within a sphere having a diameter of from 0.1 to 4 cm, preferably from 0.5 to 2 cm.
[0022] The thermal insulation product including the expanded microspheres 11 can be formed by dispersing, preferably uniformly, the expanded microspheres 11 in the loose fill 10 before or at the same time as the loose fill is poured or blown into an interior, empty space of a hollow or open object, such as a hollow wall (before application of the drywall) or an attic. Methods of pouring and blowing loose fill 10 are well known in the art and will not be repeated here in detail. Generally, blowing loose fill 10 involves feeding compressed loose fill 10 into a blower where it is mixed with a gas, such as air, expanded, processed through a blowing hose, and then blown into a hollow or open structure to form thermal insulation.
[0023] In certain embodiments, a mixture including one or more expanded or expandable microspheres 11 , such as hollow plastic and glass microspheres, and a dry binder (i.e., an adhesive later activated by water or elevated temperatures at the time of installation of the loose fill) can be sprayed onto or otherwise mixed with the loose fill 10 before the loose fill 10 is compressed and/or when the loose fill 10 is decompressed. Also, a mixture including one or more microspheres 11 and a binder (i.e., an adhesive) can be mixed with the loose fill by spraying on the loose fill at or near the end of the blowing hose before the loose fill is installed in a hollow or open space. The binder serves to join and hold the microspheres 11 and the loose fill insulation together. The binder can be organic or inorganic. The organic binder can include an organic water based binder such as an acrylic latex or a vinyl acetate latex. The organic binder can also include a sprayed hot melt adhesive such as a thermoplastic polymer. The inorganic binder can include an inorganic bonding agent such as sodium silicate or a hydraulic cement, such as Plaster of Paris, gypsum, or the like. Evaporation of the liquid from the liquid mixture on the loose fill 10 results in a loose fill thermal insulation 10 with the microspheres 11 and/or binder dispersed in the loose fill 10 . In various embodiments, the microspheres 11 and the binder can be added to the loose fill 10 at the same time or at different times. A mineral oil can be used instead of or in addition to the binder for the purpose of dust reduction. In other embodiments, rather than providing the microspheres 11 in a liquid mixture, the microspheres 11 may be provided to the loose fill 10 in its liquid slurry state or as a powder and, optionally, along with a mineral oil and/or binder as described above. If the microspheres 11 have not yet been expanded, they should be heated after mixing with the loose fill 10 , but prior to being blown into a building space. For example, the loose fill 10 could be heated before or after compression or in-line during the blowing operation so long as the fibers are permitted to cool prior to contacting flammable materials.
[0024] In one preferred embodiment, loose fill insulation is fed through a loose fill transport duct into a mixer to form a mixture of loose fill 10 and expanded microspheres 11 . The expanded microspheres 11 may be provided, for example, in slurry or dry form. In certain embodiments, a dry binder (to be later activated by water, heat or other material during loose fill application) and/or mineral oil can also be added in the loose fill transport duct or added in and mixed in a mixer with the loose fill. The microspheres 11 and/or other material can be added directly to the mixer and/or to the loose fill transport duct. The mixture is then fed to a compressor/packager, where the mixture is compressed to remove air and increase density and packaged as compressed loose fill including the expanded or expandable microspheres.
[0000] Microspheres
[0025] Microspheres are small solid or hollow spheres with an average diameter in the range of 12-300 microns, preferably about 15-200 microns, and most preferably about 30-120 microns. Microspheres are commonly made of glass, and are desirably made hollow for their thermal and sound insulation qualities. Borosilicate or similar glass is preferred because of its insolubility in water. Alternatively, recycled amber container glass frit is also attractive, since it can be made into hollow glass amber spheres, without the addition of a sulfur-containing compound, since sulfur is a pre-existing constituent. A number of glass microsphere grades are available, in a range of wall thicknesses, strengths, and densities from under 10 pcf to over 20 pcf, preferably about 0.125-0.60 g/cc.
[0026] Glass macrospheres were created to overcome some of the limitations of glass microspheres. As their name suggests, macrospheres are relatively large, with most common diameters in the 0.125″-0.500″ range. A wide selection is available of strengths and densities, in roughly the same range as glass microspheres. Macrospheres increase the overall packing factor to 70% or more, and are often less expensive than glass microspheres.
[0027] As the name implies, microspheres are small, spherical particles. Particle sizes range from 12 to 300 microns in diameter, and wall thickness can vary from several microns to as low as 0.1 micron. They can be composed of acrylonitrile, glass, ceramic, epoxy, polyethylene, polystyrene, acrylic, or phenolic materials. Because they are hollow, the true density of microspheres is lower than that of other non-soluble additives. The true density of hollow microspheres ranges from 0.60 g/cc to as low as 0.025 g/cc.
[0028] There are many potential applications for hollow glass microspheres. Sodium borosilicate hollow microspheres are often used as light-weight fillers of composite plastics for ship-building, aviation and car-making industries, sensitizing additives in manufacture of industrial explosives, varnishes, and paint fillers. In contrast to mineral and organic fillers, hollow microspheres are unique because they have a low density but high strength.
[0029] The production of hollow microspheres is a well-established technology. There are several methods available to produce hollow microspheres, but some methods depend on the decomposition of CaCO 3 (which decomposes to CaO and CO 2 gas), a substance known as a “blowing agent” to form a gas within in a liquid. The rapid expansion of this gaseous product causes the formation of a bubble. One of the most common methods for producing hollow microspheres is to intentionally mix a trace amounts of a sulfur-containing compound such as sodium sulfate with a sodium borosilicate glass that is similar in composition to traditional Pyrex® glassware. This mixture is then dropped into a hot flame that melts the powdered glass and sodium sulfate. The melting of sodium sulfate results in a decomposition reaction that releases minute amounts of sulfur gas that form bubbles within the molten glass droplets. (Sodium sulfate additions are not necessary when waste or virgin amber glass frit is used, since sulfur-containing compounds are mainly responsible for the amber color of the glass and are already present.) The hollow droplets are then rapidly cooled from the liquid state to form hollow microspheres. As previously mentioned, such an approach relies on the intentional addition of a sulfur-containing compound to the glass.
[0030] Microspheres have found use in many applications over the years. They are widely used in the fiber-reinforced polyester industry to improve the manufacturing process of shower stalls and boats. Lighter, more-durable fiberglass products are a direct result of the creative use of microspheres. Thick-film ink, mining explosives, and rubber and plastic products of all descriptions are just a few other examples of the many products that are made better with these versatile materials. The benefits derived by these diverse end uses vary—some are unique to a specific industry, while others are common goals shared by many manufacturers.
[0031] Likewise, certain types of microspheres may offer a particular set of advantages, and a formulator must carefully select from the many products available in order to obtain the best results. For example, the compressible nature of plastic microspheres is a unique feature that is suited to elastomeric products, while glass microspheres are ideal for areas involving high temperatures and/or chemical resistance.
[0000] Plastic Microspheres
[0032] Developed in the 1970s, thermoplastic microspheres are compressible, resilient, hollow particles. The extremely thin shell wall possible with plastic spheres results in specific gravities as low as 0.025 and allows just a small weight-percent of these materials to displace large volumes when disposed in matrices. Because the resilient plastic can deform under stress, there is virtually no breakage when mixing or pumping these products, even with high shear mixing, as in the case of blowing loose fill insulation. Additionally, the compressible nature of plastic can absorb impacts that might ordinarily deform the finished product, thereby reducing damage caused by stone chips, foot traffic or freeze-thaw cycles.
[0000] Glass Microspheres
[0033] Glass bubbles were developed in the 1960s as an outgrowth from the manufacture of solid glass beads. Since they are made of glass they provide the benefits of high heat and chemical resistance. The walls of glass bubbles are rigid. Products are available in a broad range of densities from as low as 0.125 g/cc to 0.60 g/cc. The collapse strength of the glass bubble is directly related to the density, i.e., the higher the density, the higher the strength. For example, a glass bubble with a density of 0.125 g/cc is rated at 250 psi, whereas one with a density of 0.60 g/cc is rated at 18,000 psi. In order to minimize both the cost and the weight of the final product, the appropriate glass bubble is the one that is just strong enough to survive all of the manufacturing processes and the end use of the product.
[0034] Since microspheres are closed-cell, gas-filled particles, they are extremely good insulators. This characteristic is imparted to materials that contain microspheres, such as batts, boards and loose fill insulation products. As this invention demonstrates, thermal insulation properties of batts, loose fill, facings, coatings or substrates can be improved by the addition of microspheres, calcium acetate and/or cupric carbonate.
[0000] Physical Properties and Composition
[0035] 3M Type K1 microspheres are manufactured from soda-lime-borosilicate glass and is the most economical 3M microsphere product at about $0.40 per liter. TABLES 1 and 2, below, contain selected properties of Type K1 microspheres. Trapped within the microspheres are residual gases consisting of a 2:1 ratio of SO 2 and O 2 at an absolute pressure of about ⅓ atmosphere.
[0036] Alternative glass bubbles to the Type K1 microspheres are produced by 3M and also by Emerson & Cuming. Options include a floating process that skims off low density (weak) bubbles and removes a portion of the condensed salts. A coating of methacrylaic chromic chloride is then applied that minimizes water pickup. The overall specific surface area is about half that of the Type K1 microspheres, which may allow reduced bake-out requirements due to lower water adsorption capacity. The use of thicker-walled bubbles will benefit applications where microspheres are exposed to intense localized forces.
TABLE 1* Thermal performance of 3M Type K1 microspheres APPARENT THERMAL COLD VACUUM CONDUCTIVITY COMPARATIVE THERMAL PRESSURE (torr) (mW/m-K) PERFORMANCE 1 × 10 −3 0.7 7.0 times worse than multi-layer insulation 1 × 10 −1 1.4 3.3 times better than perlite 760 22 1.5 times better than polyurethane *M. S. Allen et al., “Advances in Microsphere Insulation Systems”, 2003 Cryogenic Engineering Conference.
[0037] TABLE 2* Selected properties of 3M Type K1 microspheres True density 0.125 g/cc (7.8 lb/ft 3 ) Bulk density (@ 60% packing factor) 0.075 g/cc (4.7 lb/ft 3 ) Particle size (mean/range) 65/15-125 microns Isostatic crush strength 1.7 MPa (250 psi) Maximum operating temperature 600° C. Specific surface area 0.2 m 2 /cc of bulk volume *M.S. Allen et al., “Advances in Microsphere Insulation Systems”, 2003 Cryogenic Engineering Conference.
Expandable Microspheres
[0038] The invention preferably employs about 5-500 wt. % (based on the weight of the inorganic fibers, such as glass fibers) unexpanded or expanded hollow microspheres. An unexpanded microsphere generally consists of a thermoplastic shell encapsulating a blowing agent or gas, such as paraffin, or a hydrocarbon, such as isobutane or isopentane. When the thermoplastic shell is heated, it softens and, at the same time, the pressure of the gas or blowing agent increases. This causes the shell to stretch and expand in much the same way as a balloon. There is a difference between a balloon and/or an expanded microsphere in that, when the heat is removed, the shell of the expanded microsphere stiffens and the microsphere remains in its new expanded form. As is well known, when the air inside a balloon cools, the balloon shrinks. When the expandable microsphere is heated, it is then called an “expanded” microsphere.
[0039] The insulation products of this invention can be in the form of loose fill, batt, duct liner, or duct board, for example. They can be made with a phenolic binder, or treated with sizing and binder, as in a rotary process. The binder can be in liquid or powder form and, optionally, can contain expanded or unexpanded microspheres. The microspheres can be dry mixed into the fibers of the insulation product, or immersed into a slurry which, in turn is absorbed into the insulation product. The microspheres of this invention generally have an unexpanded diameter between about 6 and 40 micrometers, depending on the grade. When unexpanded microspheres are heated, they expand to about 20-150 micrometers in diameter.
[0040] The preferred microspheres of this invention have two major components: the shell and a gas or blowing agent. The gas or blowing agent inside the shell is usually isobutane or isopentane. The shell is typically a co-polymer of some monomers, e.g., vinylidene chloride, acrylonitrile, and methylmethacrylate. Typically, the microspheres are introduced into the thermal product, and then the product is heated to a temperature at which the microspheres start expanding. This can be anywhere between about 80° and 200° C., preferably about 100° to about 200° C., depending on the grade. The grade depends on whether or not the insulation product will be heated after the microspheres have been added, and if so, to which temperature, and for how long. It also depends on if the formulation is water borne, solid-based, or dry. Typically, if there is not heating involved in the process after the microspheres are introduced, pre-expanded microspheres are used. Microspheres can be delivered dry or wet (containing water) in the following forms: wet unexpanded, dry unexpanded, a dispersion of about 40% microspheres in a water slurry, a master batch with about 65 wt. % microspheres, wet expanded or dry expanded. In general, wet expanded and wet unexpanded microspheres are used in products where there is already water present, or water will be evaporated in the process, while dry unexpanded and dry expanded microspheres are used in products that have no water. Master batch microspheres are typically used in extrusion and injection molding, while wet unexpanded and dry unexpanded microspheres are used where the process includes heating. Wet expanded and dry expanded are used in processes that do not always include heating. It is relatively important that the matrix of the thermal insulation be able to flow, move, or be plastically deformed at the temperature at which the microspheres start to expand. Most forms of glass or inorganic fibrous insulation products meet these criteria.
[0041] Typically, unexpanded microspheres have to be heated in order for them to expand. In some cases, however, where there is an exothermic reaction involved, the energy released by this reaction increases the temperature of the product sufficiently to expand the microspheres on its own, without external forms of heat. It is possible to stop and continue expansion several times, as long as the matrix is not changed in a way that would inhibit the expansion of the microspheres.
[0042] Expandable microspheres used in connection with the thermal insulation of this invention can be selected from the variety of Expancel® microspheres, available through Expancel® division of Akzo Nobel. Expancel® products 093DU120, 820DU40, 820SLU80, and 820SLU40, are examples of expandable microspheres useful for this invention.
[0000] Fiberglass Thermal Insulation Batts and Boards
[0043] As shown in FIG. 2 , fiberglass thermal insulation batts 20 , blankets, semi-rigid and rigid boards, such as duct boards, duct liners, and the like, can be manufactured using the materials provided by this invention. In a further embodiment, a batt 20 is manufactured with a fiberglass insulation layer 23 . The fiberglass insulation layer contains randomly distributed inorganic fibers such as glass fibers and contains about 5-500 wt. % microspheres 21 , 24 or 25 , 5-500 wt. % calcium acetate, 5-500 wt. % cupric carbonate or a combination of these, which can be randomly distributed among or on the inorganic or glass fibers 22 . Alternatively, the microspheres, calcium acetate, and/or cupric carbonate, can be adhered to the top or bottom layer of the insulation layer 23 , randomly distributed or mixed with an adhesive 27 , such as a resinous adhesive like powdered phenolic binder, or bituminous mastic, often used to apply a facing to a conventional fiberglass batt insulation, or disposed within acrylic, epoxy, polyester or poly-vinyl-alcohol resinous compositions, or latex emulsions, dry powder, fibers, or solvent-based compositions. The facing 26 can be applied to one or both major surfaces of the insulation layer 23 , or can be applied to envelope the insulation layer 23 . Still further, the microspheres 24 or 25 , calcium acetate, and/or cupric carbonate, can be adhered or made integral with the facing 26 , such as by spraying, ink jet printing or using a roll to apply an adhesive layer followed by applying the microspheres, or applying them as a slurry in such a process. When applied to the facing, a uniform covering of microspheres 24 or 25 , calcium acetate, and/or cupric carbonate, is desirable, but the weight percentage of all, or at least one of said ingredients, may be less than 5%, such as 0.5-3%, based upon the weight of the fibers or the facing 26 . Alternatively, the microspheres, calcium acetate, and/or cupric carbonate, may be applied to the top surface of the fiberglass insulation 23 by use of a binder or adhesive, or by concentrating these materials in a layer or region near the surface or in the middle of the insulation layer 23 .
EXAMPLE 1
[0044] Samples of 12″×12″ fiberglass were cut at approximately 1″ thick. Materials tried are shown in Table 3 below. Samples were initially weighed dry. The material to be investigated was added to water to make a mixture. The fiberglass samples were then soaked in the mixture to distribute the microcapsules and other materials.
[0045] The samples treated with Expancel® were dried at 50° C., then expanded in an oven at 115° C. for about 15 minutes. All others were dried at 50° C. only.
[0046] Thermal conductivities of dry samples were measured at 0.9″ before adding material. Data in the table for k (after) BTU-in/hr-ft 2 -F, may have been normalized to 0.9″ thickness because of over-expansion due to foam or because they did not recover back to 0.9″. The exception is the sample with 22.37 (g) weight and 30% Expancel, where both the before and after thermal conductivities were measured at 0.9″ directly.
TABLE 3 Testing of different materials for possibly enhancing thermal performance of fiberglass. Reduction in Wt. of 12″ × 12″ thermal Material added to dry fiberglass k (before) BTU- k (after) BTU- conductivity fiberglass sample (g) % added in/hr-ft 2 - F. in/hr-ft 2 - F. (%) Expancel ® 820-SL-80 18.2 257 0.3370 0.2716 19.4 (80 micron ave. cell) Expancel ® 820-SL-80 15.8 114 0.318 0.274 13.8 (80 micron ave. cell) Expancel ® 820-SL-80 22.37 30 0.2967 0.2707 8.8 (80 micron ave. cell) Expancel ® 820-SL-40 17.71 217 0.3083 0.2684 12.9 (40 micron ave. cell) Cupric Carbonate 18.2 28 0.307 0.286 6.8 (mixed well when dried) Calcium Formate 16.24 56 0.312 0.330 — (material dried as skin) Ammonium 20.03 0 0.300 0.300 — Bicarbonate* Calcium Acetate 15.6 50 0.3297 0.3236 1.85 (material dried as skin) Potassium Phosphate 14.4 70.4 0.3282 0.3508 — *Ammonium Bicarbonate decomposed when exposed to 50° C. to dry the sample
[0047] Heat expandable microspheres, 6 microns to 40 microns in diameter and composed of a polymer shell surrounding a blowing agent or gas, calcium acetate, and/or cupric carbonate additions, are introduced into fiber glass insulation in slurry form, or injected into the hot mineral fibers in the forming section of a typical glass batt manufacturing operation, for example. When expandable microspheres are employed, the insulation and microspheres are exposed to heat in the curing oven where the blowing agent expands and the polymer shell softens causing the microsphere to increase in size to between 20 and 150 microns in diameter. The slurry of unexpanded microspheres such as Expancel® 820SL40 and 820SL80, calcium acetate, and/or potassium phosphate, may also be mixed into the phenolic binder and sifted, mixed or sprayed onto fiber glass fibers. The intermingled matrix of fibers, binder, calcium acetate, cupric carbonate and/or microspheres are collected on a conveyor and transported through a curing oven where the insulation matrix is dried, the binder is cured and/or cross-linked, and the microspheres expanded, preferably simultaneously. The formed fiber glass loose fill mat, batt or board is subsequently cut to size and packaged. The addition of the microspheres reduced the thermal conductivity of the insulation samples by about 12.3% on average, as shown in Table 3. The addition of about 5-500 wt. % calcium acetate, and or 5-500 wt. % cupric carbonate has been shown in our examples to reduce thermal conductivity by about 1-7% on average. These latter materials can be applied as a coating, flakes, granular material, or as a liquid, for example.
[0048] From the foregoing, it can be realized that this invention provides improved loose fill insulation, and batts and boards which include expandable or expanded microspheres, calcium acetate, and/or cupric carbonate for increasing the thermal insulation efficiency. These materials can be distributed among glass fibers, cellulosic particles, or adhered to facing layers or glass fibers, for example, to provide a great variety of more efficient thermal insulation products. The glass and polymeric spheres of this invention also possibly assist in sound deadening and may assist in allowing loose fill insulation to flow through hoses used for blowing such products into attic cavities and wall spaces. Although various embodiments have been illustrated, this is for the purpose of describing, but not limiting the invention. Various modifications which will become apparent to one skilled in the art, are within the scope of this invention described in the attached claims.
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Thermal insulation is provided which includes randomly distributed inorganic fibers and about 5-500 wt. % unexpanded hollow microspheres comprising a polymeric shell having disposed therein a blowing agent or gas, said unexpanded hollow microspheres increasing in size when heated. Also provided is an insulated attic, including a plurality of rafters, an attic floor and a thermal insulation comprising randomly distributed glass fibers in at least about 5 wt. % hollow expanded microspheres having a diameter of 20-140 microns, which have been expanded from about 6-40 microns. The hollow expanded microspheres reduce the thermal conductivity of the thermal insulation by at least about 5%, and have shown improvement up to 19.4% decreased thermal conductivity during tests at loadings from 30% to 257%. Additionally, calcium acetate and cupric carbonate additions to glass fiber insulation products showed improvement by at least about a 1% decrease in thermal conductivity.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for the preparation of a phenylhydrazine or an inorganic acid salt thereof of the formula (1):
wherein X is a hydrogen atom or a halogen atom; Y is a halogen atom; and W is a hydrogen atom or —ZR in which Z is an oxygen atom or a sulfur atom, and R is a hydrogen atom, a C 1 -C 6 alkyl group, a C 1 -C 6 haloalkyl group, a C 3 -C 8 cycloalkyl group, a benzyl group, a C 3 -C 6 alkenyl group, a C 3 -C 6 haloalkenyl group, a C 3 -C 6 alkynyl group, a cyano-C 1 -C 6 alkyl group, a C 2 -C 8 alkoxyalkyl group, a C 2 -C 8 alkylthioalkyl group, a carboxy-C 1 -C 6 alkyl group, (C 1 -C 8 alkoxy) carbonyl-C 1 -C 6 alkyl group, a [(C 1 -C 4 alkoxy)-C 1 -C 4 alkoxy]carbonyl-C 1 -C 6 alkyl group, (C 3 -C 8 cycloalkoxy)carbonyl -C 1 -C 6 alkyl group or a [(C 1 -C 6 alkoxy)carbonyl-C 1 -C 6 alkyl]oxycarbonyl-C 1 -C 6 alkyl group.
A phenylhydrazine of the formula (1) is a useful intermediate for the preparation of, for example, pyridazin-3-on compounds of the formulae (4):
which have good herbicidal activities.
2. Prior Art
JP-A-9-323977 describes that a phenylhydrazine of the above formula (1) is synthesized by diazotizing an aniline derivative of the formula (3):
wherein X, Y and W are the same as defined above, and then reducing the diazotized compound with tin chloride.
However, the above synthesis process has drawbacks such that a reaction mixture has low filterability when insoluble tin-containing by-products are removed by filtration after the reaction, since the reduction is performed with tin chloride, and that tin compounds should be treated after the reaction. Therefore, such a synthesis process may not be industrially preferred. Thus, it is highly desired to develop a new synthesis process of a phenylhydrazine or an inorganic acid salt thereof of the formula (1) using no metal reducing agents.
SUMMARY OF THE INVENTION
Extensive studies have been made to solve the drawbacks of the conventional synthesis process. As a result, it has been found that a phenylhydrazine or an inorganic acid salt thereof of the formula (1) is advantageously obtained by hydrolyzing a phenylhydrazine derivative of the following formula (2) by allowing the phenylhydrazine derivative in contact with an inorganic acid in a concentration of at least 6 moles of the inorganic acid per 1 kg of water in a reaction system, and furthermore dehalogenated by-products can be efficiently reduced.
Accordingly, the present invention provides a process for the preparation of a phenylhydrazine or an inorganic acid salt thereof of the formula (1):
wherein X is a hydrogen atom or a halogen atom; Y is a halogen atom; and W is a hydrogen atom or —ZR in which Z is an oxygen atom or a sulfur atom, and R is a hydrogen atom, a C 1 -C 6 alkyl group, a C 1 -C 6 haloalkyl group, a C 3 -C 6 cycloalkyl group, a benzyl group, a C 3 -C 6 alkenyl group, a C 3 -C 6 haloalkenyl group, a C 3 -C 6 alkynyl group, a cyano-C 1 -C 6 alkyl group, a C 2 -C 8 alkoxyalkyl group, a C 2 -C 8 alkylthioalkyl group, a carboxy-C 1 -C 6 alkyl group, (C 1 -C 8 alkoxy)carbonyl-C 1 -C 6 , alkyl group, a [(C 1 -C 4 alkoxy)-C 1 -C 4 alkoxy]carbonyl-C 1 -C 6 alkyl group, (C 3 -C 8 cycloalkoxy)carbonyl-C 1 -C 6 alkyl group or a [(C 1 -C 6 alkoxy) carbonyl-C 1 -C 6 alkyl]oxycarbonyl-C 1 -C 6 alkyl group comprising the step of hydrolyzing a phenylhydrazine derivative of the formula (2):
wherein X, Y and W are the same as defined above, and the Q groups are the same or different and represent a hydrogen atom, an ammonium group or an alkali metal atom in the presence of water and an inorganic acid, wherein the concentration of the inorganic acid is at least 6 moles per 1 kg of water in a reaction system.
DETAILED DESCRIPTION OF THE INVENTION
Herein, a halogen atom for X and Y may be a fluorine atom, a chlorine atom, a bromine atom or an iodine atom.
Examples of a C 1 -C 6 alkyl group for R include a methyl group, an ethyl group, an isopropyl group, a propyl group, an isobutyl group, a tert.-butyl group, an amyl group, an isoamyl group, a tert.-amyl group, etc.
Examples of a C 1 -C 6 haloalkyl group include a 2,2,2-trifluoroethyl group, etc.
Examples of a C 3 -C 8 cycloalkyl group include a cyclopropyl group, a cyclobutyl group, a cyclopentyl group, a cyclohexyl group, etc.
Examples of a C 3 -C 6 alkenyl group include an allyl group, a 1-methyl-2-propenyl group, a 3-butenyl group, a 2-butenyl group, a 3-methyl-2-butenyl group, a 2-methyl-3-butenyl group, etc.
Examples of a C 3 -C 6 haloalkenyl group include a 2-chloro-2-propenyl group, a 3,3-dichloro-2-propenyl group, etc.
Examples of a C 3 -C 6 alkynyl group include a propargyl group, a 1-methyl-2-propynyl group, a 2-butynyl group, a 1,1-dimethyl-2-propynyl group, etc.
Examples of a cyano-C 1 -C 6 alkyl group preferably include a C 1 -C 6 cyanoalkyl group such as a cyanomethyl group, etc.
Examples of a C 2 -C 8 alkoxyalkyl group include a methoxyethyl group, an ethoxymethyl group, an ethoxyethyl group, etc.
Examples of a C 2 -C 8 alkylthioalkyl group include a methylthioethyl group, etc.
Examples of a carboxy-C 1 -C 6 alkyl group include a carboxymethyl group, a 1-carboxyethyl group, a 2-carboxyethyl group, etc.
Examples of (C 1 -C 6 alkoxy) carbonyl-C 1 -C 6 alkyl group include a methoxycarbonylmethyl group, an ethoxycarbonylmethyl group, a propoxycarbonylmethyl group, an isopropoxycarbonylmethyl group, a butoxycarbonylmethyl group, an isobutoxycarbonylmethyl group, a tert.-butoxycarbonylmethyl group, an amyloxycarbonylmethyl group, an isoamyloxycarbonylmethyl group, a tert.-amyloxy-carbonylmethyl group, a 1-methoxycarbonylethyl group, a 1-ethoxycarbonylethyl group, a 1-propoxycarbonylethyl group, a 1-isopropoxycarbonylethyl group, a 1-butoxycarbonylethyl group, a 1-isobutoxycarbonylethyl group, a 1-tert.-butoxycarbonylethyl group, a 1-amyloxycarbonylethyl group, a 1-isomyloxycarbony-ethyl group, a 1-tert.-amyloxycarbonylethyl group, etc.
Examples of a [(C 1 -C 6 alkoxy)-C 1 -C 6 alkoxy]carbonyl-C 1 -C 6 alkyl group include a methoxyethoxycarbonylmethyl group, a 1-methoxyethoxycarbonylethyl group, etc.
Examples of (C 3 -C 8 cycloalkoxy)carbonyl-C 1 -C 6 alkyl group include a cyclobutyloxycarbonylmethyl group, a cyclopentyloxycarbonylmethyl group, a cyclohexyloxycarbonyl-methyl group, a 1-cyclobutyloxycarbonylethyl group, a 1-cyclopentyloxycarbonylethyl group, a 1-cyclohexyloxy-carbonylethyl group, etc.
Examples of a [(C 1 -C 6 alkoxy)carbonyl-C 1 -C 6 alkyl]oxy-carbonyl-C 1 -C 6 alkyl group include an (ethoxycarbonyl)methoxy-carbonylmethyl group, etc.
Examples of an alkali metal atom for Q include a sodium atom, a potassium atom, etc.
A phenylhydrazine derivative of the formula (2) may be prepared by diazotizing an aniline derivative of the formula (3) and then reacting the obtained diazonium salt with sulfurous acid, a sulfite salt or a hydrogensulfite salt.
A diazotizing agent used in the above preparation method is usually a nitrite salt. Examples of a nitrite salt include sodium nitrite, potassium nitrite, etc. A nitrite salt is usually used in the form of an aqueous solution, although a nitrite salt in a solid form may be used. The amount of a nitrite salt is usually from 1 to 1.2 moles per one mole of an aniline derivative of the formula (3).
In general, an inorganic acid is used in the diazotizing reaction. Examples of an inorganic acid include hydrochloric acid, sulfuric acid, phosphoric acid, nitric acid, etc. Preferably, hydrochloric acid and sulfuric acid are used. Usually, an inorganic acid is used in the form of an aqueous solution.
The amount of an inorganic acid is about 1 to 10 moles, preferably about 2 to 6 moles, more preferably about 2.5 to 4 moles, per one mole of an aniline derivative of the formula (3).
In the diazotizing reaction, the order of the addition of reagents is not limited. Usually, an aniline derivative is mixed with the aqueous solution of an inorganic acid, and then the aqueous solution of a nitrite salt is added thereto.
A reaction temperature is usually from about −20 to 20° C., preferably from about −10 to 100, more preferably from about −5 to 5° C.
Examples of a sulfite salt used as a reducing agent include ammonium sulfite, sodium sulfite, potassium sulfite, etc. Examples of a hydrogensulfite salt include ammonium hydrogensulfite, sodium hydrogensulfite, potassium hydrogensulfite, etc. They are usually used in the form of an aqueous solution, although they may be used in a solid form.
The amount of sulfurous acid, a sulfite salt or a hydrogensulfite salt is usually at least 2 moles, preferably from about 2.5 to 4 moles, per one mole of an aniline derivative of the formula (3).
pH of the reaction system is adjusted usually in the range between 5.5 and 8, preferably in the range between 6 and 7.5. The pH of the reaction system can be adjusted with acids (e.g. hydrochloric acid, sulfuric acid, etc.), or aqueous solutions of alkali compounds (e.g. sodium hydroxide, potassium hydroxide, ammonia, etc.).
In the above reaction, a diazonium salt, which has been obtained by diazotizing an aniline derivative of the formula (3), is added to an aqueous solution containing sulfurous acid, a sulfite or a hydrogensulfite, pH of which is adjusted in the range between 5.5 and 8. A reaction temperature is usually from about 0 to 80° C., preferably from about 10 to 70° C.
A reaction time varies with other conditions such as kinds and amounts of reagents, a reaction temperature, and the like, and cannot be unconditionally limited. The reaction time is usually from about 30 minutes to about 24 hours.
After the termination of the reaction, the obtained reaction mixture is filtrated, and thus a hydrophobic phenylhydrazine derivative of the formula (2) is recovered. A water-soluble phenylhydrazine derivative of the formula (2) can be recovered by concentration, or extraction with an organic solvent followed by concentration. Furthermore, the recovered phenylhydrazine derivative can be purified by recrystallization, etc.
The phenylhydrazine derivative of the formula (2) formed in the above-described reaction may be used in the hydrolysis reaction in the presence of an inorganic acid, as it is, in the form of an aqueous solution without being isolated.
Aniline derivatives of the formula (3) are known from, for example, EP-A-61741, U.S. Pat. Nos. 4,670,046, 4,770,695, 4,709,409, 4,640,707, 4,720,927 and 5,169,431, JP-A-63-156787, and the like, or may be prepared by the methods described in these patent publications.
Typical examples of a phenylhydrazine derivative of the formula (2) are listed in Table 1.
TABLE 1
(2)
Compound No.
X
Y
W
Q
2-1
H
Cl
H
Na
2-2
F
Cl
H
Na
2-3
F
Cl
OH
Na
2-4
F
Cl
OH
NH 4
2-5
F
Cl
OCH(CH 3 ) 2
Na
2-6
F
Cl
OCH 2 C≡CH
Na
2-7
F
Cl
OCH 2 COOH
Na
2-8
F
Cl
SCH 2 C≡CH
Na
2-9
F
Cl
SCH 2 COOH
Na
2-10
Cl
Cl
H
Na
2-11
Cl
Cl
OCH(CH 3 ) 2
Na
2-12
F
Cl
OCH 3
Na
2-13
F
Cl
OCH 2 CH 3
Na
In the present invention, a phenylhydrazine of the formula (1) can be obtained by hydrolyzing a phenylhydrazine derivative of the formula (2).
The hydrolysis is performed using an inorganic acid. An inorganic acid is preferably a protonic acid such as hydrochloric acid or sulfuric acid. Furthermore, the aqueous solution of an inorganic acid may be used.
An organic solvent may be used together with an inorganic acid, insofar as the organic solvent does not interfere with the hydrolysis.
The amount of an inorganic acid is usually at least 1 mole, preferably from 4 to 50 moles, per one mole of a phenylhydrazine derivative of the formula (2).
The concentration of an inorganic acid is preferably at least 6 moles per 1 kg of water in the reaction system, from the viewpoint of a yield. The concentration of an inorganic acid in the reaction system is preferably set within the prescribed range by taking into account the amount of the inorganic acid and that of water contained in an aqueous solution of the acid and in the phenylhydrazine derivative of the formula (2) or an aqueous solution thereof. The aqueous solution of the phenylhydrazine derivative of the formula (2) may be prepared by dilution with water or by the steps of a diazotization process and subsequent reduction as described above in which various aqueous solutions of reactants as mentioned and water are used.
In the process of the present invention, a phenylhydrazine derivative of the formula (2) or its aqueous solution (or suspension) is added to an inorganic acid or its aqueous solution, although an inorganic acid or its aqueous solution may be added to a phenylhydrazine derivative of the formula (2) or its aqueous solution (or suspension).
Alternatively, the aqueous solution of a phenylhydrazine derivative of the formula (2) is concentrated and then reacted with an inorganic acid.
A reaction temperature in the hydrolysis is usually from −5 to 80° C., preferably from 0 to 50° C.
A reaction time for the hydrolysis varies with other conditions such as kinds and amounts of reagents, a reaction temperature, and the like, and cannot be unconditionally limited. The hydrolysis reaction time is usually from about 30 minutes to about 24 hours.
After the termination of the hydrolysis, the obtained reaction mixture is filtered as it is, or neutralized with an alkaline aqueous solution of, for example, sodium hydroxide, and then filtrated. Thus, a phenylhydrazine or an inorganic acid salt thereof of the formula (1) is recovered. The recovered phenylhydrazine or an inorganic acid salt thereof can be purified by recrystallization, etc.
Typical examples of a phenylhydrazine of the formula (1) are listed in Table 2, but the present invention is not limited to those exemplified compounds.
TABLE 2
(1)
Compound No.
X
Y
W
1-1
H
Cl
H
1-2
F
Cl
H
1-3
F
Cl
OCH(CH 3 ) 2
1-4
F
Cl
OH
1-5
F
Cl
OCH 2 C≡CH
1-6
F
Cl
OCH 2 COOH
1-7
F
Cl
SCH 2 C≡CH
1-8
F
Cl
SCH 2 COOH
1-9
Cl
Cl
H
1-10
Cl
Cl
OCH(CH 3 ) 2
1-11
F
Cl
OCH 3
1-12
F
Cl
OCH 2 CH 3
EFFECTS OF THE INVENTION
According to the present invention, a phenylhydrazine of the formula (1) can be efficiently prepared by hydrolyzing a phenylhydrazine derivative of the formula (2) in the presence of water without the use of any tin compound and without the isolation of the phenylhydrazine derivative from a reaction mixture.
The present invention will be illustrated by following Examples, which do not limit the scope of the present invention in any way.
EXAMPLE 1
4-Chloro-2-fluoro-5-hydroxyaniline (162.0 g; content: 99.6%, 0.999 mole) was added to 10% hydrochloric acid (1093.3 g) at 25° C. while stirring. Then, a 35% aqueous solution of sodium nitrite (205.9 g) was dropwise added to the mixture at a temperature of −3° C. to 0° C. over 1 hour to diazotize 4-chloro-2-fluoro-5-hydroxyaniline to obtain an aqueous solution of a corresponding diazonium salt (1456.7 g).
The diazonium salt was quickly added at 10° C. to an aqueous solution of sodium sulfite, which had been prepared by adding sodium sulfite (398.1 g) to water (1323.2 g) and then adjusting pH of the mixture at 7.2 with 95% sulfuric acid (15.1 g), and the mixture was heated up to 65° C., and maintained at the same temperature for 2 hours. Thus, the aqueous solution (3141.5 g) of sodium 4-chloro-2-fluoro-5-hydroxyphenylhydrazine-N,N′-disulfonate was obtained. According to LC-IS analysis, the yield of this sodium salt was 96.0% based on 4-chloro-2-fluoro-5-hydroxyaniline.
The obtained aqueous solution of disodium 4-chloro-2-fluoro-5-hydroxyphenylhydrazine-N,N′-disulfonate was dropwise added to 35% hydrochloric acid (2913.8 g, 27.97 moles), which corresponds to 28 moles per one mole of 4-chloro-2-fluoro-5-hydroxyaniline, over 2.5 hours while cooling hydrochloric acid at 10° C., and further reacted at the same temperature for 8 hours to obtain a reaction mixture (6048.7 g) (90.0% of 4-chloro-2-fluoro-5-hydroxyphenylhydrazine; 3.1% of the dechlorinated compound (by-product); LC area percentages). After the filtration of the reaction mixture, the residue was dried to obtain a pale pink solid mixture containing 4-chloro-2-fluoro-5-hydroxyphenylhydrazine hydrochloride (438.7 g) (95.6% of 4-chloro-2-fluoro-5-hydroxyphenylhydrazine; 0.3% of the dechlorinated compound (by-product); LC area percentages).
According to LC-IS analysis, the yield of 4-chloro-2-fluoro-5-hydroxyphenylhydrazine was 89.3% based on 4-chloro-2-fluoro-5-hydroxyaniline.
The water content in the reaction system means the total amount of water contained in 10% hydrochloric acid, water contained in the 35% aqueous solution of sodium nitrite, water added to sodium sulfite, water contained in 95% sulfuric acid, and water contained in 35% hydrochloric acid, and it was 4336 g. Thus, the amount of the inorganic acids in the reaction system was 6.5 moles per 1 kg of water.
EXAMPLE 2-1
An aqueous solution (1314.1 g) of disodium 4-chloro-2-fluoro-5-hydroxyphenylhydrazine-N,N′-disulfonate was prepared in the same manner as in Example 1 using 10% hydrochloric acid (437.7 g), 4-chloro-2-fluoro-5-hydroxyaniline (65.0 g; content: 99.6 g; 0.401 mole), a 35% aqueous solution of sodium nitrite (83.1 g), water (539.6 g), sodium sulfite (159.5 g) and 95% sulfuric acid (12.7 g). The obtained aqueous solution was concentrated to 865.9 g by evaporating water at 56° C. under 107 mmHg over 4 hours.
EXAMPLE 2-2
Then, the concentrated aqueous solution (266.4 g) of disodium 4-chloro-2-fluoro-5-hydroxyphenylhydrazine-N,N′-disulfonate was dropwise added to 35% hydrochloric acid (223.5 g, 2.146 moles) over 2.5 hours while cooling hydrochloric acid at 10° C., and further reacted at the same temperature for 9 hours to obtain a reaction mixture (486.5 g) (81.2% of 4-chloro-2-fluoro-5-hydroxyphenylhydrazine; 2.7% of the dechlorinated compound (by-product); LC area percentages). After the filtration of the reaction mixture, the residue was dried to obtain a pale pink solid mixture containing 4-chloro-2-fluoro-5-hydroxyphenylhydrazine hydrochloride (61.9 g) (96.5% of 4-chloro-2-fluoro-5-hydroxyphenylhydrazine; 0.1% of the dechlorinated compound (by-product); LC area percentages).
According to LC-IS analysis, the yield of 4-chloro-2-fluoro-5-hydroxyphenylhydrazine was 89.4% based on 4-chloro-2-fluoro-5-hydroxyaniline.
The water contained in the reaction mixture was 311 g, and thus the amount of the inorganic acids in the reaction system was 6.9 moles per 1 kg of water.
EXAMPLE 3
4-Chloro-2-fluoro-5-hydroxyaniline (20.1 g; content: 99.6%; 0.124 mole) was added to 10% hydrochloric acid (135.8 g) at 25° C. while stirring. Then, a 35% aqueous solution of sodium nitrite (25.9 g) was dropwise added to the mixture at a temperature of −3° C. to 0° C. over 1 hour to diazotize 4-chloro-2-fluoro-5-hydroxyaniline to obtain an aqueous solution of a corresponding diazonium salt (181.7 g).
The diazonium salt was quickly added at 10° C. to a 50% aqueous solution of ammonium hydrogensulfite (73.8 g), pH of which had been adjusted at 7.2 by adding a 30% aqueous solution of sodium hydroxide (41.0 g), and the mixture was heated up to 65° C., and maintained at the same temperature for 2 hours. Thus, the aqueous solution (290.5 g) of diammonium 4-chloro-2-fluoro-5-hydroxyphenylhydrazine-N,N′-disulfonate was obtained.
The obtained aqueous solution of diammonium 4-chloro-2-fluoro-5-hydroxyphenylhydrazine-N,N′-disulfonate was dropwise added to 35% hydrochloric acid (361.5 g, 3.470 moles) over 2 hours while cooling hydrochloric acid at 10° C., and further reacted at the same temperature for 4 hours to obtain a reaction mixture (648.4 g) (93.5% of 4-chloro-2-fluoro-5-hydroxyphenylhydrazine; 0.6% of the dechlorinated compound (by-product); LC area percentages). After the filtration of the reaction mixture, the residue was dried to obtain a pale pink solid mixture containing 4-chloro-2-fluoro-5-hydroxyphenylhydrazine hydrochloride (44.4 g) (96.5% of 4-chloro-2-fluoro-5-hydroxyphenylhydrazine; no dechlorinated compound being detected; LC area percentages).
According to LC-IS analysis, the yield of 4-chloro-2-fluoro-5-hydroxyphenylhydrazine was 88.0% based on 4-chloro-C 1-2 -fluoro-5-hydroxyaniline.
The water contained in the reaction mixture was 440 g, and thus the amount of the inorganic acids in the reaction system was 7.9 moles per 1 kg of water.
EXAMPLE 4
The aqueous solution of disodium 4-chloro-2-fluoro-5-hydroxyphenylhydrazine-N,N′-disulfonate (2610.6 g) was prepared in the same manner as in Example 1 except that 10% hydrochloric acid (896.4 g), 4-chloro-2-fluoro-5-hydroxyaniline (132.9 g, content: 99.6%, 0.819 mole), a 35% aqueous solution of sodium nitrite (169.6 g), water (1084.5 g), sodium sulfite (326.2 g) and 96% sulfuric acid (14.8 g) were used.
The obtained aqueous solution (200.0 g) of disodium 4-chloro-2-fluoro-5-hydroxyphenylhydrazine-N,N′-disulfonate was cooled to 10° C. Then, to the cooled solution, 96% sulfuric acid (178.5 g, 1.747 moles) was charged at 10° C. over 30 minutes, and reacted at 15° C. for 2 hours to obtain a reaction mixture (377.9 g) (90.4% of 4-chloro-2-fluoro-5-hydroxyphenylhydrazine; 1.2% of the dechlorinated compound (by-product); LC area percentages). After the filtration of the reaction mixture, the residue was washed with saturated brine (115.7 g) and dried to obtain an ash gray solid mixture containing 4-chloro-2-fluoro-5-hydroxyphenylhydrazine sulfate. (21.2 g) (96.2% of 4-chloro-2-fluoro-5-hydroxyphenylhydrazine; 0.3% of the dechlorinated compound (by-product); LC area percentages).
According to LC-IS analysis, the yield of 4-chloro-2-fluoro-5-hydroxyphenylhydrazine was 85.5% based on 4-chloro -2-fluoro-5-hydroxyaniline.
The water contained in the reaction mixture was 161 g, and thus the amount of the inorganic acids in the reaction system was 10.9 moles per 1 kg of water.
The results of Examples 1-4 are summarized in Table 3.
TABLE 3
Amount of Inorganic
acid per 1 kg of
Yield 1) of
water in reaction
phenyl-
Inorganic
system
hydrazines
acid
(moles)
(%)
Example 1
Hydrochloric acid
6.5
89.3
Example 2
Hydrochloric acid
6.9
89.4
Example 3
Hydrochloric acid
7.9
88.0
Example 4
Sulfuric acid
10.9
85.5
Note:
1) A yield based on the raw material aniline derivative.
|
A process for the preparation of a phenylhydrazine or an inorganic acid salt thereof of the formula (1):
wherein X is a hydrogen or halogen atom; Y is a halogen atom; and W is a hydrogen atom or —ZR in which Z is an oxygen or sulfur atom, and R is a hydrogen atom, an alkyl group, a haloalkyl group, and so on, by the hydrolysis of a phenylhydrazine derivative of the formula (2):
where X, Y and W are the same as defined above, and the Q groups are a hydrogen atom, an ammonium group or an alkali metal atom in the presence of water and an inorganic acid, in which the concentration of the inorganic acid is at least 6 moles per 1 kg of water in a reaction system.
| 2
|
This application is a continuation-in-part of application Ser. No. 08/081,900 filed on Jun. 25, 1993 which is, in turn, a division of application Ser. No. 07/816,503 filed on Dec. 31, 1991, now U.S. Pat. No. 5,258,407.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to 3,4-disubstituted phenols, methods for their preparation and, to their use as immunomodulating agents. More specifically, the present invention relates to 3,4-disubstituted phenols having interleukin 1 (hereinafter IL-1) mimetic activity, which can be used as a stimulant of the immune functions.
2. Reported Developments
IL-1 is a 17kD polypeptide hormone which induces a wide range of biological effects by binding IL-1 to a specific receptor protein on responsive cells. Some of the activities of IL-1 include: induction of IL-2 secretion from T cells, induction of fibroblasts to secrete PGE, stimulation of osteoclasts to resorb bone, triggering the appearance of CSF receptors on stem cell progenitors, increasing synthesis of CSF's, activation of T and B cells, induction of cartilage destruction in joints, elevation of collagenase levels in synovial fluid and action as an endogenous pyrogen.
Because of the multiple activities of IL-1, a variety of uses for compounds influencing these responses have been envisioned. An IL-1 agonist or mimetic would have therapeutic applications as an immunostimulant, an anticancer agent or in inducing haemopoesis.
IL-1 has been produced in the prior art by inducing secretion thereof by normal macrophages/monocytes of peripheral blood by means of application of an inducing agent of bacterial origin. IL-1 has also been produced by culturing a human leukemic cell line of haematopoietic origin by means of application of phorbols as inducing agents. Another approach to provide for IL-1 activity is disclosed in U.S. Pat. No. 4,762,914 which teaches the production of truncated protein of IL-1 made by a genetic engineering procedure. The so obtained biologically active human IL-1 protein is said to be useful to induce the production of IL-2 by activated T-cells. Still another approach to provide IL-1 activity is disclosed in U.S. Pat. No. 4,774,320 which concerns the preparation and use of the following peptide that mimics human IL-1 activity:
Val-Gln-Gly-Glu-Glu-Ser-Asn-Asp-Lys-X
where
X cysteine (Cys), OH, NH 2 , benzyl ester or an alkyl ester group having a number of carbon atoms from 1 to 7.
IL-2, also known as T cell growth factor, has been found to influence cell-mediated immune responses in mammals, such as: enhancement of thymocyte mitogenesis; production of cytotoxic T lymphocytes; promotion of proliferation of antigert specific killer T cell lines; and promotion of anti-erythrocyte placque forming cell responses.
Disruptions of the immunodefense system can be ascribed to the insufficient presence of IL-2 in the mammalian body, as a result of the lack of cells that produce IL-2, inadequate IL-2 production, or insufficient formation of IL-2 receptors (U.S. Pat. No. 4,752,573). In light of these findings by the prior art, IL-2 appears to be useful in promoting humoral and cellular immune responses and in restoring an immune deficient state to a normal immune state. Accordingly, IL-2 is indicated for medical immunotherapy against immunological disorders, including neoplastic diseases, bacterial or viral infections, immune deficient disorders and autoimmune diseases.
IL-2 has been produced in the prior art by stimulating mouse, rat or human lymphocytes with a mitogen (Gillis, S. et al., Nature, 268, 154-156, (1977), Farrat, J. et al., J. Immunol., 121, 1353-1360, (1978), Gillis, S. et al., J. Immunol., 120, 2027-2033, (1978)) or by stimulating human peripheral blood mononuclear lymphocytes with a mitogen (Gillis, S. et al., J. Immuno., 124, 1954-1962, (1980)). Gillis et al. reported the preparation of murine ILo2 from murine T cell lymphoma cell line (Gillis, S. et al. J. Immunol., 125, 2570-2578 (1980)) and preparation of human IL-2 from a human leukemia cell line (Gillis, S. et al., J. Exp. Med., 152, 1709-1719, (1980)).
Other methods of preparations, compositions and use thereof are illustrated by the following references.
U.S. Pat. No. 4,404,280 discloses a process for producing murine IL-2 from malignant neoplastic cells in vitro in a protein-containing medium. The process includes the utilization of IL-1 as a co-stimulant to induce IL-2 production.
U.S. Pat. No. 4,406,830 relates inter alia. to a process for producing a serum-free and mitogen-free IL-2 in vitro by adding glycoprotein to a serum-free and mitogen-free IL-1 preparation.
U.S. Pat. No. 4,738,927 discloses a method of producing IL-2 by isolating a gene which possesses IL-2 activity, connecting said gene with a vector DNA which is capable of replicating in a procaryotic or eucaryotic cell at a position down-stream of a promoter gene in the vector to obtain a recombinant DNA, with which the cell is transformed to produce IL-2.
U.S. Pat. No. 4,752,573 relates to the use of pterins to increase the activity of lymphokines and other cell growth factors, including IL-2.
U.S. Pat. No. 4,780,313 discloses a method for immunostimulating a warm-blooded animal by administering to said animal a substance having IL-2 activity, such as a recombinant non-glycosylated human IL-2, in combination with muramyldipeptide.
U.S. Pat. No. 4,789,658 relates to an immunoprophylactic and immunotherapeutic composition comprising grade E human IL-2 of human T-lymphocyte origin.
The utility of IL-2 to supplement immune responses and thus the need for IL-2 mediators to proliferate other effector cells, such as T-helper and suppressor cells, cytotoxic T-cells and natural killer cells (hereinafter NKC's) to promote cell-mediated immunity, is apparent from the above-described references.
It should also be noted that IL-1, or a biologically active compound that mimics IL-1 activity, plays a very important role as an immunostimulating agent by inducing IL-2 synthesis and subsequent IL-2 receptor expression.
We have now discovered a class of organic compounds which promote cell-mediated immunity based on their capability to elevate IL-2 and granulocyte macrophage colony stimulating factor (hereinafter GM-CSF) levels in vitro and thus proliferate effector cells, such as cytotoxic T-cells lines and other subpopulations of T-cells.
SUMMARY OF THE INVENTION
In accordance with the present invention, certain 3,4-disubstituted phenols and pharmaceutically acceptable salts thereof are provided which mimic IL-1 activity by inducing IL-2 synthesis and subsequent IL-2 receptor expression. Specifically, the invention provides compounds of Formula I and acid addition salts thereof: ##STR3## wherein
Y is ##STR4## NHSO 2 or SO 2 NH where R 4 is H;
Z is --O--, --NH--, --NR--, --S--, or other heteroatoms capable of hydrogen bonding with R 4 to give a preferred conformation;
R is alkyl;
R 1 is --OH;
R 2 is H, alkyl, cycloalkyl, aralkyl, substituted or unsubstituted aryl, or a substituted or unsubstituted nitrogen heterocyclic group having 4 to 5 nuclear carbon atoms; and
R 3 is a lipophilic moiety selected from the group consisting of substituted C 1 -C 10 alkyl, C 3 -C 16 cycloalkyl and 2,4-di-t-pentylphenyl.
DETAILED DESCRIPTION OF THE INVENTION
As employed above and throughout the specification the following terms, unless otherwise indicated, shall be understood to have the following meaning:
The "alkyl" group per se and in alkoxy means a saturated or unsaturated aliphatic hydrocarbon which may be either straight- or branched-chained containing from one to about 10 carbon atoms. Lower alkyl is preferred having from one to six carbon atoms.
The "cycloalkyl" groups may be mono or polycyclic and contain 3 to 16 carbon atoms and include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl and cyclooctyl.
"Aryl" contains from 6 to 10 carbon atoms and include phenyl, tolyl, xylyl, naphthyl and the like.
"Substituted aryl" means an aryl group substituted by one or more lower alkyl, lower alkoxy, amino, lower alkyl amino, lower alkyl mercapto, hydroxy, hydroxy lower alkyl, acetoxy, benzyloxy, phenoxy, carboxy, carboalkoxy, halo, amido, halosulfonyl, lower alkyl sulfinyl or lower alkyl sulfonyl.
"Aralkyl" means an aromatic hydrocarbon radical containing from 7 to about 16 carbon atoms and include benzyl, phenethyl, naphthylmethyl and the like.
The "heterocyclic" groups may be mono or polycyclic and include such groups as pyridyl, pyrimidinyl, quinolyl, quinolinyl, piperidyl, pyrrolyl, morpholinyl, thiomorpholinyl, thiophenyl, furyl, furfuryl, thienyl, imidazolyl, benzimidazolyl, and the like. These groups may carry substitutents such as alkyl, alkenyl, alkynyl, hydroxy, thio, amino, alkylamino, dialkylamino, alkoxy, alkylthio and halo.
"Lipophilic" means a moiety having from about 1 to about 22 carbon atoms in the entire group and includes substituted or unsubstituted, straight-or branched-chain alkyl, cycloalkyl, neopentyl, nonyl, isononyl, alkyladamantyl, 2,4-dimethylbenzyl, substituted or unsubstituted phenyl, such as 2,4-di-t-pentylphenyl or 2-naphthyl.
When R 2 is substituted aryl it can have up to five of the lipophilic substituents described under "lipophilic" above or any combination of members of said lipophilic group with a polar substituent, such as cyano, amino, hydrazino, acetylhydrazino, arylazo, fiuorosulfonyl or carboxamido.
"Halogen" means Cl, F, I or Br.
Preferred compounds of this invention are aryloxyphenols having the structure of Formula II: ##STR5## wherein
R 1 is --OH;
R 10 , R 11 and R 12 are independently H or a lipophilic group, or any two of R 10 , R 11 and R 12 can be taken together with the phenyl nucleus to which they are attached to form a β-naphthyl group; and
R 13 , R 14 and R 15 are independently H, a lipophilic group or a polar group.
Still more preferred compounds are: 2-(2,4-bis(1,1-dimethylpropyl) phenoxy)-5-hydroxybenzanilide, 3'-carboetho xy-ethyl-2-(2,4-bis(1,1-dimethyl-propyl)phenoxy)-5-hydroxy-benzanilide, 3'-(2-hydroxyethyl)-2-(2,4-bis(1,1-dimethylpropyl) phenoxy)-5-hydroxybenzanilide, 3'-hydroxymethyl-2-(2,4-bis(1,1-dimethylpropyl)phenoxy)-5-hydroxybenzanilide, 3'-(1-methyl-2-carboethoxyethyl)-2-(2,4-bis(1,1-dimethylpropyl) phenoxy)-5-hydroxy-benzanilide, 4'-iodo-2-(2,4-bis(1,1-dimethylpropyl) phenoxy)-5-hydroxy-benzanilide, 2'-chloro-5'-(1-oxo-2-carboethoxyethyl)-2-(2,4-bis(1,1-dimethylpropyl)phenoxy)-5-hydroxybenzanilide, 2',5'-bis(1,1-dimethylethyl)-2-(2,4-bis(1,1-dimethylpropyl)phenoxy)-5-hydroxybenzanilide, 3',5'-dichloro-2-(2,4-bis(1,1-dimethylpropyl) phenoxy)-5-hydroxybenzanilide, 3,'5'-dicarbomethoxy-2-(2,4-bis(1,1-dimethyl-propyl)phenoxy)-5-hydroxy-benzanilide, 3',5'-bis(1,1-dimethylethyl)-5-hydroxy-2-phenoxybenzanilide, N-(methyl)-2-(2,4-bis(1,1-dimethylpropyl)phenoxy)-5-hydroxy-benzamide, N-(dimethylamino)-2-(2,4-bis(1,1-dimethylpropyl)phenoxy)-5-hydroxybenzamide, N-(ethyl)-2-(2,4-bis(1,1-dimethylpropyl)phenoxy)-5-hydroxybenzamide, N-(1-methylethyl)-2-(2,4-bis(1,1-dimethylpropyl) phenoxy)-5-hydroxybenzamide, N-(1,1-dimethylethyl)- 2-(2,4-bis(1,1-dimethylpropyl)phenoxy)-5-hydroxybenzamide, S-(N-alpha-chloromethylbenzyl)-2-(2,4-bis(1,1-dimethylpropyl)phenoxy)-5-hydroxybenzamide, N-(1-adamantyl)-2-(2,4-bis(1,1-dimethylpropyl) phenoxy)-5-hydroxybenzamide, N-(2-pyrimidinyl)-2-(2,4-bis(1,1-dimethylpropyl)phenoxy)-5-hydroxybenzamide, N-(1,1-dimethylpropyl)-2-(2,4-bis(1,1-dimethylpropyl)phenoxy)-5-hydroxybenzamide and N-(1,1-dimethylpropyl)-2-(2,4-bis(1,1-dimethylpropyl)phenoxy)benzthioamide.
The compounds of the present invention may be prepared by art recognized procedures from known starting materials available from chemical supply houses (such as Aldrich Chemical Company). The following schemes illustrate such preparative procedures: ##STR6##
Scheme 1 describes the synthetic pathway to the desired 5-hydroxyl materials. Commercially available 2-bromo-5-methoxybenzoic acid 1 was converted to the corresponding methyl ester 2. The aryl ether 3 was prepared from 2 and the desired phenol or alcohol through a modified Ullmann coupling using cuprous chloride and pyridine. Base hydrolysis of the ester yielded acid 4 which allowed several approaches to the desired products. Formation of the acid chloride of 4 with oxalyl chloride or thionyl chloride and subsequent reaction with the desired amine afforded the amide 5. Deprotection of the methyl ether with BBr 3 in methylene chloride yielded the desired phenols 7-33 (Tables 1 and 2) in generally good yield.
The phenolic acid 6 was successfully obtained by treatment of 4 with 31% HBr in acetic acid at reflux.
Formation of the acid chloride of 6 was accomplished with oxalyl chloride without detriment to the hydroxyl group. Subsequent reaction with the desired amine afforded the desired phenolic amides 7-33 in good yield. Tables 1 and 2 list the materials which could be prepared using this methodology.
TABLE 1______________________________________ ##STR7##COMPOUND NO. R______________________________________ 7 H 8 2-COOH 9 3-CH(CH.sub.3)CH.sub.2 COOH10 3-CH.sub.2 COOCH.sub.2 CH.sub.311 3-CH.sub.2 CH.sub.2 OH12 3-CH.sub.2 COOH13 3-CH.sub.2 OH14 3-CH(CH.sub.3)CH.sub.2 COOCH.sub.2 CH.sub.315 4-I16 2-Cl-5-COCH.sub.2 COOCH.sub.2 CH.sub.317 2,5-(C(CH.sub.3).sub.3).sub.218 3,5-Cl.sub.219 3,5-(COOCH.sub.3).sub.220 3,5-(C(CH.sub.3).sub.3).sub.2______________________________________
TABLE 2______________________________________ ##STR8##COMPOUND NO. R______________________________________21 CH.sub.322 N(CH.sub.3).sub.323 CH.sub.2 CH.sub.324 CH(CH.sub.3).sub.225 C(CH.sub.3).sub.326 C(CH.sub.3).sub.2 CH.sub.2 CH.sub.327 C(CH.sub.2 OH).sub.3 28 (a) CH(CH.sub.2 OH)-phenyl 29 (b) CH(CH.sub.2 OH)-phenyl 30 (a) CH(CH.sub.2 Cl)-phenyl 31 (b) CH(CH.sub.2 Cl)-phenyl32 1-Adamantyl33 2-Pyrimidinyl______________________________________ (a) R isomer (b) S isomer
Compound 34, 35, 36 and 37 shown in Table 3 can be made using the following scheme: ##STR9##
TABLE 3______________________________________COMPOUND NO. R______________________________________34 C(CH.sub.3).sub.2 CH.sub.2 CH.sub.335 H36 C(CH.sub.3).sub.337 2,4,6-(CH.sub.3).sub.3______________________________________
The following preparative examples will further illustrate the invention.
PREPARATION OF INTERMEDIATE
Methyl 2-(2,4-di-tert-pentylphenoxy)-5-methoxymethylbenzoate ##STR10## To a solution of sodium hydride (1.2 g, 0.05 mol) in pyridine (60 mL), was added a solution of 2,4-di-tert-pentlyphenol (12.9 g, 0.055 mol) in pyridine (20 mL) with stirring. Gas evolution ceased in approximately 1.5 hr at which time methyl 2-bromo-5-methoxylbenzoate was added. Copper (I) chloride (1.24 g, 0.0126 mol) was added and the mixture heated to reflux for 8 hours. The reaction mixture was diluted with diethyl ether (100 mL) and washed with 3N HCl (3×50 mL) and then washed with saturated sodium bicarbonate (1×50 mL). The organic extracts were dried over sodium sulfate, filtered and concentrated to give a dark oil. Chromatography on silica gel with 1:1 heptane:ethyl acetate yielded the pure product as a viscous oil in 90% yield. NMR and mass spectral analysis were consistent with proposed structure.
2-(2,4-di-tert-pentylphenoxy)-5-methoxybenzoic acid ##STR11## To a solution of potassium hydroxide (5.6 g, 0.1 mol) in ethanol (150 mL) was added methyl 2-(2,4-di-tert-pentylphenoxy)-5-methoxybenzoate (18.0 g, 0.045 mol) and the mixture brought to reflux for 2 hours. TLC indicated the hydrolysis to be complete. The ethanol was removed in vacuo and the residue taken up in water (75 mL) and acidified with 6N HCl. The aqueous mixture was extracted with ethyl acetate (3×100 mL). The organic layers were combined and dried over magnesium sulfate, filtered and the solvent removed in vacuo. Recrystallization from heptane yielded the product as a white solid in 90% yield. NMR and mass spectral analysis were consistent with proposed structure.
2-(2,4-di-tert-pentylphenoxy)-5-hydroxybenzoic acid ##STR12## A solution of 2-(2,4-di-tert-pentylphenoxy)-5-methoxybenzoic acid (10.0 g, 0.026 mol) in 31% HBr/HOAc (100 mL) was heated to reflux for 1 hour. The reaction mixture was cooled to room temperature and added to 500 mL water. The mixture was extracted with ethyl acetate (3×200 mL), and the combined organic extracts repeatedly washed with water to remove traces of acid. The organic extracts were dried over magnesium sulfate and concentrated to give a tan solid. Chromatography on silica gel with 1:1 heptane:ethyl acetate yielded the product in 80% yield. NMR and mass spectral data were consistent with the proposed structure.
EXAMPLE 1
2-(2,4-di-tert-pentylphenoxy)-5-hydroxybenzanilide ##STR13##
A solution of 2-(2,4-di-tert-pentylphenoxy)-5-hydroxybenzoic acid (3.3 g, 8.9 mmol) and oxalyl chloride (1.25 g, 9.8 mmol) in dichloromethane (75 mL) was stirred at room temperature for 2 hours. The solvent was removed in vacuo and the residue triturated with toluene (25 mL) followed by distillation of the solvent. The crystalline residue was taken up in dichloromethane (80 mL) and aniline (1.66 g, 17.9 mmol) was added. The reaction mixture was allowed to stir at room temperature for 8 hours, then submitted to aqueous, acidic workup. Flash column chromatography on silica gel with 90:10 heptane:ethyl acetate yielded the addition product. Recrystallization from heptane/ethyl acetate yielded analytically pure product in 79% overall yield.
EXAMPLE 2
N-tert-butyl-2-(2,4-di-tert-pentylphenoxy)-5-hydroxybenzamide ##STR14##
A solution of 2-(2,4-di-tert-pentylphenoxy)-5-methoxybenzoic acid (1.0 g, 2.6 mmol) and oxalyl chloride (0.34 g, 3 mmol) in dichloromethane (25 mL) was stirred at room temperature for 2 hours. The solvent was removed in vacuo and the residue triturated with toluene (25 mL) followed by distillation of the solvent. The crystalline residue was taken up in dichloromethane (50 mL) and tert-butylamine (0.22 g, 3.0 mmol) and triethylamine (0.4 g, 4 mmol) were added. The reaction mixture was allowed to stir at room temperature for 8 hours, then submitted to aqueous, acidic workup. Flash column chromatography on silica gel with heptane yielded the pure addition product. Demethylation of the 5-methoxy group to give the hydroxy derivative was achieved by dissolving the solid in dichloromethane (50 mL) and adding boron tribromide (1 M in dichloromethane, 2.5 equivalents) at 0° C. with stirring for 1.5 hours. The mixture was submitted to aqueous workup and extracted with diethyl ether (3×50 mL). Removal of the solvent in vacuo yielded the desired product in 86% overall yield.
EXAMPLE 3
N-tert-pentyl-2-(2,4-di-tert-pentylphenoxy)-5-hydroxybenzamide ##STR15##
A solution of 2-(2,4-di-tert-pentylphenoxy)-5-methoxybenzoic acid (1.0 g, 2.6 mmol), and oxalyl chloride (0.34 g, 3 mmol) in dichloromethane (25 mL) was stirred at room temperature for 2 hours. The solvent was removed in vacuo and the residue triturated with toluene (25 mL) followed by distillation of the solvent. The crystalline residue was taken up in dichloromethane (50 mL) and tert-pentylamine (0.26 g, 3.0 mmol) and triethylamine (0.4 g, 4 mmol) added. The reaction mixture was allowed to stir at room temperature for 8 hours, then submitted to aqueous, acidic workup. Flash column chromatography on silica gel with heptane yielded the pure addition product. Demethylation of the 5-methoxy group to give the hydroxy derivative was achieved by dissolving the solid in dichloromethane (50 mL) and adding boron tribromide (1 M in dichloromethane, 2.5 equivalents) at 0° C., with stirring, for 1.5 hours. The mixture was submitted to aqueous workup and extracted with diethyl ether (3×50 mL). Removal of the solvent in vacuo yielded the desired product in 85% overall yield.
EXAMPLE 4
N-(1-adamantyl)-2-(2,4-di-tert-pentylphenoxy)-5-hydroxybenzamide ##STR16##
A solution of 2-(2,4-di-tert-pentylphenoxy)-5-methoxybenzoic acid (1.0 g, 2.6 mmol) and oxalyl chloride (0.34 g, 3 mmol) in dichloromethane (25 mL) was stirred at room temperature for 2 hours. The solvent was removed in vacuo and the residue triturated with toluene (25 mL) followed by distillation of the solvent. The crystalline residue was taken up in dichloromethane (50 mL) and 1-adamantylamine hydrochloride (0.48 g, 2.6 mmol) and triethylamine (0.56 g, 5.4 mmol) added. The reaction mixture was allowed to stir at room temperature for 2 hours, then submitted to aqueous, acidic workup. Flash column chromatography on silica gel with 4:1heptane:ethyl acetate yielded the pure addition product. Demethylation of the 5-methoxy group to give the hydroxy derivative was achieved by dissolving the solid in dichloromethane (50 mL) and adding boron tribromide (1 M in dichloromethane, 2.5 equivalents) at 10° C., with stirring, for 3 hours. The mixture was submitted to aqueous workup and extracted with diethyl ether (3×50 mL). Removal of the solvent in vacuo yielded the desired product in 81% overall yield.
EXAMPLE 5
1-(3',5'-dicarbomethoxy)-2-(2,4-di-tert-pentylphenoxy)-5-hydroxy benzanilide ##STR17##
A solution of 2-(2,4-di-tert-pentylphenoxy)-5-methoxybenzoic acid (1.0 g, 2.6 mmol) and oxalyl chloride (0.36 g, 3 mmol) in dichloromethane (25 mL) was stirred at room temperature for 2 hours. The solvent was removed in vacuo and the residue triturated with toluene (25 mL) followed by distillation of the solvent. The crystalline residue was taken up in dichloromethane (50 mL) and dimethyl 5-aminoisophthalate (0.54 g, 2.6 mmol) and triethylamine (0.4 g, 4 mmol) added. The reaction mixture was allowed to stir at room temperature for 8 hours, then submitted to aqueous, acidic workup. Flash column chromatography on silica gel with 1:3 ethyl acetate:heptane yielded the pure addition product. Demethylation of the 5-methoxy group to give the hydroxy derivative was achieved by dissolving the solid in dichloromethane (50 mL) and adding boron tribromide (1 M in dichloromethane, 2.5 equivalents) at room temperature with stirring for 2 hours. The mixture was submitted to aqueous workup and extracted with diethyl ether (3×50 mL). Removal of the solvent in vacuo yielded the desired product in 76% overall yield.
The biological profile of the compounds of the present invention include the following characteristics:
(a) Induction of secretion of IL-2 by murine EL-4 cells at concentrations as low as 4×10 -8 M;
(b) Induction of IL-2 and granulocytes macrophage colony stimulating factor (GM-CSF) gene expression in EL-4 cells;
(c) Production of IL-3 and IL-4;
(d) Lack of binding IL-1, IL-2 or IL-4 receptors; neither agonists or antagonists to these lymphokines;
(e) Induction of proliferation of human thymocytes;
(f) Induction of proliferation of human T-cells and B-cells and murine T-cells;
(g) No indication of toxicity when administered IP, PO or IV; and
(h) Enhancement of human mixed lymphocyte reaction in a dose-dependent manner.
Based on these findings, the compounds of the present invention are useful for prophylaxis and therapy of immunological diseases. According to the kind of diseases, to the condition of the patients and to the immune state, the physician will determine the amount of the drug to be administered, the frequency of administration, routes of administration and vehicles containing the compounds to be administered.
The compounds of this invention can be normally administered parenterally, in the prophylaxis and treatment of immunological disorders.
The compounds of this invention, or salts thereof, may be formulated for administration in any convenient way, and the invention includes within its scope pharmaceutical compositions containing at least one compound according to the invention adapted for use in human or veterinary medicine. Such compositions may be formulated in a conventional manner using one or more pharmaceutically acceptable carriers or excipients. Suitable carriers include diluents or fillers, sterile aqueous media and various non-toxic organic solvents.
For parenteral administration, solutions or suspensions of these compounds in aqueous alcoholic media or in sesame or peanut oil or aqueous solutions of the soluble pharmaceutically acceptable salts described herein can be employed. Solutions of the salts of these compounds are especially suited for intramuscular and subcutaneous injection purposes. The aqueous compositions, including solutions of the salts dissolved in pure distilled water are also useful for intravenous injection purposes, provided that their pH is properly adjusted, suitably buffered, made isotonic with sufficient saline or glucose and sterilized by heating or by microfiltration. Certain compositions useful for intravenous injection or infusion may be prepared using the solid form of the active compound of the present invention. The solid compound may be suspended in propylene glycol, or a polyethylene glycol ether such as PEG 200, using a sonicator and the resulting mixture combined with aqueous media.
The dosage regimen in carrying out the methods of this invention is that which insures maximum therapeutic response until improvement is obtained and thereafter the minimum effective level which gives relief. It should be borne in mind that selecting the appropriate dosage in any specific case, consideration must be given to the patient's weight, general health, age and other factors which may influence response to the drug. The drug may be administered as frequently as is necessary to achieve and sustain the desired therapeutic response.
The present invention is also useful as an injectable dosage form which may be administered in an emergency to a patient. Such treatment may be followed by intravenous infusion of the active compound and the amount of compound infused into such patient should be effective to achieve and maintain the desired therapeutic response.
About 10 to 500 mg of a compound or mixture of compounds of formula (I) or pharmaceutically acceptable salts thereof is compounded with a physiologically acceptable vehicle, carrier, excipient, binder, preservative, stabilizer and flavor in a unit dosage form as called for by accepted pharmaceutical practice. The amount of active substance in these compositions or preparations is such that a suitable dosage in the following range indicated is obtained. A single dose, or preferably two to four divided daily doses, provided on a basis of about 0.1 to 100 mg per kilogram of body weight per day, preferably about 1 to 50 mg per kilogram of body weight per day is appropriate to introduce to a mammal for immunostimulation.
The following test results illustrate the beneficial effects of compounds of the present invention.
IL-1 BIOASSAY
EL-4 6.1 cells (murine T-cells) were first treated with mitomycin C to inhibit their proliferation. After washing the cells free of mitomycin C, the test compound (10 -5 M) or the IL-1 standard (3×10 -11 M) was incubated with 2×10 5 EL-4 6.1 cells for 24 hours to allow gene expression and IL-2 synthesis. To quantify IL-2 production, CTLL-2 cells (IL-2 hybridized mouse cytotoxic T cell line which requires IL-2 for growth) were added and incubated for 24 hours; then tritiated thymidine was added and the cells incubated an additional 4 hours. The cells were then collected by centrifugation through oil and counted. Screening results were reported relative to the IL-1 standard run concurrently. Activity was considered to be >20% cell proliferation of the IL-1 standard as determined by thymidine uptake. Positive compounds that demonstrated reproducible biological activity were then tested for a dose response at 10 -5 , 3×10 -6 , 10 -6 , 4×10 -7 M and 4×10 -8 M. The result in Table 4 gives the activity indicated where the numbers refer to compound numbers and the activity key is as shown:
TABLE 4______________________________________COMPOUND NO. ACTIVITY______________________________________ 7 ++++10 ++++11 +++12 +13 ++++14 ++++15 ++++16 ++++17 +++18 ++++19 +++++20 +++21 ++++22 +++23 ++++24 ++++25 +++++26 +++++27 ++28 ++29 +30 ++31 ++++32 +++++33 +++35 ++36 ++37 +______________________________________ + Active at 10.sup.-5 M ++ Active at 3 × 10.sup.-6 M +++ Active at 10.sup.-6 M ++ ++ Active at 4 × 10.sup.-7 M +++++ Active at 10.sup.-7 M ++++++ Active at 4 × 10.sup.-8 M
It should be understood by those skilled in the art that various modifications may be made in the present invention without departing from the spirit and scope thereof as described in the specification and defined in the appended claims.
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Certain 3,4-disubstituted phenols and pharmaceutically acceptable salts thereof are provided which mimic IL-1 activity by inducing IL-2 synthesis and subsequent IL-2 receptor expression. Specifically, the invention provides compounds of Formula I and acid addition salts thereof: ##STR1## wherein Y is ##STR2## NHSO 2 or SO 2 NH where R 4 is H; Z is --O--, --NH--, --NR--, --S--, or other heteroatoms capable of hydrogen bonding with R 4 to give a preferred conformation;
R is alkyl;
R 1 is --OH;
R 2 is H, alkyl, cycloalkyl, aralkyl, substituted or unsubstituted aryl, or a substituted or unsubstituted nitrogen heterocyclic group having 4 to 5 nuclear carbon atoms; and
R 3 is a lipophilic moiety selected from the group consisting of substituted C 1 -C 10 alkyl, C 3 -C 16 cycloalkyl and 2,4-di-t-pentylphenyl.
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PRIORITY
[0001] This application claims priority to an application entitled “Data Transmission Apparatus and Method for an HARQ Data Communication System” filed in the Korean Industrial Property Office on May 24, 2000 and assigned Ser. No. 2000-29121, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a data transmission apparatus and method in a radio communication system, and in particular, to an apparatus and method for managing retransmission of data which is subjected to transmission error during data transmission.
[0004] 2. Description of the Related Art
[0005] A radio communication system chiefly uses convolutional codes, turbo codes or linear block codes, for channel coding. Such a radio communication system may employ an HARQ (Hybrid Automatic Repeat Request) Type I using an ARQ (Automatic Repeat Request) scheme which requests retransmission of data packets upon completion of decoding and CRC error check. HARQ scheme is generally applicable to a satellite system, an ISDN (Integrated Services Digital Network) system, a digital cellular system, a CDMA-2000 (Code Division Multiple Access-2000) system, a UMTS (Universal Mobile Telecommunication System) system or an IMT-2000 (International Mobile Telecommunication-2000) system, and HARQ scheme includes the convolutional codes and the turbo codes.
[0006] The above-stated hybrid ARQ scheme is generally divided into HARQ Type I, HARQ Type II and HARQ Type III. At present, most of the multi-access schemes and the multi-channel schemes using the convolutional codes or the turbo codes employ the HARQ Type I. That is, the multi-access and multi-channel schemes of the radio communication system using the above-stated channel coding scheme, employ the HARQ Type I as an ARQ scheme for increasing the data transmission efficiency, i.e., throughput of the channel coding scheme and improving the system performance.
[0007] A principle of the HARQ Type I is based on the fact that the channel encoder using the convolutional code, the turbo code or the linear block code has a constant code rate. FIGS. 1A and 1B illustrate a conceptional data process flow by the HARQ Type I.
[0008] Commonly, a transmitter of the radio communication system combines L-bits transmission data with a CRC (Cyclic Redundancy Check) code for error detection and then encodes the combined data, L+CRC, through channel coding. The transmitter transmits the encoded data through an assigned channel. Meanwhile, a receiver of the radio communication system acquires the original L-bits data and the CRC code through a reverse operation of the transmitter, and transmits a response signal ACK/NAK to the transmitter according to the CRC check results.
[0009] This will be described in more detail with reference to FIG. 1A. A CRC encoder 110 receives an L-bits source data packet and encodes the received data using a CRC code, creating a FEC input data block, L+CRC. Commonly, CRC bits are added to the source data before channel encoding. A channel encoder 112 performs channel coding on the FEC input data block, L+CRC, creating a channel-coded data block, (L+CRC)×R −1 . The channel-coded data block, (L+CRC)×R −1 , is provided to a specific channel through other functional blocks 114 necessary for multiplexing.
[0010] Other inverse functional blocks 124 necessary for demultiplexing in the receiver receiving the channel-coded data block through the specific channel, demultiplex the received coded data block and output a channel-coded data block, (L+CRC)×R −1 . A channel decoder 122 then performs channel decoding on the channel-coded data block, (L+CRC)×R −1 , and outputs a channel-decoded data block, L+CRC. A CRC decoder 120 performs CRC decoding on the channel-decoded data block, L+CRC, to acquire the original data, i.e., the L-bits source data packet. After completion of CRC decoding, the CRC decoder 120 performs CRC checking using the CRC decoding results, thereby to determine whether the source data packet has transmission errors.
[0011] If no error is detected through the CRC check, the receiver provides the source data packet to an upper layer and transmits a confirm signal ACK (Acknowledgement) acknowledging the source data packet to the transmitter. However, upon detecting an error through the CRC check, the receiver transmits a confirm signal NAK (Not-Acknowledgement) requesting retransmission of the channel coded data packet to the transmitter.
[0012] After transmitting the channel-coded data block, the transmitter receives the confirm signal ACK/NAK from the receiver in response to the transmitted channel-coded data block. Upon receipt of the confirm signal NAK, the transmitter retransmits the corresponding channel-coded data block in the above-described operation. The transmission scheme includes Stop-and-Wait ARQ, Go-Back-N ARQ, and Selective-Repeat ARQ schemes. The detailed description of the retransmission schemes will be omitted.
[0013] [0013]FIG. 1B illustrates a conceptual transmission procedure of the channel-coded data packet between the transmitter and the receiver. FIG. 1B shows that the transmitter retransmits the channel-coded data block upon every receipt of m NAKs from the receiver.
[0014] As an example of such a procedure, in an air interface of the 3GPP-2 (3 rd Generation Partnership Project-2; a standard for a synchronous CDMA system) mobile communication system (hereinafter, referred to as “CDMA-2000” system), the multi-access scheme and the multi-channel scheme of the system employ the HARQ Type I in order to increase data transmission efficiency of the channel coding scheme and to improve the system performance. In addition, in an air interface of the 3GPP (3 rd Generation Partnership Project; a standard for an asynchronous CDMA system) mobile communication system (hereinafter, referred to as “UMTS system”), the multi-access scheme and the multi-channel scheme of the system also employ the HARQ Type I in order to increase data transmission efficiency of the channel coding scheme and to improve the system performance.
[0015] However, the HARQ Type I has the following disadvantages.
[0016] First, the HARQ Type I has higher throughput, compared with a pure ARQ scheme. However, as a signal-to-noise ratio (S/N) of a signal is increased more and more, the throughput becomes saturated to a code rate R of the FEC code, thus resulting in a reduction in the throughput as compared with the pure ARQ. That is, the throughput cannot approach 1.0 (100%) even at very high S/N. Such a problem is shown by a characteristic curve of the HARQ Type I in FIG. 2. That is, as for the HARQ Type I, the throughput is saturated to the code rate R (<1.0) as shown in FIG. 2, so that it cannot approach 1.0.
[0017] Second, the HARQ Type I improves the throughput by performing error correction using the FEC code, compared with the pure ARQ. However, since the HARQ Type I uses a constant redundancy, i.e., constant code rate regardless of variation in S/N, it has low transmission efficiency. Therefore, the HARQ Type I cannot adaptively cope with variations in the channel condition, thus causing limitation of throughput.
[0018] To solve such problems, the HARQ Type II or the HARQ Type III is used. The HARQ Type II and the HARQ Type III have an adaptive structure which adaptively determines an amount of redundancies used for the FEC code according to how good the channel condition is. Therefore, the HARQ Type II and the HARQ Type III have improved throughput, compared with the HARQ Type I. That is, the adaptive structure reduces the amount of redundancies to a minimum, so that as the S/N of the signal is increased more and more, the code rate R of the FEC code approaches 1, thereby enabling the throughput to approach 1. Meanwhile, the adaptive structure performs optimal error correction such that if the S/N of the signal is decreased, the amount of redundancies is increased to a maximum to enable the code rate R of the FEC code to approach 0, or the redundancies are repeated so as not to enable the throughput to approach 0. Accordingly, the HARQ Type II and the HARQ Type III have improved throughput at both a low S/N and a high S/N.
[0019] The HARQ Type I, the HARQ Type II and the HARQ Type III transmit the response signal ACK/NAK, channel condition indication bit, or packet number through a control channel or a through control message channel in response to the received channel-coded data block. In the following description, the channel for transmitting the response signal or control signal message will be referred to as “message channel”, and the message transmitted over the message channel will be referred to as “control message.”
[0020] The message channel can be divided into a forward message channel and a reverse message channel according to the transmitting subject. The HARQ Type I, the HARQ Type II and the HARQ Type III generally use a reverse message channel as a response channel. On the other hand, sort of response message, ACK/NACK, can be transmitted on physical control channel. The reverse message channel is used when the receiver transmits to the transmitter the signal indicating the receiving results of the received data block.
[0021] In some cases, however, the HARQ Type I uses the forward message channel according to the ARQ scheme. For example, when using a Selective Repeat ARQ (SR-ARQ) scheme, the HARQ Type I transmits a serial number of every data block transmitted from the transmitter to the receiver over the forward message channel. Meanwhile, the HARQ Type II and the HARQ Type III transmit a redundancy version used during each retransmission in addition to the serial number of the data block generated during each redundancy retransmission to the receiver through the forward message channel.
[0022] One of the important factors for guaranteeing performance of the HARQ Type I, the HARQ Type II and the HARQ Type III is reliability of a message channel transmitting the control message.
[0023] For example, upon failure to correctly receive the response signal ACK transmitted from the receiver in response to the transmitted data block due to an error of the reverse message channel, the transmitter will continuously retransmit the erroneous data block even though the receiver didn't request retransmission of the data block. Such a problem takes place even in the forward message channel as well as the reverse message channel. That is, upon failure to correctly receive the control message, for example, the data block's serial number and the redundancy type transmitted from the transmitter due to an error of the forward message channel, the receiver will endeavor to decode the erroneous data block retransmitted from the transmitter.
[0024] Therefore, in order to solve the above problem, the HARQ scheme is required to use a message channel having higher reliability compared with the channel transmitting the data block. In addition, a response speed of the message channel, i.e., how fast the message channel can transmit the message, is also an important factor in determining performance of the HARQ scheme.
[0025] However, to date there has not been proposed a concrete design rule for one case where the multi-access scheme and the multi-channel scheme of the 3GPP-2 CDMA-2000 system including the existing data communication system employ the channel coding scheme (HARQ Type I), and another case where the multi-access scheme and the multi-channel scheme of the 3GPP UMTS system employ the HARQ Type II and the HARQ Type III. That is, since a transmission method and scheme of the message channel in the HARQ Type II and the HARQ Type III used by the existing data systems has been not duly considered, there may occur a performance-related problem. Therefore, in order to optimize performance of the HARQ scheme, it is necessary to realize an HARQ Type II/III message channel satisfying the foregoing description.
[0026] In addition, to date there has not been proposed a concrete method for transmitting the message channel for one case where the multi-access scheme and the multi-channel scheme of the CDMA-2000 system including the conventional data communication system employ the channel coding scheme (HARQ Type I), and another case where the multi-access scheme and the multi-channel scheme of the UMTS system employ the HARQ Type II and the HARQ Type III, or a modified HARQ Type I using symbol combining.
SUMMARY OF THE INVENTION
[0027] It is, therefore, an object of the present invention to provide an apparatus and method for increasing reliability of a message channel in an HARQ data communication system.
[0028] It is another object of the present invention to provide an apparatus and method for increasing reliability of a message channel by assigning bit redundancy of a data block transport channel as a message channel.
[0029] It is a further object of the present invention to provide a transmission scheme designed considering the conditions necessary for a message channel most efficient in an HARQ Type II and an HARQ Type III or a modified HARQ Type I using symbol combining.
[0030] It is yet another object of the present invention to provide a message channel for a high-speed HARQ scheme, structured to increase its response speed.
[0031] It is still another object of the present invention to provide an apparatus and method for transmitting a control message over a message channel in an HARQ data communication system using convolutional codes.
[0032] It is still another object of the present invention to provide an apparatus and method for transmitting a control message over a message channel in an HARQ data communication system using turbo codes.
[0033] It is still another object of the present invention to provide an apparatus and method for transmitting a control message over a message channel in an HARQ data communication system using linear block codes.
[0034] It is still another object of the present invention to provide an apparatus and method for transmitting a control message over a message channel in an HARQ data communication system using convolutional codes, turbo codes and linear block codes.
[0035] It is still another object of the present invention to provide an apparatus and method for transmitting a control message over a message channel in a most efficient manner in an HARQ scheme of an asynchronous mobile communication system.
[0036] To achieve the above and other objects, there is provided an apparatus provided with a plurality of transport channels, for transmitting a data block having a sequence of data bits and a control message having control bits required in decoding the sequence of data bits. A first rate matching part provided in a selected one of the transport channels, passing the data block, punctures a predetermined number of data bits from the data bits within the data block. A second rate matching part provided in another transport channel, repeats the control bits for as many as the predetermined number of punctured bits.
[0037] Preferably, the second transport channel includes the control message arranged at either the head or tail thereof.
[0038] Preferably, the control message includes a serial number of a transmission data block, a version number of a given data block and a redundancy type in a given version.
[0039] Preferably, the second transport channel has a transmission delay time equal to or less than that of the first transport channel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings in which:
[0041] [0041]FIG. 1A is a diagram illustrating structures of a transmitter and a receiver for processing data based on a common HARQ Type I;
[0042] [0042]FIG. 1B is a diagram illustrating a conceptual data processing flow based on the common HARQ Type I;
[0043] [0043]FIG. 2 is a graph illustrating the relationship between S/N (or Es/No) and throughput in common hybrid ARQ types;
[0044] [0044]FIG. 3A is a diagram illustrating structures of a transport channel TrCH and its message field according to an embodiment of the present invention;
[0045] [0045]FIG. 3B is a diagram illustrating structures of a transport channel TrCH and its message field according to another embodiment of the present invention;
[0046] [0046]FIG. 4 is a block diagram illustrating a structure of a transport channel included in a transmitter in a downlink according to an embodiment of the present invention;
[0047] [0047]FIG. 5 is a block diagram illustrating a structure a transport channel included in a transmitter in an uplink according to an embodiment of the present invention; and
[0048] [0048]FIG. 6 is a graph showing improvements on performance of the transport channels according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0049] A preferred embodiment of the present invention will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the invention in unnecessary detail.
[0050] In the following description, a message transmission method of the HARQ Type I using convolutional codes, turbo codes or linear block codes will first be analyzed to set out its disadvantages. Based on the analysis, a message transport channel transmission method for performance improvement of the HARQ scheme will be described. Next, several embodiments will be provided in which the conditions of the message transport channel are applied to the 3GPP mobile communication system, and then, their advantages and disadvantages will be described.
[0051] First, a description of the present invention will be made with reference to a message channel transmission method for the HARQ scheme and an embodiment where the message channel transmission method is applied to the 3GPP standard.
[0052] Message Channel Transmission Method for HARQ
[0053] Table 1 below shows several methods for transmitting a control message over a dedicated control transport channel (hereinafter, referred to as “dedicated control TrCH” for short).
TABLE 1 Disadvantage Advantage Method 1 Using TTI Problem occurs. Fast Signaling in an upper layer is very simple. DCCH Response Time Required Method 2 Assigning Signaling for New TrCH It is very simple to modify physical channel, and New TrCH must be Complemented. effects on physical channel are minimized. That is, it can be implemented with existing rate matching. Method-= Using Implementation It is possible to implement a message channel with 3 Block Complexity Increased. high reliability using a powerful coding gain, Coding when TFCI or a new block code is used.
[0054] Here, the control message to be transmitted requires more powerful protection compared with the existing control data. Therefore, it is preferable to include (or insert) the control message to be transmitted in the head or tail part of the dedicated control TrCH when encoding the dedicated control TrCH, thereby effectively guaranteeing the improved performance to the corresponding part compared with other parts. This is based on the known information that when the coding scheme uses convolutional codes, a trellis starts from a zero state and ends at the zero state.
[0055] [0055]FIGS. 3A and 3B illustrate example structures of a dedicated control TrCH and its message field, for transmitting an HARQ control message according to two different embodiments of the present invention. Some of fields in the HARQ message can be transmitted on a physical control channel.
[0056] As illustrated in FIGS. 3A and 3B, the HARQ message field includes a NACK/ACK field indicating a retransmission response, a Frame_# field indicating a serial number of a transmission data block, a Version_# field indicating a version number of a given packet, and a Redundancy_Type field indicating a redundancy type in a given version. Of course, the HARQ message field can be arranged at either the head or the tail of the dedicated control TrCH, as shown in FIGS. 3A and 3B. The number of bits assigned to the respective fields is determined according to the HARQ type and its restrictions. That is, the bit number can be determined depending on the maximum allowable transmission delay and the memory requirement at the receiver. Table 2 below shows an example of bit assignments for the HARQ message field.
TABLE 2 Message Field Bits Reserved 0-4 NACK/ACK 1 Frame # 4 Version # 2 Redundancy Type 2
[0057] In addition, the control message for HARQ generally requires a fast response. To this end, the dedicated control TrCH transmitting the control message must be received at the receiver together with a dedicated traffic TrCH transmitting a data block. Therefore, the dedicated control TrCH should use TTI (Transport Time Interval), which is equal to or less than that of the dedicated traffic TrCH for HARQ. It is preferable to use 10 msec TTI in transmitting the HARQ control message through the dedicated control TrCH, if the identical TTI is used.
[0058] Message Channel Transmission Applied to 3GPP Standard (Dedicated Control TrCH Used)
[0059] Next, a description will be made regarding a method for efficiently transmitting a message transmission channel in the 3GPP standard to which HARQ is applied. That is, a method for increasing transmission reliability of the message transport channel by using a rate matching technique used in the 3GPP standard will be described.
[0060] In general, a data block transport channel has a much higher data rate compared with a message transport channel. For example, the message transport channel transmits a maximum of several tens of control message bits per TTI. That is, if the message transport channel transmits 20 control message bits per 10 msec TTI, the data rate becomes 2 Kbps. However, the data block transport channel has a data rate of from several tens of Kbps to several hundreds of Kbps. In this state, by performing symbol puncturing, using rate matching (RM), on n bits from TrCH used for the data block transport channel and assigning them to TrCH used for the message transport channel, it is possible to drastically increase the reliability of the message transport channel by symbol repetition.
[0061] [0061]FIGS. 4 and 5 illustrate structures of the transport channels in the transmitter, for puncturing specific bits from the data block transport channel and assigning data bits to the message transport channel for as many as the number of the punctured bits.
[0062] More specifically, FIG. 4 illustrates a structure of the transport channel included in the transmitter for a downlink according to an embodiment of the present invention, and FIG. 5 illustrates a structure of the transport channel included in the transmitter for an uplink according to an embodiment of the present invention.
[0063] In FIGS. 4 and 5, two shaded blocks indicate transport channels used during HARQ. That is, the shaded blocks 420 , 430 , 520 , 530 indicate a data block transport channel for HARQ and a message transport channel for transmitting a control message used in association with the data block transport channel. Meanwhile, by applying the present invention to the existing data transport channel and message transport channel, it is possible to differentiate a rate matching part of the data transport channel and a rate matching part of the message transport channel, from those of the prior art.
[0064] The transport channel structure of the transmitter according to the present invention will be described assuming that one of the transport channels TrCHs shown in FIGS. 4 and 5 is used as a message transport channel 420 and 520 , while the other transport channels are used as data block transport channels 430 and 530 .
[0065] First, the structure of the message transport channel among the transport channels of the transmitter for the downlink according to an embodiment of the present invention will be described with reference to FIG. 4. A CRC inserter 421 receives a control message block comprised of control bits and adds a CRC to the received control message block. That is, the CRC inserter 421 refers to a CRC encoder used in the transmitter to detect whether an error has occurred in the control message block. A code block segmentation part 422 performs block segmentation on the CRC-added control message block. The code block segmentation can be omitted in this invention. A channel encoder 423 encodes the CRC added control message block with a predetermined channel code, for which convolutional codes or turbo codes can be used which can correct errors generated in the channel transmission process as mentioned above. A rate matching part 424 receives the coded control message block and repeats/puncture a specific number of data bits of the coded control message block. The specific number of data bits is determined by the number of the data bits to be transmitted by the data block transport channel 430 . A scheme for repeating/puncturing the specific number of data bits from the data block will be described hereinbelow. A DTX inserter 425 inserts DTX (Discontinuous Transmission) bit in the rate matched-control message block (i.e., temporarily discontinuing transmission of the rate matched-control message block), and an interleaver 426 interleaves the DTX-inserted control message block. A radio frame segmentation block 427 segments the interleaved control message block into radio frames.
[0066] For reference, the CRC blocks 411 , 421 , and 431 shown in FIG. 4 refer to CRC encoders used in the transmitter to detect whether errors have occurred in the data block. Meanwhile, a tail bit insertion block (not shown) inserts termination bits used for zero state termination necessary for the convolutional codes or the turbo codes, used for the channel encoders 413 , 423 and 433 . Next, the channel encoders 413 , 423 and 433 refer to encoders for the convolutional codes or the turbo codes, used when the receiver corrects the errors that have occurred in the channel transmission process, as described above.
[0067] Next, the structure of the data block transport channel among the transport channels of the transmitter for the downlink according to an embodiment of the present invention will be described with reference to FIG. 4. The CRC inserter 431 receives a data block with an associated message number from an upper layer and adds a CRC to the received data in a predetermined way. That is, the CRC inserter 431 refers to a CRC encoder used in the transmitter to detect whether an error has occurred in the data block. A code block segmentation part 432 performs block segmentation on the CRC-added data block. A channel encoder 433 encodes the block segmented-data block from the block segmentation part 432 with a predetermined channel code, and provides the coded data block to a redundancy selector 434 . For the channel code, the convolutional codes or the turbo codes can be used which can correct errors that have occurred in the channel transmission process as mentioned above. The redundancy selector 434 selects redundancies according to first transmission, second transmission and third transmission based on a selection criterion (or selection rule) of a transmission apparatus and method of the HARQ data communication system, and provides the selected redundancies to a rate matching part 435 . The rate matching part 435 repeats/punctures a predetermined number of data bits from the data block provided from the redundancy selector 434 , and provides its output data block to a DTX inserter 436 . The DTX inserter 436 inserts DTX bit in the rate matched-data block, and an interleaver 437 interleaves the DTX-inserted data block. A radio frame segmentation block 438 segments the interleaved data block into radio frames.
[0068] Meanwhile, a multiplexer 440 multiplexes the data blocks output from the respective transport channels before transmission. Though not shown in FIG. 4, a tail bit insertion block inserts termination bits used for zero state termination necessary for the convolutional codes or the turbo codes, used for the channel encoders 413 , 423 and 433 .
[0069] In the embodiment of the present invention described with reference to FIG. 4, the rate matching part 424 of the message transport channel 420 repeats data bits of the message transport channel 420 in place of the data bits punctured during rate matching of the data block transport channel 430 , thereby making it possible to use the message transport channel 420 more stably.
[0070] The structure of the transport channel of the transmitter for the uplink according to an embodiment of the present invention, shown in FIG. 5, replaces the DTX inserters 415 , 425 and 436 in the transport channel structure of FIG. 4 with equalizers 514 , 524 and 535 , respectively. In addition, FIG. 5 shows a structure of the transport channel in which rate matching is performed by rate matching parts 517 , 527 and 538 after radio frame segmentation at segmentation blocks 516 , 526 and 537 , respectively. As the other elements of FIG. 5 have the same operation as that of the corresponding ones of FIG. 4, a detailed description will not be provided.
[0071] Now, a detailed description will be made regarding an operation of puncturing a predetermined number of data bits from the data block and repeating a predetermined number of data bits of the control message according to an embodiment of the present invention.
[0072] As shown in FIGS. 4 and 5, TrCHi is defined as TrCH assigned for a message transport channel, and a size of the message block transmitted thereby is defined as Ni. Further, TrCHk is defined as TrCH assigned for transmission of a data block, and a size of the data block transmitted thereby is defined as Nk. In addition, rate matching (RM) parameters determined for TrCHi and TrCHk by an upper service determining layer at a QoS request are defined as Pi and Pk, respectively. Next, rate matching parameters finally determined when n bits are separated from TrCHk and then moved to TrCHi are defined as Pi′ and Pk′, respectively. Then, the relationship among the parameters can be represented by the following equations.
(Pi,Ni)→(Pi′,Ni′) (1)
(Pk,Nk)→(Pk′,Nk′) (2)
( Nk (1 −Pk ) −n )/ Nk= 1 −Pk′ (3)
( Ni (1 −Pi ) +n )/ Ni = 1 −Pi′ (4)
[0073] If it is assumed that Nk>>n and Nk>>Ni, the Equations (3) and (4) can be rewritten as Equations (5) and (6), respectively.
( Nk (1 −Pk )− n )/ Nk= 1 −Pk ′=(1 −Pk )− n/Nk≈ 1 −Pk (5)
( Ni (1 −Pi )+ n )/ Ni= 1 −Pi ′=(1 −Pi )+ n/Ni>> 1.0 (6)
[0074] Therefore, even though the n bits are deleted, TrCHk undergoes minute variation n/Nk(<<1.0) which causes little performance variation at the initially set RM parameter Pk. However, TrCHi can increase an RM parameter value by n/Ni by the addition of n bits, and is subject to symbol repetition for which a substantial RM parameter is larger than 1.0. Such relationships are represented by connecting Pk′ and Pk′with a dotted line in FIGS. 4 and 5. Therefore, when the rate matching part 424 of TrCH uses doubled symbol repetition, the symbol energy increases by about +3 dB, thereby drastically increasing reliability of the message channel TrCHi.
[0075] Such performance variation is shown in FIG. 6, wherein solid lines indicate bit error rates (BERs) of TrCHi and TrCHk to which the present invention is not applied, while dotted lines indicate BERs of TrCHi and TrCHk to which the present invention is applied. Application of the present invention is determined depending on whether TrCHk is subjected to puncturing and TrCHi is subjected to repetition. As shown in FIG. 6, when the present invention is applied, TrCHk experiences little performance deterioration. whereas TrCHi shows remarkable performance improvement.
[0076] As described above, the present invention provides an HARQ scheme for increasing a response speed of the message channel in consideration of the conditions necessary to provide for the most effective message channel. Therefore, the present invention can increase reliability of the data communication system and improve throughput, thereby improving performance of future mobile communication systems as well as data communication systems.
[0077] While the invention has been shown and described with reference to a certain preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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An apparatus provided with a plurality of transport channels, transmits a data block and a control message having control bits required in decoding data bits. A first rate matching part provided in a selected one of the transport channels, passing the data block, punctures a predetermined number of data bits from the data bits within the data block. A second rate matching part provided in another transport channel, repeats the control bits as many as the predetermined number of punctured bits.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of International Application No. PCT/GB2008/003913, filed Nov. 24, 2008, which claims the benefit of GB Application No. 0723100.4, filed Nov. 23, 2007, and the benefit of U.S. Application No. 60/990,933, filed Nov. 29, 2007, and this application is a continuation of International Application No. PCT/GB2009/050539, filed May 20, 2009, the entire contents of all of which are incorporated by reference herein.
FIELD OF THE INVENTION
The invention relates to treatment of heart failure with normal left ventricular (LV) ejection fraction syndrome (HFnEF).
BACKGROUND OF THE INVENTION
Significant advances in therapy for heart failure (HF) with impaired systolic function have improved quality of life, and increased survival. However up to 50% of patients who have clinical evidence of HF are found to have a relatively (or near) normal left ventricular ejection fraction (HF with normal left ventricular (LV) ejection fraction syndrome (HFnEF), also referred to as HF with preserved left ventricular ejection fraction syndrome (HFpEF). Patients with HFnEF represent a rapidly increasing proportion of patients hospitalised and suffering mortality from heart failure.
Despite a normal EF, HFnEF patients manifest subtle systolic dysfunction but the principal abnormality in most is a disorder of active relaxation and/or passive filling of the LV. However resting measures of active relaxation and filling relate poorly to symptoms and exercise capacity therefore no ‘gold standard’ diagnostic echocardiographic test exists for HFnEF. Effective ventricular filling results from a highly energy dependent active relaxation process and from passive filling which is dependent on loading conditions as well as the intrinsic (passive) properties of the LV. Since both these parameters change markedly during exercise due to sympathetic activation, it is not surprising that these resting parameters are so poorly predictive of exercise capacity and symptoms.
The treatment of patients with HFnEF is discussed in Hunt et al., “ACC/AHA 2005 Guideline Update for the Diagnosis and Management of Chronic Heart Failure in the Adult”, 2005, Section 4.3.2, available at www.acc.org.
Perhexiline (2-(2,2-dicyclohexylethyl) piperidine) is a known anti-anginal agent that operates principally by virtue of its ability to shift metabolism in the heart from free fatty acid metabolism to glucose, which is more energy efficient.
WO-A-2005/087233 discloses the use of perhexiline for the treatment of chronic heart failure (CHF) where the CHF is a result of an initial inciting influence of ischaemia or where the CHF is a result of an initial non-ischaemic inciting influence.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention, there is provided a method of treating HFnEF, which comprises administering to an animal in need thereof an effective amount of perhexiline, or a pharmaceutically acceptable salt thereof, to treat said HFnEF. The animal is preferably a mammal and most preferably a human.
According to another aspect of the present invention, perhexiline, or a pharmaceutically acceptable salt thereof, is provided for use in the treatment of HfnEF.
According to a further aspect of the invention there is provided a treatment program for treating HFnEF, which involves the co-use or co-administration of perhexiline or pharmaceutically acceptable salt thereof with one or more other compounds that are advantageous in treating HFnEF or the symptoms thereof, for example a diuretic, an angiotensin receptor blocker or a calcium channel blocker.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1C display variables correlating with Aerobic Exercise Capacity (VO2max) in HFnEF patients and controls.
FIGS. 2A and 2B show MR images of a patient with HFpEF lying prone over a 31 P surface coil and FIG. 2C shows the corresponding localized 31 P MR spectra from the left ventricle. FIG. 2D is Individual PCr/γ-ATP ratio in Patients with HfpEF and Controls.
FIG. 3 is a flow chart of a study carried out to establish a causative role for energy deficiency and to evaluate the impact of perhexiline on cardiac energy status in HCM.
FIGS. 4A-4D represent the baseline data of HCM vs controls, more particularly:
FIG. 4A represents the peak oxygen consumption (peak V O2 ) results;
FIG. 4B represents the diastolic ventricular filling results (nTTPF, normalized for heart rate Time To Peak Filling) and shows that PCr/ATP ratio (a measure of cardiac energetic state) is lower in HCM patients versus controls;
FIG. 4C is an example of 31 P cardiac spectra of a HCM patient in which Point C indicates centre of phosphorus coil, VOI; voxel of interest, 2,3-DPG indicates 2,3-diphosphoglycerate; PDE, phosphodiesters; PCr, phosphocreatine; α, β,γ indicate the three phosphorus nuclei of ATP, and shows that nTTPF (a measure of the rate of active relaxation of the LV) is essentially unchanged on exercise in the controls bu abnormally slows in the HCM patients; and
FIG. 4D represent the myocardial energetic results (PCr/γ ATP ratio) and shows that exercise capacity (peak VO2) is lower in HCM patients versus controls.
FIGS. 5A and 5B respectively represent the effect of Placebo and Perhexiline on peak oxygen consumption (peak V O2 ), p=0.003 and myocardial energetic (PCr/γ ATP ratio), p=0.003, where the p value represents the significant difference between perhexiline and placebo response. Peak VO2 (exercise capacity) increases with Perhexiline ( FIG. 5A ). Perhexiline improves PCr/ATP ratio (energetic status of heart), but this was unchanged in the placebo group ( FIG. 5B ).
FIGS. 5C and 5D respectively represent nTTPF changes in the placebo group ( 3 C) and the perhexiline group ( 3 D), p=0.03, where the p value represents the significant difference between perhexiline and placebo response. In the placebo group nTTPF (a measure of the rate of LV active relaxation) abnormally lengthened at baseline and on treatment. The response in healthy controls is shown in dotted lines. Perhexiline ( FIG. 5D ) normalises the response to similar to that seen in healthy controls (also shown in dotted lines).
FIGS. 5E and 5F illustrate that NYHA score (of breathlessness) falls (improves) with perhexiline ( 5 E) and Minnesota living with heart failure questionnaire score falls (=improved quality of life) on perhexiline ( 5 F).
FIG. 6 illustrate the causative role for energy deficiency in the pathophysiology of HCM.
DETAILED DESCRIPTION OF THE INVENTION
The findings of the study reported in Example 1 herein are that a) HfpEF patients manifest a significant reduction in PCr/ATP ratio at rest, indicating impairment of myocardial energy ‘reserves’ and b) during exercise, the energetically demanding active relaxation stage of diastole lengthened in patients (vs. a shortening in controls) and there was also a failure of contractile function to increase in patients. These abnormalities together resulted in a lower stroke volume on exercise. It was also found that HfpEF patients demonstrated chronotropic incompetence on exercise.
These findings correlate closely with findings in a study of patients with hypertrophic cardiomyopathy (HCM), which is reported in Example 2. The study of Example 2 also demonstrated the effectiveness of the agent perhexiline in the treatment of patients with HCM. Because of the related pathophysiology of HfnEF and HCM, the inventors are able to predict, based on the effectiveness of perhexiline in the treatment of HCM, that this same agent will be an effective therapeutic agent for treatment of HFnEF.
In aspects of the present invention, the perhexiline exists in the form of a salt of perhexiline, preferably the maleate salt. The perhexiline may be used at doses titrated to achieve therapeutic but non-toxic plasma perhexiline levels (Kennedy J A, Kiosoglous A J, Murphy G A, Pelle M A, Horowitz J D. “Effect of perhexiline and oxfenicine on myocardial function and metabolism during low-flow ischemia/reperfusion in the isolated rat heart”, J Cardiovasc Pharmacol 2000; 36(6):794-801). Typical doses for a normal patient would be 100 mg to 300 mg daily, although smaller doses may be appropriate for patients who are slow metabolisers of perhexiline.
Physiologically acceptable formulations, such as salts, of the compound perhexiline, may be used in the invention. Additionally, a medicament may be formulated for administration in any convenient way and the invention therefore also includes within its scope use of the medicament in a conventional manner in a mixture with one or more physiologically acceptable carriers or excipients. Preferably, the carriers should be “acceptable” in the sense of being compatible with the other ingredients of the formulation and not deleterious to the recipient thereof. The medicament may be formulated for oral, buccal, parental, intravenous or rectal administration. Additionally, or alternatively, the medicament may be formulated in a more conventional form such as a tablet, capsule, syrup, elixir or any other known oral dosage form.
The invention is illustrated by the following non-limiting examples.
EXAMPLE 1
The role of exercise related changes was evaluated in left ventricular (LV) relaxation and of vasculo-ventricular coupling as the mechanism of exercise limitation in patients with heart failure with normal (or preserved) LV ejection fraction (HFnEF) and whether cardiac energetic impairment may underlie these abnormalities.
The study involved 37 patients with HFpEF and 20 matched controls. Vasculo-ventricular coupling (VVC) and Time to Peak LV Filling (a measure of LV active relaxation) (nTTPF) were assessed at rest and on exercise by Multiple Uptake Gated Acquisition scanning Cardiac energetic status (PCr/ATP ratio) was assessed by 31 P Magnetic Resonance Spectroscopy. At rest nTTPF and VVC were similar in patients and controls. Cardiac PCr/ATP ratio was reduced in patients vs. controls (1.57±0.52 vs. 2.14±0.62; P=0.003). VO2max was lower in patients vs. controls (19±4 vs. 36±8 ml/kg/min; P<0.001). During maximal exercise the heart rate increased less in patients vs. controls (52±16 vs. 81±14 bpm; p<0.001) and the relative changes in stroke volume and cardiac output during submaximal exercise were lower in patients vs. controls (0.99±0.34 vs. 1.25±0.47, P=0.04; 1.36±0.45 vs. 2.13±0.72, P<0.001). nTTPF fell during exercise in controls, but increased in patients (−0.03±12 sec vs. +0.07±0.11; P=0.005). VVC decreased on exercise in controls but was unchanged in patients (−0.01±0.15 vs. −0.25±0.19; p<0.001). Heart rate, VVC and nTTPF were independent predictors of VO2max.
Methods
Patients
The study involved 37 HFpEF patients prospectively recruited from heart failure clinics. Also studied were twenty age-gender-matched healthy controls with no cardiac history or diabetes mellitus. Study participants had clinical examination, 12-lead electrocardiogram, pulmonary function test, echocardiogram, metabolic exercise test, radionuclide ventriculography and a subgroup underwent cardiac 31 P MRS studies to assess cardiac energetic status. All controls had a normal cardiovascular examination, 12-lead electrocardiogram and echocardiogram. HFpEF patients were defined in accordance with ACC/AHA recommendation (1): i) symptoms and signs of heart failure, ii) ejection fraction ≧50%, iii) no valvular abnormalities. In addition it was stipulated that patients should have iv) VO2max <80% of age and gender predicted with a pattern of gas exchange on metabolic exercise testing indicating a cardiac cause for limitation, v) absence of objective evidence of lung disease on formal lung function testing and/or absence of arterial desaturation during exercise and with a ventilatory reserve at peak exercise ≧15 L. This definition was chosen in order to have robust evidence that patients had exercise limitation that was cardiac rather than non cardiac in origin and so as not to prejudge the underlying pathophysiology by stipulating the presence of resting diastolic abnormalities because mild diastolic abnormalities are frequently present also in healthy elderly subjects and moderate to severe resting diastolic abnormalities are frequently not present in patients with clear evidence of HfpEF. Patients with rhythm other than sinus were excluded.
Echocardiography
Echocardiography was performed with participants in the left lateral decubitus position with a Vivid 7 echocardiographic machine using a 2.5-MHz transducer. Cardiac quantifications were determined in accordance with European Association of Echocardiography. (2) LV end-systolic elastance (Ees), a measure of LV contractility, was determined using the non-invasive single-beat technique. (3) Arterial elastance (Ea), a measure of the stiffness of the entire arterial tree, was calculated as the ratio of LV end-systolic pressure/stroke volume. Studies were stored digitally and analyzed off-line.
31 P Cardiac Magnetic Resonance Spectroscopy (MRS)
In vivo myocardial energetics was measured by MRS at 3-Tesla (4). 31 P cardiac magnetic resonance spectroscopy was performed using a Phillips Achieva 3T scanner and a linearly polarized transmitter and receiver 31 P coil with a diameter of 14 cm. The repetition time was 10000 ms with 136 averages and 512 samples. Acquisition was ECG gated and the trigger delay was set to acquire in diastole. Total scan time was 23 minutes (5). Java magnetic resonance user interface v3.0 (jMRUI) was used for analysis. PCr and γ-ATP was used to determine the PCr/ATP ratio which is a measure of cardiac energetic state (6). Patients with ischemic heart disease and diabetes (N=7) were excluded from the MRS studies because these conditions are known to have impaired cardiac energetics (7,8). Patients with contraindications were also excluded from the MRS study (N=5). One patient's spectra was excluded from the analysis due to poor quality. Three controls had contraindication to MRS study. Data were analysed separately by an investigator unaware of participants' clinical status.
Radionuclide Ventriculography
LV ejection fraction and diastolic filling were assessed by radionuclide ventriculography at rest and during graded semi erect exercise on a cycle ergometer as previously described. (9,10) Three minutes of data were acquired at rest and during exercise after a 30-second period for stabilisation of heart rate at the commencement of each stage. Exercise was performed at 50% workloads of heart rate reserve. Data were analysed using LinkMedical MAPS software, Sun Microsystems (Hampshire, UK). Peak left ventricular filling rate in terms of end-diastolic count per second (EDC/s) and time to peak filling normalised for R—R interval (nTTPF) in milliseconds after end systole were calculated from the first derivative of the diastolic activity-time curve. Venous blood samples were obtained for weighing and for counting of blood gamma activity during each scan in order to correct for physical and physiological decay as well as for determination of relative volume changes. (11) The validity of these radionuclide measures of diastolic filling at high heart rates has been established previously. (12)
All gated blood pool scan-derived volumes were normalized to body surface area, yielding their respective indexes: end-diastolic volume index (EDVI), end-systolic volume index (ESVI), stroke volume index (SVI), and cardiac index. The following indexes were calculated: a) arterial elastance index (EaI)=ESP/SVI; b) LV end-systolic elastance index (ELVI)=ESP/ESVI and c) vasculo-ventricular coupling ratio (VVC)=EaI/ELVI=(1/EF)−1. (13)
Metabolic Exercise Test
All participants underwent a symptom-limited erect treadmill exercise using a standard ramp protocol with simultaneous respiratory gas analysis. (14)
Statistics
Continuous variables are expressed as means±SD. Unpaired Student's t-test (2-tail) was used to assess differences between mean values. Categorical variables were compared with Pearson Chi-Square test. All reported P values were calculated on the basis of two sided tests and a P value of <0.05 was considered to indicate statistical significance. Variances of data sets were determined using F-test. Pearson correlation coefficient (r) was used to describe the relationship between variables. All subjects were included into the model. Variables of interest that were found to correlate with the dependent variable on univariate analysis were included in a stepwise linear regression analysis to identify independent variables. SPSS (v15.0) was used to perform the statistical operations.
Results
The results obtained are set forth in Tables 1-3 below and in FIGS. 1A-1C and 2 A- 2 D.
In FIGS. 1A-1C variables correlating with Aerobic Exercise Capacity (VO2max) are shown. Panel A: VO2max correlated negatively with Exercise-induced Changes in nTTPF. Panel B: VO2max correlated negatively with Exercise-induced Changes in Vasculo-Ventricular Coupling Ratio. Panel C: VO2max correlated directly with Exercise-induced Changes in Heart Rate. Black circles indicate patients with HFpEF, and Open circles represents healthy controls. When patients on beta blockers were excluded from analysis, the level of significance were similar.
FIGS. 2A and 2B shows MR images of a patient with HFpEF lying prone over a 31 P surface coil and the corresponding localized 31 P MR spectra from the left ventricle is shown in FIG. 2C . The resonances derive from PCr and the γ-, α-, and β-phosphate Resonances of the ATP. Panel C Individual PCr/ γ-ATP ratio in Patients with HfpEF and Controls. The PCr/ γ-ATP ratio was significantly reduced in patients with HfpEF compared to healthy controls, P=0.003.
TABLE 1
Baseline Characteristics of the Subjects
Patient
Control
Variable
(N = 37)
(N = 20)
P Value
Age - yr
67 ± 9
63 ± 7
0.51
Female sex - no. (%)
28
(76)
10 (50)
0.05
Body Mass Index
30 ± 4
26 ± 5
<0.01
Left Ventricular Hypertrophy -
19
(51)
5 (25)
0.05
no. (%)
Diabetes mellitus - no. (%)
4
(11)
0
—
Hypertension - no. (%)
27
(73)
0
—
Ischemic Heart Disease - no.
4
(11)
0
—
(%)
NYHA functional class - no.
I
10
0
—
II
18
0
—
III
8
0
—
Drug therapy - no. (%)
Diuretic
10
(27)
0
—
ACE inhibitor
20
(54)
0
—
ARB
6
(16)
0
—
Beta-blocker
8
(22)
0
—
Calcium blocker
10
(27)
0
—
Alpha Blocker
4
(11)
0
—
Spironolactone
2
(5)
0
—
Nitrate
3
(8)
0
—
VO2max (ml/kg/min)
19 ± 4
36 ± 8
<0.001
Respiratory Exchange Ratio
1.06 ± 0.07
1.13 ± 0.10
0.003
(RER)
Breathing Reserve - L/min
36 ± 15
43 ± 18
0.16
Exercise Time - min
6 ± 2
7 ± 1
0.03
Resting HR - beats/min
74 ± 14
83 ± 17
0.03
Peak HR - beats/min
127 ± 20
166 ± 11
<0.001
ΔHR - beats/min
52 ± 16
81 ± 14
<0.001
Rest SBP (mmHg)
138 ± 19
131 ± 23
0.23
Rest DBP (mmHg)
81 ± 11
81 ± 12
0.98
Rest MABP (mmHg)
100 ± 12
96 ± 15
0.30
Peak SBP (mm/Hg)
182 ± 26
190 ± 30
0.30
Peak DBP (mmHg)
81 ± 13
84 ± 10
0.36
Peak MABP (mmHg)
113 ± 17
114 ± 25
0.91
Left ventricular ejection
64 ± 14
63 ± 6
0.77
fraction - %
Mitral E-wave velocity - m/sec
0.72 ± 0.19
0.61 ± 0.12
0.02
Mitral A-wave velocity - m/sec
0.80 ± 0.20
0.59 ± 0.17
<0.001
Ratio of E-wave:A-wave
0.96 ± 0.35
1.03 ± 0.32
0.47
velocity
Mitral E-wave deceleration -
274 ± 70
269 ± 73
0.82
msec
E/E′ (septum)
15 ± 5
11 ± 3
0.003
E/E′ (lateral)
12 ± 4
8 ± 2
<0.001
E es
3.07 ± 1.07
2.60 ± .53
0.09
E a
2.22 ± 0.63
2.28 ± 0.48
0.69
Plus-minus values are means±SD. When patients on beta blockers were excluded from analysis, the level of significance were similar apart from resting HR (P=0.14). NYHA denotes New York Heart Association, ACE angiotensin-converting enzyme, ARB angiotensin II receptor blockers, BMI body mass index, SBP systolic blood pressure, DBP diastolic blood pressure, MABP mean arterial blood pressure, LA left atrium, E/E′ mitral E-wave velocity-E′ tissue velocity (PW-TDI) at basal inferoseptum ratio, Ees denotes Left Ventricular End-Systolic Elastance and Ea is Arterial elastance. The bodymass index is the weight in kilograms divided by the square of the height in meters.
TABLE 2
MUGA at Rest and on Exercise: Diastolic Filling Characteristics, Systolic
Function, Relaxation, Stiffness, and Ventricular-Arterial Coupling
Patient
Control
Variable
(N = 37)
(N = 20)
P Value
Heart Rate - rest (beats/min)
71 ± 12
68 ± 15
0.40
Heart Rate - exercise (beats/min)
97 ± 14
114 ± 11
<0.001
Exercise SBP (mm/Hg)
204 ± 26
198 ± 27
0.45
Exercise DBP (mmHg)
95 ± 15
97 ± 7
0.56
Exercise MABP (mmHg)
132 ± 15
131 ± 9
0.85
Ejection fraction - rest (%)
65 ± 9
64 ± 9
0.61
Ejection fraction - exercise (%)
66 ± 9
72 ± 8
0.05
Peak emptying rates - rest (EDC/sec)
382 ± 106
400 ± 90
0.56
Peak emptying rates - exercise (EDC/sec)
477 ± 123
563 ± 144
0.04
Peak filling rates - rest (EDC/sec)
342 ± 120
321 ± 111
0.54
Peak filling rates - exercise (EDC/sec)
504 ± 127
602 ± 163
0.02
Time to peak filling - at rest (msec)
176 ± 80
181 ± 56
0.84
Time to peak filling - exercise (msec)
246 ± 91
162 ± 80
0.001
Relative Δ Stroke Volume Index
0.99 ± 0.34
1.25 ± 0.47
0.04
Relative Δ Cardiac Output Index
1.36 ± 0.45
2.13 ± 0.72
<0.001
Relative Δ E LV I - exercise
1.35 ± 0.50
1.85 ± 0.63
0.01
Relative Δ E a I - exercise
1.52 ± 0.48
1.28 ± 0.44
0.17
Vasculo-Ventricular Coupling ratio (VVC)
0.57 ± 0.20
0.62 ± 0.22
0.36
(E a I/E LV I) - rest
Vasculo-Ventricular Coupling ratio (VVC)
0.55 ± 0.19
0.41 ± 0.15
0.01
(E a I/E LV I) - exercise
Δ VVC
−0.01 ± 0.15
−0.25 ± 0.19
<0.001
Plus-minus values are means±SD. When patients on beta blockers were excluded from analysis, the level of significance were similar apart from peak filling rates during exercise (P=0.08). EDC end diastolic count. SBP systolic blood pressure, DBP diastolic blood pressure, MABP mean arterial blood pressure. Relative Δ Stroke Volume Index is SVi EXERCISE/SVi REST, Relative Δ Cardiac Output Index is COi EXERCISE/COi REST. Relative Δ ELVI is ELVIEXERCISE/ELVIREST. Relative Δ EaI is EaIEXERCISE/EaIREST. Δ Vasculoventricular coupling ratio is (EaI/ELVI)EXERCISE−(EaI/ELVI)REST. A VVC −0.01±0.15−0.25±0.19<0.001
TABLE 3 Multivariate Predictors of VO 2 max Variable R Square P Value Exercise-induced change in HR* 0.584 <0.001 Exercise-induced change in VVC † 0.696 0.003 Age ‡ 0.728 0.018 Exercise-induced change nTTPF § 0.769 0.018 *Predictors: ΔHR, † Predictors: ΔHR and Δ VVC coupling ratio, ‡ Predictors: ΔHR, Δ VVC coupling ratio and age, § Predictors: ΔHR, Δ VVC coupling ratio, age and ΔTTPF. Multivariate analysis was adjusted for the variable that some patients were on betablockers.
Characteristics of the Patients
HFpEF Patients were generally females, overweight, aged 67±9years old with a history of hypertension, however blood pressure was well treated (systolic BP 138±19 mmHg vs. 131±23 mmHg; p=0.23, in patients vs. controls) (see Table 1 below). The tissue Doppler E/E′ at the basal anterolateral left ventricular wall (a measure of left ventricular end-diastolic pressure) (15), was significantly higher in patients than controls. There was also a trend (non-significant) to higher Ees in patients than in the control group. HFpEF patients also had significantly reduced VO2max and reduced peak HR on metabolic exercise testing. There was a positive correlation between VO2max and ΔHR (HREXERCISE - HRREST) (r=0.7, P<0.001) (see FIG. 1C ). During semi-erect cycle exercise the relative stroke volume (SVi EXERCISE /SVi REST) was lower in patients compared to controls (0.99±0.34 vs. 1.25±0.47; P=0.04), and relative cardiac output (COiEXERCISE/COiREST) was also lower (1.36±0.45 vs 2.13±0.72; p<0.001). (see Table 2)
Left Ventricular Active Relaxation
nTTPF is determined by the rate of active relaxation (16) and by transmitral pressure gradient at the time of mitral valve opening. nTTPF was similar at rest in HFpEF patients and controls. During exercise it shortened in controls, but lengthened in patients (Table 2). There was a negative correlation between VO2max and ΔnTTPF (nTTPFEXERCISE-nTTPFREST) (r=-0.4, P=0.005) (see FIG. 1A ). Furthermore, during exercise other radionuclide ventriculography diastolic filling variables such as peak filling rates as well as systolic function parameters e.g. EF and peak emptying rates, were significantly reduced in patients compared to controls. (see Table 2).
Left Ventricular Contractile Function and Vasculo-Ventricular Coupling
VVC was similar at rest in HfpEF patients and controls. During exercise, LV arterial elastance, a measure of the stiffness of the entire arterial tree, increased in both patients and controls but tended to increase more in patients. LV end systolic elastance, a measure of LV contractile function, markedly increased on exercise in controls but increased substantially less in patients. Accordingly the vasculoventricular coupling ratio was essentially unchanged on exercise inpatients but fell substantially on exercise in healthy controls furthermore whilst resting LVEF and peak emptying rate were similar in patients and controls on exercise both were lower in patients. There was a negative correlation between VO2max and Δ VVC on exercise (r=-0.6, P<0.001) ( FIG. 1B ).
In Vivo Myocardial Energetic State
At rest, cardiac PCr/ATP ratio in HFpEF patients (N=24) was significantly reduced compared to healthy controls (N=17), 1.57±0.52 and 2.14±0.63, respectively, P=0.003 (see FIG. 2D ).
Independent Predictors of Aerobic Exercise Capacity
In the multivariate analysis, a linear-regression model was used to examine VO2max as the dependent variable and found that exercise-induced changes in HR, VVC and nTTPF were independent predictors of VO2max. (see Table 3)
Discussion
The principal findings are: a) HFpEF patients manifest a significant reduction in PCr/ATP ratio at rest, indicating impairment of myocardial energy “reserve” that is likely to be exacerbated during exercise. b) As a corollary, during exercise, the energetically demanding active relaxation stage of diastole lengthened in patients (vs. a shortening in controls) and was accompanied with a failure to increase LV contractile function. These combined dynamic abnormalities of both diastolic and contractile function together resulted in a lower stroke volume on exercise. c) Consistent with previous studies, HFpEF patients demonstrated chronotropic incompetence on exercise. (17). d) This study underlines the importance of dynamic (rather than resting) assessment of cardiac function to comprehensively characterise patients with HfpEF.
The pathophysiology of HFpEF has been the subject of considerable controversy. These patients are typically hypertensive and exhibit impaired LV active relaxation and/or increased passive left ventricular diastolic stiffness at rest. (18) This has led many to conclude that exercise limitation is primarily a result of impaired LV diastolic filling and to the use of the term ‘diastolic heart failure’ by some. (19) However, diastolic dysfunction is also a common finding at rest in healthy elderly subjects. (20) Furthermore, ‘subtle’ abnormalities of systolic function, in particular long axis systolic function, are also almost universally observed in HFpEF patients despite normal LV ejection fraction. (21) This has led others to propose that HFpEF is predominantly a disorder of contractile function. (22) In order to compare both of these possibilities, we defined HfpEF as a limitation of exercise with an unequivocally cardiac cause as assessed by VO2max (rather than using resting diastolic parameters) to avoid biasing our mechanistic studies to a select group of patients with HfpEF.
Little attention has been directed to changes in systolic and diastolic function during dynamic exercise, which is when the majority of patients experience most severe symptoms. In one study, ten patients with HFpEF were assessed with invasive pressure volume loops and compared with age-matched controls. (23) The former had increased arterial elastance (a measure of the stiffness of the entire arterial tree), and increased LV end-systolic elastance (a measure of the stiffness of the ventricle during systole, and the relatively load independent measure of the contractile state of the left ventricle. (24) Whilst diastolic abnormalities were not universally present in patients at rest, marked differences appeared during handgrip exercise. The rate of LV active relaxation increased in healthy subjects but it slowed in patients. (25) Another study from the same group, exercise-related symptoms in Afro-Caribbean hypertensive patients appeared to be strongly associated with chronotropic incompetence and an inadequate vasodilator reserve on exercise. (26)
The present study examined the patho-physiological mechanisms and predictors of exercise limitation in a substantially larger series of patients during a much more physiologically relevant form of exercise (dynamic leg exercise). There were marked dynamic abnormalities in both contractile and diastolic function of the left ventricle, and a lower peak exercise HR in patients. The independent predictors of impaired exercise capacity were abnormal ventricular-arterial coupling on exercise, a reduced HR response on exercise and a ‘paradoxical’ slowing of the rate of LV active relaxation on exercise (manifest as a prolongation of nTTPF). Despite the relative robustness of these observations, deciding whether these changes are adaptive or maladaptive remains challenging. The independent value of an impaired chronotropic response in predicting exercise capacity in HfpEF exemplifies this challenge. For example, VO2max is largely determined by cardiac output on exercise and the latter is simply the product of HR and SV. On this basis, the detrimental consequences of an impaired HR appear plausible. However, in the setting of a profound slowing of active relaxation and increased LV passive diastolic stiffness, a longer diastolic filling period might be expected to be beneficial, both by increasing SV and reducing the cardiac energy load. This in part explains the efficacy of β blocker therapy in hypertrophic cardiomyopathy, a classic cause of HFpEF. (27) The latter also seems plausible, since increasing heart rate by atrial pacing has been shown to reduce supine resting stroke volume and cardiac output in patients with HFpEF. (28) Nevertheless, despite a longer diastolic filling time, the relative change in SV was lower in our patients during sub-maximal exercise. However, this failure to increase cardiac workload through limiting HR may represent a strategy of energetic parsimony in a heart with limited energy reserves. Finally, an alternative explanation is that an inadequate chronotropic response is simply a consequence and/or contributor to heart failure. (29) Such incompetence is typically present in systolic heart failure and is in part a manifestation of impaired vagal tone. (30) Clearly it will be important to undertake further studies to assess whether heart rate plays a causal role in exercise limitation in HFpEF, because if so this may be amenable to rate responsive pacing.
The same challenges arise when interpreting the role of an impairment of vasculo-ventricular coupling in HfpEF. The patients in this study had a history of hypertension but were well treated with antihypertensives (in most cases including vasodilators) therefore resting blood pressure and arterial elastance were not significantly higher than in the control group. Consistent with prior studies (31), at rest, LV end-systolic elastance (a measure of contractility or systolic stiffness) tended to be higher in patients although this did not reach significance. The increase in arterial elastance during exercise tended to be greater in patients vs. controls (presumably reflecting a greater increase in large artery stiffness). However, whilst left ventricular end-systolic elastance almost doubled during exercise in controls, the increase was only 35% in patients; hence VVC reduced by 33% during exercise in controls but was unchanged in patients. These findings indicate a blunting of the physiological increase in the contractile state of the left ventricle on exercise. As with heart rate, these changes may be interpreted to be either maladaptive or adaptive. A failure to adequately augment contractile function against a high “relative load” of disease and hence a failure to optimise cardiac energetic efficiency might be considered contributory to HfpEF. On the other hand, a smaller increment in LV end-systolic elastance will reduce the absolute increase in energy demand in an already energy constrained heart at the cost of an impaired dynamic increase in cardiac output.
Integrating these observations, we speculate that dynamic energy impairment may account for the slowing of LV active relaxation on exercise as well as the failure of LV contractile function to increase. To increase the generalisability of this hypothesis, we avoided positively biasing our study by excluding patients with established causes of cardiac energy deficiency (ischemic heart disease and diabetes) (32,33). Nevertheless, the PCr/ATP ratio was still substantially reduced in HfpEF patients vs controls at rest. The lower PCr/ATP ratio in patients indicates a reduction of high energy phosphates reserve at rest. (34,35) Although the time required for acquisition of Cardiac MRS signals precluded the measurement of high energy phosphate status on exercise, it is likely that any basal energetic impairment will be exacerbated dynamically. This exacerbation of dynamic energetic impairment would explain the prolongation of the energy demanding active relaxation as manifest by nTTPF. Moreover, the lower hearts rates and lesser increases in LV end-systolic elastance may represent strategies to limit dynamic cardiac energy demands. The cause for this resting energy deficit may relate to insulin resistance (36), to impaired mitochondrial function as a result of ageing (37), and to neuroendocrine activation and aberrant substrate metabolism. (38) Such observations provide a rationale to assess the therapeutic value of ‘metabolic agents’ that increase cardiac energetic status by altering cardiac substrate use (39). These agents have shown promise in patients with systolic heart failure. (40)
Study Limitations
The radionuclide exercise protocol involved asking subjects to maintain a HR which was 50% of HR reserve above their resting HR. Since this HR reserve was calibrated to peak HR rate, the absolute workload in patients was lower. To have compared patients at the same workload would be inappropriate since this would represent a higher relative workload in patients. Moreover, most changes in SV occur in the first part of exercise with subsequent increases in cardiac output being principally due to increases in HR. (41) A small proportion of patients were on β-blockers which may have affected their cardiovascular response to exercise, however, when these patients were excluded from the analysis the findings and the level of significance remained unchanged. In addition, some patients were on calcium blockers however these were all peripherally acting (dihydropyridines for hypertension) and therefore are not expected to affect the myocardium. Ideally we would have liked to measure cardiac energetics during exercise however cardiac MRS studies during exercise is currently quite challenging more so if we tried to replicate the same dynamic leg exercise in the confinement of a MR scanner. MRS and Radionuclide studies also require a regular rhythm, thus patients with atrial fibrillation were excluded from the study. In contrast, the strength of radionuclide studies is their increasing temporal resolution at higher heart rates. This obviates the confounding E:A fusion as is frequently experienced with exercise echocardiography. Radionuclide studies are thus not subject to systematically biasing mechanistic HfpEF towards a subgroup of patients without E:A fusion.
Conclusion
HFpEF patients have abnormal resting cardiac energetic status which when exacerbated dynamically may contribute to the abnormal active relaxation on exercise and to a failure to increase LV end-systolic elastance. In addition chronotropic response was markedly impaired on exercise in patients. The independent predictors of exercise capacity in patients with HFpEF are exercise-induced changes in active relaxation, heart rate and ventricular-arterial coupling.
EXAMPLE 2
A study was carried out to establish a causative role for energy deficiency and to evaluate the impact of perhexiline on cardiac energy status in HCM.
The study was approved by the South Birmingham Research Ethics Committee and the investigation conforms with the principles outlined in the Declaration of Helsinki All study participants provided written informed consent. The study was a randomized, double blind, placebo-controlled parallel-group design of minimum 3 months duration. FIG. 3 represents a flow chart of the study. The pre-defined primary end point was peak oxygen consumption (peak VO2). Pre-defined secondary end points were symptomatic status, resting myocardial energetics (PCr/γ-ATP ratio) and diastolic function at rest and during exercise (nTTPF). 33 controls of similar age and gender distribution were recruited for comparison with baseline data of HCM patients. All controls had no history or symptoms of any cardiovascular disease with normal ECG and echocardiogram (LVEF≧55%).
Patients were recruited from dedicated cardiomyopathy clinics at The Heart Hospital, University College London Hospitals, London and Queen Elizabeth Hospital, Birmingham, UK between 2006 and 2008. Inclusion criteria were 18 to 80 years old symptomatic HCM patients (predominant symptom breathlessness) in sinus rhythm with reduced peak VO2 (<75% of predicted for age and gender) and no significant LVOT obstruction at rest (gradient<30 mmHg). Exclusion criteria were presence of epicardial coronary artery disease, abnormal liver function test, concomitant use of amiodarone or selective serotonin reuptake inhibitors (due to potential drug interactions with perhexiline), peripheral neuropathy and women of childbearing potential. Diabetic patients were also excluded to maintain the blindness of the study as Perhexiline may lead to a reduction in plasma glucose in such patients necessitating a reduction in anti-diabetic therapy. 46 consecutive consenting patients who met these entry criteria were recruited into the study.
Patients were subjected to a number of tests and assessments as follows.
Cardiopulmonary Exercise Test
This was performed using a Schiller CS-200 Ergo-Spiro exercise machine which was calibrated before every study. Subjects underwent spirometry and this was followed by symptom-limited erect treadmill exercise testing using a standard ramp protocol with simultaneous respiratory gas analysis (Bruce R A, McDonough J R. Stress testing in screening for cardiovascular disease. Bull N Y Acad Med 1969; 45(12):1288-1305.; Davies N J, Denison D M. The measurement of metabolic gas exchange and minute volume by mass spectrometry alone. Respir Physiol 1979; 36(2):261-267). Peak oxygen consumption (peak VO2) was defined as the highest VO2 achieved during exercise and was expressed in ml/min/kg.
Symptomatic Status Assessment
All HCM patients filled in Minnesota Living with heart failure questionnaire and were also assessed for NHYA class.
Transthoracic Echocardiography
Echocardiography was performed with participants in the left lateral decubitus position with a Vivid 7 echocardiographic machine (GE Healthcare) and a 2.5-MHz transducer. Resting scans were acquired in standard apical 4-chamber and apical 2-chamber. LV volumes were obtained by biplane echocardiography, and LVEF was derived from a modified Simpson's formula (Lang R M, Bierig M, Devereux R B et al. Recommendations for chamber quantification: a report from the American Society of Echocardiography's Guidelines and Standards Committee and the Chamber Quantification Writing Group, developed in conjunction with the European Association of Echocardiography, a branch of the European Society of Cardiology. J Am Soc Echocardiogr 2005; 18(12):1440-1463.) Pulse wave doppler sample volume was used to assess resting LVOTO gradient.
Radionuclide Ventriculography
Diastolic filling were assessed by equilibrium R-wave gated blood pool scintigraphy using a standard technique at rest and during graded semi erect exercise on a cycle ergometer (Atherton J J, Moore T D, Lele S S et al. Diastolic ventricular interaction in chronic heart failure. Lancet 1997; 349 (9067):1720-1724; Lele S S, Macfarlane D, Morrison S, Thomson H, Khafagi F, Frenneaux M. Determinants of exercise capacity in patients with coronary artery disease and mild to moderate systolic dysfunction. Role of heart rate and diastolic filling abnormalities. Eur Heart J 1996; 17(2):204-212). Peak left ventricular filling rate in terms of end-diastolic count per second (EDC/s) and time to peak filling normalised for R—R interval (nTTPF) in milliseconds were measured at rest and during exercise (50% of heart rate reserve). The validity of these radionuclide measures of diastolic filling at high heart rates has been established previously (Atherton et al. and Lele et al., see above).
31P Cardiac Magnetic Resonance Spectroscopy (MRS)
In vivo myocardial energetics were measured using a MRS at 3-Tesla Phillips Achieva 3T scanner (Shivu G N, Abozguia K, Phan T T, Ahmed I, Henning A, Frenneaux M. (31)P magnetic resonance spectroscopy to measure in vivo cardiac energetics in normal myocardium and hypertrophic cardiomyopathy: Experiences at 3T. Eur J Radiol 2008). A java magnetic resonance user interface v3.0 (jMRUI) was used for analysis (see Naressi A, Couturier C, Castang I, de Beer R, Graveron-Demilly D. Java-based graphical user interface for MRUI, a software package for quantitation of in vivo/medical magnetic resonance spectroscopy signals. Comput Biol Med 2001; 31(4):269-286)). PCr and γ-ATP peaks was used to determine the PCr/γ-ATP ratio which is a measure of the cardiac energetic state (Neubauer S, Krahe T, Schindler R et al. 31P magnetic resonance spectroscopy in dilated cardiomyopathy and coronary artery disease. Altered cardiac high-energy phosphate metabolism in heart failure. Circulation 1992; 86(6):1810-1818). Data were analyzed by an investigator who was blinded to the participants' clinical status. Carmeo-Rao ratio was used to assess signal to noise ratio. A typical example of cardiac 31P MRS spectra from a patient with HCM is shown in FIG. 4C .
Intervention
Following baseline studies, patients were randomized in a double-blind fashion to receive either perhexiline (n=25) or placebo (n=21) 100 mg OD. Serum perhexiline levels were obtained at 1 and 4 weeks after initiation of the drug. Dose adjustments were advised by an unblinded physician according to serum level to achieve therapeutic level and to avoid drug toxicity. Identical dosage adjustments were also made for randomly allocated placebo-treated patients by the unblinded observer to ensure that blinding of the investigators was maintained. At the end of study, patients were re-evaluated as described earlier.
Statistical Analysis
Data were analyzed using SPSS ver. 15.0 for Window and Microsoft Office Excel 2007, and expressed as Mean±Standard Deviation (SD). Comparison of continuous variables between Perhexiline and Placebo baseline data were determined by unpaired Student's t-test (2-tail) if variables were normally distributed and the Mann-Whitney U-test if the data were non-normally distributed. ANCOVA with baseline values as covariates was performed to test for the significance of differences in the perhexiline versus placebo group after treatment. For the primary end point, the sample size required to detect a change in peak Vo2 of 3 ml/kg/min versus placebo group with a power of 90% and probability of 5% is 44. 30 patients will be required to identify a 5% change in cardiac PCr/ATP ratio with a power of 90% and a p value of <0.05. 40 patients will be required to detect a change ≧25% in nTTPF with power of 0.99 with probability of 5%. Therefore, we aimed to study 50 patients including the drop-outs, 32 of them will take part in the MRS study.
The characteristics and treatment of participants are shown in Table 1 below. Vo 2 : refers to peak oxygen consumption, ACE: refers to angiotensin-converting enzyme, and ARB refers to angiotensin II receptor blockers.
TABLE 1 The clinical characteristics of HCM patients and controls. HCM HCM P HCM Controls P value (Perhexiline) (Placebo) value Age [years] 55 ± 0.26 52 ± 0.46 0.2 56 ± 0.46 54 ± 0.64 0.42 Number (Male) 46 (34) 33 (20) 0.64 25 (19) 21 (17) 0.69 Heart Rate [bpm] 69 ± 0.27 82 ± 0.47 <0.001* 69 ± 0.53 69 ± 0.52 0.97 Systolic BP [mmHg] 126 ± 0.64 126 ± 0.44 0.93 123 ± 0.84 130 ± 0.92 0.2 Diastolic BP [mmHg] 76 ± 0.25 78 ± 0.34 0.33 74 ± 0.45 78 ± 0.57 0.24 Peak Vo 2 23 ± 0.12 38 ± 0.24 <0.0001* 22.2 ± 0.2 23.56 ± 0.27 0.42 [ml/kg/min] Resting nTTPF 0.17 ± 0.002 0.18 ± 0.003 0.44 0.19 ± 0.003 0.17 ± 0.004 0.52 (sec) PCr/γATP ratio 1.28 ± 0.01 2.26 ± 0.02 <0.0001* 1.27 ± 0.02 1.29 ± 0.01 0.86 Drug therapy - no. Beta-blocker 17 0 — 10 7 0.21 CC-blocker 24 0 — 11 8 0.53 Diuretic 10 0 — 4 5 0.49 ACE inhibitor 6 0 — 3 2 0.84 ARB 4 0 — 3 1 0.41 Warfarin 5 0 — 2 3 0.48 Statin 15 0 — 7 7 0.9 *indicates statistical significance
Baseline Data (HCM Versus Controls)
The clinical characteristics and cardiopulmonary exercise test results of all the HCM patients and controls are shown in Table 1. The groups were well matched with respect to age and gender. Heart rate was lower in the HCM group compared to controls due to medication use (beta blockers and/or calcium channel blockers).
The resting cardiac PCr/γATP ratio was lower in HCM patients than in controls (1.28±0.01 vs 2.26±0.02, p<0.0001) (see FIGS. 4A and B), and this remained so after excluding patients taking beta blocker therapy (p<0.0001). At rest, nTTPF, a sensitive marker of LV relaxation, was similar in HCM patients and controls (0.17±0.002 vs 0.18±0.003 sec, p=0.44). During submaximal exercise (at a workload that achieved 50% of heart rate reserve) it remained relatively constant in controls (from 0.18±0.003 sec to 0.16±0.002 sec, [nTTPF=−0.02±0.003 sec]), but lengthened in patients (from 0.17±0.002 to 0.34±0.002 sec, [nTTPF=+0.17±0.002 sec]) p<0.0001, ( FIG. 4C ). This pattern persisted after exclusion of patients on beta blockers and remained significantly different from controls (p<0.0001). Patients exhibited marked exercise limitation compared to controls (23±0.12 vs 38±0.24 ml/kg/min, p<0.0001) ( FIG. 4D ).
Randomized, Double Blinded, Placebo-Controlled Parallel-Group
The perhexiline and placebo groups were well matched (see Table 1). Only one patient (on placebo) did not complete the study due to poor compliance. Side effects were restricted to transient nausea (n=3) and dizziness (n=2) in the perhexiline group and transient nausea (n=2) and headache (n=1) in the placebo group during the first week of treatment. There were no deaths during the study period.
Myocardial Energetics
The PCr/γATP ratio increased with perhexiline (1.27±0.02 to 1.73±0.02) as compared with placebo (1.29±0.01 to 1.23±0.01), p=0.003 (see FIG. 5A ). The mean Cramer-Rao ratios for PCr and γATP were 7.5% and 10.8% respectively. The effect of perhexiline on PCr/γATP ratio remained significant after inclusion of the 3 patients with Cramer Rao ratios >20 from the analysis (p=0.02).
Diastolic Ventricular Filling
Whereas the placebo group showed similar prolongation of nTTPF during exercise before and after therapy (0.17±0.004 to 0.35±0.005 [nTTPF 0.18±0.006 sec] and 0.23±0.006 to 0.35±0.005 sec [nTTPF 0.12±0.006 sec], respectively), in the perhexiline group there was a substantial improvement on therapy with nTTPF at rest and exercise similar (0.19±0.003 to 0.19±0.004 sec[nTTPF 0.00±0.003 sec]) p=0.03 between the perhexiline and placebo response (see FIGS. 5B and 5C ).
Symptomatic Status
More patients in the perhexiline group than in the placebo group had improvements in NYHA classification (67 percent vs. 30 percent) and fewer had worsening (8 percent vs. 20 percent) (p<0.00). Minnesota Living with heart failure questionnaire score showed an improvement (fall in score) in the perhexiline group (from 36.13±0.94 to 28±0.75) but did not change in the placebo group (p<0.001) (see FIGS. 5D and 5E ).
Exercise Capacity (Peak Oxygen Consumption)
Peak V O2 at baseline was similar in the perhexiline and placebo groups (Table 1). After treatment, Peak V O2 fell by -1.23 ml/kg/min in the placebo group (from 23.56±0.27 to 22.32±0.27 ml/kg/min) but increased by 2.09 ml/kg/min in the perhexiline group (from 22.2±0.2 to 24.29±0.2 ml/kg/min), p=0.003 (see FIG. 5F ).
Discussion of Results
The study indicates that patients with symptomatic HCM manifest a cardiac energy defect at rest (reduced PCr/γATP ratio). This defect was accompanied by a slowing of the energy-requiring early diastolic LV active relaxation during exercise (prolongation of nTTPF). The metabolic modulator perhexiline resulted in significant myocardial energy augmentation. Supporting a causative role for energy deficiency in the pathophysiology of HCM, this energy augmentation was accompanied by striking normalisation of HCM's characteristic “paradoxical” nTTPF-prolongation in exercise. These biochemical and physiological improvements translated into significant subjective (NYHA classification and QoL score) and objective (V O2 ) clinical benefits in symptomatic HCM patients already on optimal medical therapy (see FIG. 6 ).
The content of all cited references is expressly incorporated herein by reference for all purposes.
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The invention relates to perhexiline, or a pharmaceutically acceptable salt thereof, for use in the treatment of HfnEF, as well as to a method of treating HfnEF, which comprises administering to an animal in need thereof an effective amount of perhexiline, or a pharmaceutically acceptable salt thereof, to treat said HFnEF. The invention further relates to a treatment program for treating HFnEF, which involves the co-use or co-administration of perhexiline with one or more other compounds that are advantageous in treating HFnEF or the symptoms thereof.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to image-forming apparatuses with ink-eject heads that enable to eject inks to form images on image-formed media.
[0003] 2. Description of Related Art
[0004] There has been widely used an ink-jet recording apparatus as recording means for recording images on image-formed media, such as paper, based on image information. The ink-jet recording apparatus is usually applied on printers, facsimiles or copying machines, and the recording images include characters or symbols in general.
[0005] During the recording of images, however, the landing of ink droplets from respective ink-eject heads tends to deviate from predetermined positions. This will be below called the “landing misalignment”. The landing misalignment is divided into two components: the DC component that shifts with at a constant amount; and the AC component that fluctuates periodically.
[0006] The AC component of a landing misalignment is caused by unevenness in the thickness of a belt or unevenness in the radius of a roller. In order to reduce a landing misalignment with the circumferential length of a belt as one cycle due to the former unevenness or a landing misalignment with the circumferential length of a roller as one cycle due to the latter one, the following methods have been conventionally proposed. Note here that the former cycle will be below called the “belt cycle” and the latter called the “roller cycle”.
[0000] [Landing Misalignment with Belt Cycle]
[0007] (1-1) There is proposed a method to enlarge the diameter of a roller or reduce the thickness of a belt so as to make unevenness in the thickness of the belt relatively small. The former, however, makes an image forming device or its components large and heavy and the latter makes its endurance weak. This method can reduce but cannot eliminate a landing misalignment.
[0008] (1-2) There is proposed a method to measure the rotation speed of a belt by bringing a roller into contact with the surface of the belt without any influence of unevenness in the thickness of the belt.
[0009] Japanese Patent Publication Laid-open No. 2004-188921 discloses a method to measure the thickness of a belt using a laser Doppler measurement device.
[0010] The measurement of the rotation speed of a belt at a contact line of the roller and belt, however, frequently gets false detection due to slide or vibrations. Increasing the pressure of the roller to prevent the slide causes the deformation of the belt. Accordingly, the measurement receives some influence of unevenness in the thickness or elasticity of the belt. Also, the laser Doppler measurement device is quite expensive. Moreover, these methods get detection error due to paper dust or ink-mist.
[0011] (1-3) Japanese Patent Publication Laid-open No. 2000-356875 discloses a method to measure the thickness of a belt in advance and to adjust a recording timing or transfer speed based on obtained data. This method, however, requires a thickness measurement device with high-accuracy so as to accumulate minute unevenness in thickness. Moreover, when a multilayer belt is used, this method cannot deal with landing misalignments other than that due to unevenness in thickness.
[0012] (1-4) Japanese Patent Publication Laid-open No. H10-186787 discloses a method to measure and correct unevenness in the thickness of a belt by reading a registered pattern on the belt surface at a position different from recording positions. This, however, requires reading means with high-accuracy and high-speed. In addition, the measuring ability of the reading means decreases due to paper dust or ink-mist.
[0000] [Landing Misalignment with Roller Cycle]
[0013] (2-1) Japanese Patent Publication Laid-open No. H03-2067 discloses a method to eliminate a landing misalignment with a roller cycle by adjusting intervals between image-recording units to the roller cycle. This method, when combined with the method (1-1) or (1-2), enables to reduce the landing misalignment due to the unevenness of a belt and roller.
[0014] When the method (2-1) is combined with the method (1-1), an image-forming device is made large because it also requires widening an interval between ink heads. This causes to degrade the accuracy of the manufacturing dimension of head mounting units and to increase the deformation of these units. Also, when the method (2-1) is combined with the method (1-2), it cannot solve the problem of the method (1-2) itself.
[0015] Japanese Patent Publication Laid-open No. H03-2068 discloses a method to resolve unevenness with a belt cycle by using the method (1-2) and unevenness with a roller cycle by storing the roller cycle and performing correction. However, this method cannot solve the problem of the method (1-2), either.
SUMMARY OF THE INVENTION
[0016] An object of the present invention is to eliminate the AC component of a landing misalignment due to unevenness in the thickness of a belt or unevenness in the radius of a roller.
[0017] To achieve the above described object, the first aspect of the present invention provides an image-forming apparatus comprising: a transfer unit (for example, a transfer belt according to the first embodiment) that transfers an image-formed medium by rotation thereof; an image-forming unit that includes a first ink head and a second ink head (e.g. ink heads K, C according to the first embodiment) arranged in a transfer direction of the image-formed medium at a predetermined interval and controls the first ink head and the second ink head to eject first and second inks on the image-formed medium; a transfer amount detecting unit (e.g. an encoder according to the first embodiment) that outputs a pulse signal in response to a rotational motion of the transfer unit; a transfer reference position detecting unit (e.g. a belt reference sensor according to the first embodiment) that detects a reference position provided on the transfer unit; an ink landing position calculating unit (e.g. a first accumulator according to the first embodiment) that calculates an ink landing position corresponding to the reference position on the image-formed medium by counting a pulse signal after detection of the reference position; a storage unit that stores correction values for printing timing for one rotational cycle of the transfer unit as a correction table; and a printing timing signal generating unit (e.g. a second accumulator according to the first embodiment) that reads out a correction value for printing timing, which corresponds to the ink landing position on the image-formed medium, from the correction table and generates a printing timing signal by shifting a phase of the pulse signal by the correction value for printing timing; wherein the correction table includes a set of values, each value being calculated based on a measurement value of an interval between a first ink landing position by the first ink head and a second ink landing position by the second ink head in a predetermined image pattern formed on the predetermined image-formed media which are corresponding to a length longer than the one rotational cycle of the transfer unit, and canceling an error of a transfer amount of the predetermined image-formed media by the transfer unit, and wherein the image-forming unit forms an image on the image-formed medium in transfer by controlling the first and second ink heads to eject respective inks in synchronization with the printing timing signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a schematic view of an image-forming apparatus according to the first embodiment of the present invention.
[0019] FIG. 2 is a view of steps for correcting a landing misalignment.
[0020] FIG. 3 is a schematic view of the internal structure of a correction circuit according to the first embodiment.
[0021] FIG. 4 is a view of operations of the correction circuit according to the first embodiment.
[0022] FIG. 5 is a view of a landing misalignment amount “g” at a position “y′” of a transfer belt when the driving radius “r” [mm] of a driven roller fluctuates in a sine wave form with the circumferential length of the transfer belt as one cycle.
[0023] FIG. 6 is a view of the landing misalignment amounts of the color inks K, C, M and Y from a value in design at a printing position.
[0024] FIG. 7 is a view of the landing misalignment amount of K relative to these of C, M and Y at a printing position.
[0025] FIG. 8 is a view of the measurement values of a relative landing misalignment amount KC(y), and landing misalignment amounts K(y) and C(y) when K(0)=0.
[0026] FIG. 9 is a view of K(y) when K(y)=0 where 0≦y≦110, a wave form S(y) with one cycle (110 [mm]) of K(y), and a landing misalignment amount Δ(y) which is a difference between S(y) and K(y).
[0027] FIG. 10 is a schematic view of an image-forming apparatus according to the second embodiment of the present invention.
[0028] FIG. 11 is a schematic view of the internal structure of a correction circuit according to the second embodiment.
[0029] FIG. 12 is a view of landing misalignment amounts KY(y), KM(y), KC(y) and K(y) obtained from KC(y), K(y) obtained from KM(y), and K(y) obtained from KY(y).
[0030] FIG. 13 is a view of K(y) obtained from KY(y), KM(y) and KC(y), a wave form S(y) with one cycle (110 [mm]) of K(y), and a landing misalignment amount Δ(y) which is a difference between K(y) and S(y).
[0031] FIG. 14A is a view of the landing misalignment amounts of K, C, M and Y from a precise dot pitch.
[0032] FIG. 14B is a view of the landing misalignment amounts of C, M and Y relative to that of K.
[0033] FIG. 14C is a view of an arrangement of ink heads.
[0034] FIG. 14D is a view of a landing position in design and landing positions of K, C, M and Y.
[0035] FIG. 15A is a view of the total landing misalignment amounts of K, C, M and Y, from a landing position in design, each of which is a landing misalignment amount with a belt cycle plus a landing misalignment amount with a roller cycle.
[0036] FIG. 15B is a view of the total landing misalignment amounts of C, M and Y relative to that of K.
[0037] FIG. 15C is a view of the landing misalignment amounts with the belt cycle of C, M and Y relative to that of K, each of which is the total landing misalignment amount minus the landing misalignment amount with the roller cycle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] Referring to Figures, several embodiments of the invention will be below explained.
First Embodiment
[0039] FIG. 1 is a schematic view of an image-forming apparatus according to the first embodiment of the present invention. The transfer of sheets is performed in the following steps:
[0040] (1) Picking up a sheet from a paper feeding tray 101 to transfer the sheet to a register roller 103 at rest;
[0041] (2) Hitting a tip end line of the sheet to the register roller 103 at rest for correcting a landing misalignment in a sub scanning direction;
[0042] (3) Rotating the register roller 103 and transferring the sheet to a transfer belt 105 at a speed faster than that of the transfer belt 105 ;
[0043] (4) Transferring the sheet to right of a sub scanning direction in a stuck state over the transfer belt 105 by a negative pressure from an absorbing fan (not shown) just below the transfer belt 105 ;
[0044] (5) Sequentially printing an image on the sheet with a plurality of line ink-jet heads (ink heads), K (black) 107 , C (cyan) 109 , M (mazenda) 111 and Y (yellow) 113 , aligned above the transfer belt 105 ; and
[0045] (6) Discharging the sheet to a paper receiving tray (not shown) on the right of the transfer belt 105 .
[0000] [Specification of Units]
[0000]
The circumferential length of the transfer belt 105 in the sub-scanning direction is 1275 mm, the thickness is 0.45 mm, and the width in the main-scanning direction is 355 mm;
The diameter of a driven roller 115 is φ40 mm; and
The pulse number of a rotary encoder (encoder) 117 is 1500 ppr (pulse/round), the pulse array cycle is 84.67 μm (≅300 dpi), and the interval between neighboring ink heads is 110 mm.
[0049] During the steps (3)-(5), the step (1) is started for another sheet. Since this shortens a sheet transfer interval, the number of sheets printed per time is increased. Printing an image on a sheet with each ink head is synchronized to a pulse series of the encoder 117 , which is provided along the axis of the driven roller 115 . Accordingly, no influence is given on the image from unevenness in the rotation of a driving roller 121 driven by a driving motor 119 . However, the landing misalignment of each color ink occurs with the circumferential length of the transfer belt 105 as a belt cycle. This is so called the “AC component of the landing misalignment”. The transfer belt 105 has a belt reference mark 123 on a surface thereof. The belt reference mark 123 is detected by a belt reference sensor 125 . Signals from the encoder 117 and the belt reference sensor 125 are sent to a correction circuit 127 . The correction circuit 127 outputs a driving signal to a head driving circuit 129 . A sheet tip sensor 131 measures a tip end line of the sheet. Ink heads 107 , 109 , 111 , and 113 respectively have six ink heads of 2-inch each arranged in a houndstooth check shape.
[0050] FIG. 2 shows the following steps for correcting the landing misalignment of each ink color:
[0051] (1) Printing an image on a sheet in an initial state, and in particular, sequentially printing a predetermined image pattern on a plurality of sheets with their total length longer than a belt rotational cycle (in this case, three A3 sheets with the length of 420 mm and the interval between neighboring sheets of 50 mm);
[0052] (2) Measuring the landing misalignment amount of each color ink, and in particular, reading the landing misalignment amount of each color ink relative to that of a reference color ink on the sheets by an external or device-equipped scanner;
[0053] (3) Creating a table of correction values (correction table) 37 based on the measurement results and storing this table within the correction circuit 127 ; and
[0054] (4) Printing the predetermined image pattern on the sheets with correcting the AC component of the landing misalignment by generating a timing signal that is an encoder pulse signal with a phase shifted based on the correction table 37 stored in the correction circuit 127 .
[0055] Here, the predetermined image pattern is a pattern for analyzing an amount of color misalignment on an image-forming device such as an ink-jet. The international publication WO2003/082587 discloses a test chart as such a pattern in FIG. 8 .
[0000] [Outline of Correction Circuit]
[0056] FIG. 3 shows the internal structure of the correction circuit 127 and FIG. 4 shows operations of the correction circuit 127 . According to FIGS. 3 and 4 , there is explained an example of operations of the correction circuit 127 .
[0000] [Specification of Phase Shifting of Encoder Pulse at Correction Circuit]
[0000]
The phase shifting ability is as follows: the dividing ability is 1/256 pulse (0.33 μm) with data of 10 bits per point; the shift range is 0˜3.996 pulses (0˜338.34 μm).
The total volume of the correction table 37 is 640 bits according to 1387 mm, that is, every 256 lines (about 21.7 mm)×64 sections.
[0059] There is explained the internal structure of the correction circuit 127 .
[0060] The correction circuit 127 comprises an Lck counter (not shown), an Lck×256 frequency multiplier 31 , a belt Lck counter 32 , a first accumulator 33 , a second accumulator 34 , a comparator 35 , a pulse counter 36 , and the correction table 37 .
[0061] The Lck×256 frequency multiplier 31 generates 256 signals in one cycle of a signal “Lck” and counts them. Here, “Lck” is a pulse signal with a same phase as an encoder phase A generated per one printing cycle (300 dpi).
[0062] The belt Lck counter 32 is a counter for measuring a current position (of the belt reference mark 123 ) of the transfer belt 105 in a rotating state. A correction value corresponding to the measured current position of the transfer belt 105 is selected from the correction table 37 .
[0063] The first accumulator 33 adds a counted value of the Lck counter and a counted value of the Lck×256 frequency multiplier 31 .
[0064] The second accumulator 34 adds a correction value of the correction table 37 to a value of a counted value of the pulse counter 36 plus 1.
[0065] The comparator 35 compares the added value of the first accumulator 33 and that of the second accumulator 34 . When the former value is greater than or equal to the latter value, the comparator 35 outputs a corrected pulse to the pulse counter 36 .
[0066] The pulse counter 36 outputs the corrected pulse and counts up its own value.
[0067] Referring to FIG. 4 , the above described “addition” and “comparison” operations are explained in detail.
[0068] The first accumulator 33 adds “a shifted value 41 of the counted value (N+1 in this example) of the Lck counter by 8 bits to the left” and “the counted value 43 of the Lck×256 frequency multiplier 31 ″. The second accumulator 34 adds “a shifted value 45 , (N+1), of the counted value (N) of the pulse counter 36 plus 1 by 8 bits to the left” and “the correction value (the counted value of the Lck×256 frequency multiplier 31 ) 47 , 01100100, (corresponding to H N+1 =100)”. The comparator 35 compares the added value of the first accumulator 33 and that of the second accumulator 34 . If the former value is more than or equal to the latter value, the comparator 35 outputs the corrected pulse.
[0069] The above described structure enables to shift the phase of an encoder pulse based on the position of the transfer belt 105 and the correction values of the correction table 37 .
[0000] [Method of Creating Correction Table]
[0070] There is explained a method to create the correction table 37 from a landing misalignment due to unevenness in the thickness of the transfer belt 105 .
[0071] Now define “y′”[mm] as a distance (position) from a predetermined fixed (static) reference position “O” to the belt reference mark 123 of the transfer belt 105 in a sheet transfer direction (see FIG. 1 ), and set the circumferential length “L” of the transfer belt 105 as 1275 mm. This definition is equivalent to define “y′” as a distance from the belt reference sensor 125 to the belt reference mark 123 of the belt transfer belt 105 in the transfer direction, but this definition will be below used for explanation as a matter of convenience. FIG. 5 shows a landing misalignment amount “g” at a position “y′” of the transfer belt 105 when the driving radius “r” [mm] of the driven roller 115 fluctuates in a sine wave form with the belt cycle.
[0072] Supposing the average radius of the driven roller 115 as 20.225 mm and the amplitude as ±3 μm, we can represent the driving radius r(z′)[mm] at a position “z′”[mm] of the transfer roller 105 as
r ( z ′ ) = 20.225 + 0.003 sin ( 2 π · z ′ 1275 ) . ( 1 )
[0073] Thus, when the transfer belt 105 moves from the static reference position “O” to a position “y′”[mm], the transfer amount G(y′)[mm] of a sheet is obtained by
G ( y ′ ) = ∫ 0 y ′ r ( z ′ ) ⅆ z ′ = ∫ 0 y ′ { 20.225 + 0.003 sin ( 2 π · z ′ 1275 ) } ⅆ z ′ = 20.225 y ′ + 1275 2 π · 0.003 { 1 - cos ( 2 π · y ′ 1275 ) } = 20.225 y ′ + 1275 2 π · 0.003 - 1275 2 π · 0.003 cos ( 2 π · y ′ 1275 ) . ( 2 )
[0074] Accordingly, the landing misalignment amount “g”[mm] at the position “y′” [mm] of the transfer belt 105 is given by
g ( y ′ ) = 20.225 y ′ + 1275 2 π · 20.225 · 0.003 - G ( y ′ ) = 1275 2 π · 20.225 · 0.003 cos ( 2 π · y ′ 1275 ) . ( 3 )
[0075] Since the pulse number of the encoder 117 is 1500 ppr and the average of a driving radius r(y′) is 20.225 mm, the average interval of neighboring dots (average printing interval) is given by 84.718 μm (=20.225×2π/1500). When this value is set as a dot interval in design (target), the landing misalignment amount “g”[mm] from a dot position in design is represented by (3).
[0076] Thus, it is considered the integration value of the deviations of the driving radius “r” from the average radius in the transfer direction of the transfer belt 105 as a landing misalignment amount (that is, the expansion and contraction of an image) from a value in design.
[0077] For example, in FIG. 1 , when an A3 sheet (length 420 mm) is transferred lengthwise on the transfer belt 105 from the left hand and the printing of the predetermined image pattern on the sheet is started with the ink head “K” arranged above the position y′=100 mm of the transfer belt 105 , the printing range of each color ink, which depends on the ink head positions (interval: 110 mm) of K, C, M and Y, is as follows:
[0078] Printing range of K: 100 mm≦y′≦520 mm (line 501 in FIG. 5 );
[0079] Printing range of C: 210 mm≦y′≦630 mm (line 502 in FIG. 5 );
[0080] Printing range of M: 320 mm≦y′≦740 mm (line 503 in FIG. 5 ); and
[0081] Printing range of Y: 430 mm≦y′≦850 mm (line 504 in FIG. 5 ).
[0082] The next step is to conform the landing misalignment amounts K(y), C(y), M(y) and Y(y) of K,C,M and Y to each other at a printing position “y” of an A3 sheet, that is, K(y)=C(y)=M(y)=Y(y). As shown in FIG. 1 , “y” is a position measured backward from a tip end line of the A3 sheet in the transfer direction. Then, as shown in FIG. 6 , K(y), C(y), M(y) and Y(y) at a dot position “y” in design are represented by
K ( y )= g ( y+ 100), (4-1)
C ( y )= g ( y+ 210)= K ( y+ 110), (4-2)
M ( y )= g ( y+ 320)= K ( y+ 220), (4-3)
Y ( y )= g ( y+ 430)= K ( y+ 330) (4-4)
In FIG. 6 , the interval from a dotted line 601 to a dotted line 602 corresponds to the length of an A3 sheet. Note here that g(y+100) in (4-1) is obtained by substituting y′=y+100 into (3) (See FIG. 1 ).
[0083] It is possible to specify a position “y” of the transfer belt 105 to which the position “y” of a point of the predetermined image pattern on the A3 sheet corresponds from a positional relationship between the register roller 103 and each ink head. This is achieved by starting the rotation of the register roller 103 to transfer the A3 sheet to the transfer belt 105 in the instance when the belt reference mark 123 passes through the belt reference sensor 125 . This is still achieved by starting the rotation when particular counts of encoder pulse are generated after the belt reference mark passes through the belt reference sensor 125 .
[0084] Suppose here that KC(y) represents the landing misalignment amount of K relative to that of C at a dot position “y” in design; KM(y) the landing misalignment amount of K relative to that of M; and KY(y) the landing misalignment amount of K relative to that of Y.
[0085] As shown in FIG. 7 , they are expressed as
KC ( y )= K ( y )− C ( y )= K ( y )− K ( y+ 110)= g ( y+ 100)− g ( y+ 210), (5-1)
KM ( y )= K ( y )− M ( y )= K ( y )− K ( y+ 220)= g ( y+ 100)− g ( y+ 320), (5-2)
KY ( y )= K ( y )− Y ( y )= K ( y )− K ( y+ 330)= g ( y+ 100)− g ( y+ 430) (5-3)
[0086] KY(y) tends to be the largest in them since the ink-head interval between K and Y is the widest. The landing misalignment amount changes depending on a sheet position.
[0087] Accordingly, if a landing misalignment amount g(y′) with the belt cycle of the transfer belt 105 is obtained from (3), it is possible to make KC(y), KM(y) and KY(y) zero, that is K(y)=C(y)=M(y)=Y(y), by setting the values of the correction table 37 as −g(y′).
[0088] Next, to get g(y) from K(y) using the measurement value KC(y), solving the recurrence equation (5-1), K(y+110)=K(y)−KC(y), with y=110n, we obtain
K ( 110 ) = K ( 0 ) - KC ( 0 ) , K ( 220 ) = K ( 110 ) - KC ( 110 ) = K ( 0 ) - KC ( 0 ) - KC ( 110 ) , K ( 330 ) = K ( 220 ) - KC ( 220 ) = K ( 0 ) - KC ( 0 ) - KC ( 220 ) - KC ( 330 ) , ⋮ K ( 110 n ) = K ( 0 ) - ∑ i = 0 n KC ( 110 i ) ( 6 )
where “n” is an integer that satisfies the relationship d×n≧L and “i” is an integer that satisfies the inequality 0≦i≦n.
[0089] Thus, by accumulating the measurement value KC(y), we obtain K(y) and C(y) with the interval of 110 mm. In FIG. 8 , K(y) is denoted as the symbol “●”, and C(y) is denoted as the symbol “X” when K(0)=0. The equation (6) becomes
K ( 110 n ) = - ∑ i = 0 n KC ( 110 i ) ( 7 )
when K(0)=0.
[0090] It is possible to generalize (6) for arbitrary y=110n+a where “a” is a real number which satisfies the inequality 0≦a≦110. For example, if K(y)=0 for 0≦y<110, we obtain, in the same way to obtain (7),
K ( y ) = K ( 110 n + a ) = - ∑ i = 0 n KC ( 110 i + a ) ( 8 )
where “i” is an integer which satisfies the inequality 0≦i≦n. It is shown as a discontinuous function 901 in FIG. 9 .
[0091] From the discontinuous function 901 , we can construct a continuous function
S ( y ) = 1 L ∑ i = 0 L - 1 K ( 110 i + m ) ( 9 )
where “m” represents the remainder of y/110 and “L” the frequency of 110 mm within the belt cycle. In this case, L=12 is set by using a KC(y) wave form with 1320 mm, which is longer than the transfer belt cycle of 1275 mm. This continuous function (9) is shown as a waveform 902 in FIG. 9 .
[0092] Subtracting (9) from (8), we obtain
Δ( y )= K ( y )− S ( y ). (10)
This is the very landing misalignment amount of K to be obtained. This function is shown as a continuous function 903 in FIG. 9 .
[0093] Here is explained (9) in detail. The equations (5-1)-(5-3) show that a 110 mm periodic component of K(y) is canceled from KC(y), KM(y) and KY(y). It is therefore impossible to restore the 110 mm periodic component of K(y). This means that there is no influence on KC(y), KM(y) and KY(y) even though any kind of 110 mm periodic wave is added to or subtracted from K(y). The continuous function S(y) may be considered as an arbitrary wave with 110 mm cycle which makes K(y) continuous. It is however preferable to use the waveform S(y) of (9) so as to prevent the image expansion and contraction of a single color as much as possible.
[0094] Since the equations (4-1)-(4-4) show that K(y) only differs from g(y) in phase, it is easy to obtain g(y) from K(y). Storing “−g(y)” as a value in the correction table 37 in the correction circuit 127 and then adjusting the timing of ink-eject from the ink heads 107 , 109 , 111 , 113 enables to eliminate a landing misalignment.
[0095] It is possible to create the correction table 37 before product shipment. It is preferable to urge users or service persons to recreate the correction table 37 regularly, such as every one-year, through a display on the image-forming apparatus.
[0096] A method of printing in an initial state before measuring the landing misalignment can be any one of the methods:
[0097] (a) Printing in a corrected state using a already stored correction table; and
[0098] (b) Printing in non-corrected state after clearing the already stored correction table.
[0099] The method (a) is comprised of:
[0100] (1) At the step (1) of FIG. 2 , printing the predetermined image pattern in a corrected state with an already used correction table;
[0101] (2) At the step (2), measuring a landing misalignment based on the printed predetermined image pattern; and
[0102] (3) At the step (3), calculating a new correction value based on the measured landing misalignment and adding the new correction value to the already used correction table in the correction circuit 127 .
[0103] For example, supposing that, although printing with the correction value of +100 μm at a certain position of the transfer belt 105 is done, the landing misalignment amount of −30 μm is still remained. Then, it is possible to add 30 μm to the previous correction value of +100 μm to get the new correction value of +130 μm.
[0104] When the transfer belt 105 is used continuously, the method (a) is better because of the less amount of change in correction values. On the other hand, when the transfer belt 105 is exchanged, the method (b) is better because of clearing the previous correction values.
[0105] The above initial state makes some gaps (lack of data) corresponding to sheet intervals in measured data of landing misalignment. As an example of initial setting, printing three A3 sheets sequentially with the sheet interval of 50 mm enables to measure the landing misalignment of a length longer than the belt cycle (1275 mm), but makes the two gaps of 50 mm. It is therefore preferable to set appropriate sheet intervals depending on a sheet length and a belt cycle.
[0106] As an example of proper setting, printing four A3 sheets with the sheet interval of 220 mm between the first and second sheets and the third and forth sheets and the sheet interval of 535 mm between the second and third sheets enables to measure landing misalignment with no gap in data over the belt cycle (1275 mm) with about 100 mm overlapped.
[0107] With a correction value obtained from the above method, it is also possible to eliminate periodical landing misalignment due to unevenness in units other than the transfer unit composed of the transfer belt and the rotary encoder. Such a unit is a cylindrical sheet transfer unit that rotates with clamping a tip of a sheet, a liner encoder with unevenness in a slit or ruled line on the belt surface thereof, or the like.
[0000] [Correction Circuit]
[0108] The correction circuit 127 shown in FIG. 3 comprises a FPGA (Field Programmable Gate Array), an ASIC (Application Specific Integrated Circuits), and a CPU (Central Processing Unit). Although the correction circuit 127 is separated from the head driving circuit 129 in FIG. 1 , it is possible to configure them on an identical device or an identical plate. The belt Lck counter 32 in FIG. 3 selects a collection value from the correction table 37 every 256 lines. It is however preferable to change a correction value more frequently than every 256 lines using a liner interpolation value calculated from anteroposterior correction values.
[0000] [Creation of Correction Table]
[0109] As described above, a sine wave as the rotational cycle of the transfer belt 105 can be used to create the correction table 37 . However, it is also possible to use other waveforms. In addition, it is possible to use a color ink other that K as a reference color ink and to use other calculation methods other than the present calculation method, depending on the size of machines.
Second Embodiment
[0110] FIG. 10 shows a schematic picture of an image forming apparatus according to the second embodiment. This image forming apparatus differs from that according to the first embodiment in FIG. 1 in the following points:
A roller reference mark 229 and a roller reference sensor 223 are added for the driven roller 115 ; An encoder reference mark 227 and an encoder reference sensor 225 are added for the encoder 117 ; An encoder speed-reducing device (not shown), which makes two rotations of the encoder correspond to one rotation of the roller, is added; and The pulse number of the encoder 117 is 750 ppr instead of 1500 ppr.
[0115] Compared with the first embodiment, the above structure further enables to correct the unevenness of the driven roller 115 and the encoder 117 and costs less for the encoder 117 .
[0000] [Outline of Correction Circuit]
[0116] FIG. 11 shows the internal structure of a correction circuit 221 according to the second embodiment. Referring to FIG. 11 , there is explained an example of operations of the correction circuit 221 .
[0000] [Specification of Phase Shifting of Encoder Pulse at Correction Circuit]
[0000]
The phase shifting ability is as follows: the dividing ability is 1/256 pulse (0.33 μm) with data of 10 bits per point; the shift range is 0˜3.996 pulses (0˜338.34 μm).
The total volume of a correction table for a belt is 640 bits corresponding to 1387 mm, that is, every 256 lines (about 21.7 mm)×64 sections. That of a correction table for a roller is 320 bits corresponding to 173 mm, that is, every 64 lines (about 5.4 mm)×32 sections. That of a correction table for an encoder is 160 bits corresponding to 86 mm, that is, every 64 lines (about 5.4 mm)×16 sections.
[0119] There is explained the internal structure of the correction circuit 221 .
[0120] The correction circuit 221 comprises an Lek counter (not shown), an Lek×256 frequency multiplier 201 , a belt Lck counter 202 , a roller Lek counter 207 , an encoder Lck counter 208 , a first accumulator 203 , a second accumulator 204 , a comparator 205 , a pulse counter 206 , a correction table for belt (belt correction table) 211 , a correction table for roller (roller correction table) 212 , and a correction table for encoder (encoder correction table) 213 .
[0121] The first accumulator 203 adds a counted value of the Lck counter and a counted value of the Lck×256 frequency multiplier 201 .
[0122] The second accumulator 204 adds respective correction values of the above correction tables 211 , 212 and 213 to a value of a counted value of the pulse counter 206 plus 1.
[0123] The roller Lck counter 207 is a counter for measuring a current position (of the roller reference mark 229 ) of the driven roller 115 . A correction value (roller correction value) corresponding to the measured current position of the roller reference mark 229 is selected from the roller correction table 212 .
[0124] The encoder Lck counter 208 is a counter for measuring a current position (of the encoder reference mark 227 ) of the encoder 117 . A correction value (encoder correction value) corresponding to the current position of the encoder reference mark 227 is selected from the encoder correction table 213 .
[0125] With the above structure, it is possible to shift the phase of the encoder pulse by the total value of the correction values: a belt correction value corresponding to the current position of the transfer belt reference mark 123 of the transfer belt 105 ; a roller correction value of the driven roller 115 ; and a encoder correction value of the encoder 117 .
[0000] [Creation of Correction Table]
[0126] There is the unevenness of the rotations of three kinds of transfer units (the transfer belt 105 , the roller 115 , and the encoder 117 ). The transfer units have the belt cycle of 1275 mm, the roller cycle of 126 mm, the encoder cycle of 64 mm, respectively.
[0127] In the first embodiment, there is explained how to obtain K(y) from KC(y). In the second embodiment, there is explained how to obtain K(y) from KC(y), KM(y) and KY(y) with more accuracy than that of the first embodiment.
[0128] Under the condition K(0)=0 as same as the first embodiment, we obtain K(y) for y=330n [mm] (squares 231 with the interval of 330 mm in FIG. 12 ) using KY(y) as follows:
K ( 330 n ) = - ∑ i = 0 n KY ( 110 i ) ( 11 )
where “n” is an integer more than or equal to 0.
[0129] Then, using (11), KC(y) and KM(y), we obtain a value shifted by 110 mm from the respective values of (11) (circles 232 in FIG. 12 ) and a value shifted by 220 mm from the respective values of (11) (triangles 233 in FIG. 12 ) as follows:
K (330 n+ 110)= K (330 n )− KC (330 n ), (12-1)
K (330 n+ 220)= K (330 n )− KM (330 n ). (12-2)
[0130] Further, we obtain K(y) and S(y) to get a difference Δ(y) in the same way to obtain K(y) from KC(y) in the first embodiment (expressions (9), (10)). FIG. 13 shows K(y) as a discontinuous function 241 , S(y) as a continuous function 242 , and the difference Δ(y) as a line 243 .
[0131] Like this, we can obtain the unevenness of the longest cycle, that is, the belt cycle. This unevenness includes that of the roller cycle (126 mm) and that of the encoder cycle (64 mm). It is therefore possible to extract each cycle of the roller and the encoder from the unevenness of the belt cycle to create each correction table: the belt correction table 211 ; the roller correction table 212 ; and the encoder correction table 213 .
[0132] There is no need to provide the encoder reference position sensor 225 and the encoder correction table 213 when the position of the roller reference mark 229 and the position of the encoder reference mark 227 are not to be misaligned.
[0133] FIG. 14A shows the landing misalignment amounts of K, C, M and Y from a precise dot pitch. FIG. 14B shows the landing misalignment amount of C, M and Y from K. FIG. 14C shows an arrangement of ink heads. FIG. 14D shows a landing position in design and landing positions of K, C, M and Y.
[0134] Firstly, the printing position of y=0 mm is explained.
[0135] As shown in FIG. 14A , at the printing position y=0 mm, the landing misalignment amount of K is more than 20 μm, that of C is less than 20 μm, that of M is 0 μm, and that of Y is less than −20 μm.
[0136] As shown in FIG. 14B , at the printing position y=0 mm, the landing misalignment amount of C from K is less than 20 μm, that of M from K is more than 20 μm, and that of Y from K is more than 40 μm.
[0137] FIG. 14D shows the landing position in design and the landing positions of K, C, M and Y (1400) at the printing position of y=0 mm.
[0138] Next, the printing position of y=110 mm is explained.
[0139] As shown in FIG. 14A , at the printing position y=110 mm, the landing misalignment amount of K is less than 20 μm, that of C is 0 μm, that of M is less than −20 μm, and that of Y is more than −20 μm.
[0140] As shown in FIG. 14B , at the printing position y=110 mm, the landing misalignment amount of C from K is less than 20 μm, that of M from K is more than 20 μm, and that of Y from K is more than 40 μm.
[0141] FIG. 14D shows the landing position in design and the landing positions of K, C, M and Y (1411) at the printing position of y=110 mm.
[0142] Next, the printing position of y=220 mm is explained.
[0143] As shown in FIG. 14A , at the printing position y=220 mm, the landing misalignment amount of K is 0 μm, that of C is less than −20 μm, that of M is more than −20 μm, and that of Y is −30 μm.
[0144] As shown in FIG. 14B , at the printing position y=220 mm, the landing misalignment amount of C from K is less than 20 μm, that of M from K is more than 20 μm, and that of Y from K is 30 μm.
[0145] FIG. 14D shows the landing position in design and the landing positions of K, C, M and Y (1422) at the printing position of y=220 mm.
[0146] Next, the printing position of y=330 mm is explained.
[0147] As shown in FIG. 14A , at the printing position y=330 mm, the landing misalignment amount of K is less than −20 μm, that of C is more than −20 μm, that of M is −30 μm, and that of Y is more than −20 μm.
[0148] As shown in FIG. 14B , at the printing position y=330 mm, the landing misalignment amount of C from K is less than 20 μm, that of M from K is less than 20 μm, and that of Y from K is less than 20 μm.
[0149] FIG. 14D shows the landing position in design and the landing positions of K, C, M and Y (1433) at the printing position of y=330 mm.
[0150] Next, the printing position of y=440 mm is explained.
[0151] As shown in FIG. 14A , at the printing position y=440 mm, the landing misalignment amount of K is more than −20 μm, that of C is −30 μm, that of M is more than −20 μm, and that of Y is less than −20 μm.
[0152] As shown in FIG. 14B , at the printing position y=440 mm, the landing misalignment amount of C from K is less than 20 μm, that of M from K is less than −20 μm, and that of Y from K is less than −20 μm.
[0153] FIG. 14D shows the landing position in design and the landing position of K, C, M and Y (1444) at the printing position of y=440 mm.
[0154] Next, the printing position of y=550 mm is explained.
[0155] As shown in FIG. 14A , at the printing position y=550 mm, the landing misalignment amount of K is −30 μm, that of C is more than −20 μm, that of M is less than −20 μm, and that of Y is less than 20 μm.
[0156] As shown in FIG. 14B , at the printing position y=550 mm, the landing misalignment amount of C from K is less than −20 μm, that of M from K is less than −20 μm, and that of Y from K is more than −20 μm.
[0157] FIG. 14D shows the landing position in design and the landing positions of K, C, M and Y (1455) at the printing position of y=550 mm.
[0158] As described above, the landing misalignment amount of Y from the landing position in design at the printing position y=220 mm is −30 μm, the landing misalignment amount of M from the landing position in design at the printing position y=330 mm is −30 μm, the landing misalignment amount of C from the landing position in design at the printing position y=440 mm is −30 μm, and the landing misalignment amount of K from the landing position in design at the printing position y=550 mm is −30 μm.
[0159] Shifting the timing of ejecting the ink Y earlier by 30 μm at the printing position y=220 mm enables to shift: the timing of ejecting the ink M earlier by 30 μm at the printing position y=330 mm, which is 110 mm apart from the printing position y=220 mm; the timing of ejecting the ink C earlier by 30 μm at the printing position y=440 mm, 220 mm apart; and the timing of ejecting the ink K earlier by 30 μm at the printing position y=550 mm, 330 mm apart. As a result, all the color inks come to land at the position in design.
[0160] FIG. 15A shows the total landing misalignment amount of K, C, M and Y from a landing position in design, each of which is a landing misalignment amount with the belt cycle plus a landing misalignment amount with the roller cycle.
[0161] A thin line 1511 represents the landing misalignment amounts of K with the belt cycle, a thin line 1512 that of C with the belt cycle, a thin line 1513 that of M with the belt cycle, and a thin line 1514 that of Y with the belt cycle.
[0162] A thick line 1521 represents the total of the landing misalignment amount of K with the belt cycle and that with the roller cycle, a thick line 1522 that of C with the belt cycle and that with the roller cycle, a thick line 1523 that of M with the belt cycle and that with the roller cycle, and a thick line 1524 that of Y with the belt cycle and that with the roller cycle.
[0163] FIG. 15B shows the total landing misalignment amounts of C, M and Y relative to that of K, as same as in FIG. 15A .
[0164] A thin line 1531 represents the landing misalignment amount of C from K with the belt cycle, a thin line 1532 that of M from K with the belt cycle, and a thin line 1533 that of Y from K with the belt cycle.
[0165] A thick line 1541 represents the total of the landing misalignment amount of C from K with the belt cycle and that with the roller cycle, a thick line 1542 that of M from K with the belt cycle and that with the roller cycle, and a thick line 1543 that of Y from K with the belt cycle and that with the roller cycle.
[0166] As described above, a total landing misalignment amount that includes a landing misalignment amount with the roller cycle is shown as the thick lines 1541 , 1542 and 1543 in FIG. 15B . Supposing KC(y) as the thick line 1541 representing the landing alignment amount of C relative to that of K, KM(y) as the thick line 1542 representing the landing alignment amount of M relative to that of K, and KY(y) as the thick line 1543 representing the landing alignment amount of Y relative to that of K, we obtain the waveforms Rkc(y), Rkm(y) and Rky(y) with the cycle of 126 mm such that
Rkc ( y ) = 1 P ∑ i = 0 P - 1 kc ( 126 i + q ) , ( 13 - 1 ) Rkm ( y ) = 1 P ∑ i = 0 P - 1 km ( 126 i + q ) , ( 13 - 2 ) Rky ( y ) = 1 P ∑ i = 0 P - 1 ky ( 126 i + q ) ( 13 - 3 )
where “q” represents the remainder of y/126 and “P” the frequency of 126 mm in the cycle (1275 mm) of the transfer belt cycle. In this case, P=10≈1275/126.
[0167] FIG. 15C shows the landing misalignment amounts with the roller cycle of C, M and Y relative to that of K, each of which is the total landing misalignment amount minus the landing misalignment amount with the roller cycle. A dotted line 1551 represents Rkc(y) obtained from (13-1), a dotted line 1552 Rkm(y) obtained from (13-2), and a dotted line 1553 Rky(y) obtained from (13-3). As the above, when the cycle of a landing misalignment is known, it is possible to extract the landing misalignment amount with the cycle.
[0168] The above (7) to (12-1), (12-2) are for a method to obtain the table of correction values K(y) from arbitrary relative landing misalignment. By applying this method to the dotted lines 1551 - 1553 in FIG. 15C , it is possible to obtain correction values with the roller cycle. The method is explained below.
[0000] [Method to Obtain K from KC]
[0169] Supposing Rkc(y) as KC(y) in (7), we obtain K(y) using (7)-(10). K(y) for y=0-126 mm is the correction values of the roller correction table 212 .
[0000] [Method to Obtain K from KC, KM, KY]
[0170] Supposing Rky(y) as KY(y) in (1), Rkc(y) as KC(y) in (2), and Rkm(y) as KM(y) in (2), we obtain K(y) using (9), (10). K(y) for y=0-126 mm is the correction values of the roller correction table 212 .
[0171] As is clear from the above explanation, according to the present invention, it is possible to eliminate a landing misalignment by correcting a timing of ink-ejection from an ink head depending on a rotational position of a rotational component.
[0172] It should be noted that the above explanation is just done with several examples, so that the technical scope of the invention is not limited by them.
[0173] For example, K(y) is obtained using KC(y) in the first embodiment. However with Fourier transformation, it is possible to obtain respective graphs of K(y) of the three kinds of transfer units in any of the following methods:
[0174] (1) Obtaining K(y) by using each graph of the cycles (64 mm, 1.26 mm, and 1275 mm) which is extracted from KC(y).
[0175] (2) Extracting each cycle (64 mm, 1.26 mm, and 1.275 mm) from K(y) to be obtained. In particular, the methods are as indicated below.
[0176] In the method (1), there are obtained three KC(y)s from one KC(y): the cycle of 64 mm extracted from KC(y), the cycle of 126 mm extracted from KC(y), and the cycle of 1275 mm extracted from KC(y). Then, from the three KC(y)s, there are created three tables of correction values respectively: the correction table K(y) for encoder; the correction table K(y) for roller, and the correction table K(y) for belt.
[0177] In the method (2), there is obtained one K(y) from one KC(y). From the one K(y), there are obtained three K(y)s: “the cycle of 64 mm extracted from the one K(y)”; “the cycle of 126 mm extracted from the one K(y)”; and “the cycle of 1275 mm extracted from the one K(y)”.
[0178] This application is based on the Japanese Patent Applications No. 2006-106252, filed on Apr. 7, 2006, the entire content of which is incorporated by reference herein.
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An image-forming apparatus has: a transfer belt transferring a sheet; an encoder outputting a pulse signal in response to a rotational motion of the transfer belt; a belt reference sensor detecting a belt reference mark provided on the transfer belt; a first accumulator measuring a rotational position of the transfer belt against the reference mark by counting a pulse signal; a storage unit storing a table of printing timing correction values for one rotational cycle of the transfer belt; a second accumulator generating a printing timing signal by shifting a phase of the pulse signal by a printing timing correction value read from the table; and a image-forming unit controlling ink heads to eject inks on the sheet in synchronization with the printing timing signal, wherein an error in transfer amount of the sheet is calculated from a fluctuation in an interval of the inks ejected from the ink heads.
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BACKGROUND OF INVENTION
The present invention relates generally to (but is not limited to) snubbing units that are used to vertically move a tubing string, formed from a series of tubing joints serially interconnected by larger diameter threaded tubing collars, or threaded upset ends, into and out of a pressurized well bore.
The typical snubbing unit used to vertically move a jointed tubing string into and out of a pressurized well bore moves the tubing string through a stationary riser spool on which vertically spaced upper and lower blowout preventers (BOPs) are operatively mounted. As is well known in this art, the BOPs are used to isolate the interior of the riser spool portion above them (normally at ambient pressure) from the much higher well pressure in the riser spool portion below them, while at the same time being openable and closable in “air lock” fashion to permit sequential passage therethrough of a series of tubing joint collars. Each BOP is sized so that in its closed position it forms a sliding pressure seal around the tubing joint being moved therethrough, and in its open position permits passage therethrough of the larger diameter tubing collar.
During lowering of a particular tubing collar toward the upper BOP, the upper BOP is open, and the lower BOP is closed. When the collar enters the intermediate riser spool portion between the upper and lower BOP's, downward tubing string travel is halted and the upper BOP is closed. The interior of the intermediate riser spool portion is then brought to well pressure by opening an equalizing valve to communicate the intermediate riser spool portion with such well pressure. After this pressure equalization is achieved, the lower BOP is opened, and the tubing string is further lowered to move the collar downwardly past the open lower BOP.
The lower BOP is then closed, and the interior of the intermediate riser spool portion is vented to the atmosphere by opening a bleed-off valve operatively connected to the intermediate riser spool portion. The upper BOP is then opened to ready the intermediate riser spool portion for downward receipt of the next tubing collar. A reverse sequence of BOP opening and closing, and pressurization and depressurization of the intermediate riser spool portion interior is, of course, used as the tubing string is being moved upwardly through the riser spool by the snubbing unit.
In the snubbing operation described above, it is important to temporarily terminate vertical tubing string movement after each tubing collar has entered the intermediate riser spool section through the open BOP, and before the collar strikes the closed BOP, to permit the necessary condition reversal of the BOPs and the pressurization or depressurization of the intermediate riser spool portion interior. Failure to temporarily stop each tubing collar at this position, as is well known, can cause severe disruptions of and lengthy delays in the snubbing operation.
For example, during forcible lifting of the tubing string through the riser spool, if a tubing collar is not stopped upon its upward entry into the intermediate riser spool portion it will forcibly strike the underside of the closed upper BOP. The continuing lifting force on the tubing string above the closed upper BOP can easily tear the tubing string apart at the jammed collar, thereby permitting the entire lower portion of the string to fall to the bottom of the well bore and causing a well blowout through the upper BOP. Also, if the tubing is being forcibly lowered through the riser spool, and a tubing collar strikes the closed lower BOP, the portion of the tubing string above the jammed collar can be easily crumpled and wedged within the riser spool.
The requisite precise positioning, and temporary stoppage, of each vertically successive tubing collar within the intermediate riser spool portion has been somewhat difficult to determine for two primary reasons. First, after each tubing collar enters the BOP assembly, it can no longer be seen by the snubbing unit operator. Second, there is often at least a slight variation in the collar-to-collar lengths in the tubing string. This arises from tubing joint length variances. Accordingly, it has been previously necessary for the snubbing unit operator to laboriously keep track of each successive collar-to-collar length in the tubing string to facilitate the essentially “blind” placement and stoppage of each collar within the intermediate riser spool portion. A slight calculation error, or an attention lapse by the snubbing unit operator, can thus easily cause breakage or crumpling of the tubing string
One method of determining the position of a tubing collar or joint within a BOP stack is demonstrated in U.S. Pat. No. 5,014,781 issued to Smith. Referring now to FIG. 1 , a device according to Smith detects the approximate position of a collar 124 within a BOP stack 110 through the use of an upper 152 and a lower 154 electromagnetic coil affixed to the exterior of an intermediate riser spool section 114 .
SUMMARY OF INVENTION
In accordance with an embodiment of the invention, an apparatus is provided in which the presence of an anomaly of a longitudinal tube can be sensed through the use of one or more sensory components. The apparatus includes an external housing, for protection of the sensory components from external conditions. The external housing of this embodiment may also play a role in supporting an internal pressure-containing region.
In accordance with an embodiment of the invention, a method is provided for determining the presence of an anomaly of a longitudinal tube within a longitudinal hollow. Detection of direction of motion may also be determined through the use of directional sensory components or through the use of a plurality of sensory components, mounted within a protective housing.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a prior art sensor device.
FIG. 2 is a side view of an embodiment of the invention.
FIG. 3 a is a frontal view of an embodiment of the invention, showing position of interface.
FIG. 3 b is a frontal view of an embodiment of the invention, with interface removed and internal members visible.
FIG. 4 is a top down view of an embodiment of the invention.
FIG. 5 is a cutaway side view, showing internal members.
FIG. 6 is an embodiment of the invention, showing internal recess.
FIG. 7 is an embodiment of the invention, showing internal recess.
DETAILED DESCRIPTION
Referring to the drawings wherein like reference characters are used for like parts throughout the several views, FIG. 2 shows, in accordance with an embodiment of the present invention, a housing 2 of a pressure containing anomaly detector (“PCAD”). In this embodiment, the housing 2 include a port 4 for communication with sensors or other components (not shown) located within the housing 2 . The housing 2 has one or more fasteners 8 disposed along the top and bottom for attaching the PCAD to adjacent components (not shown), including those commonly used in a BOP stack. These fasteners 8 may be of any form commonly used in the industry, including, but not to, tap end studs, and the housing 2 may be adapted to use various fasteners 8 . Such adaptation may include threaded holes, lips, indentations, threads and any other adaptations necessary to interact with a desired type of fastener 8 . Adjacent components may include, but are not limited to, tubes, pipes and spacers, such as may be used in oilfield applications. Furthermore, in another embodiment, the housing 2 of the PCAD may be integrated into such components so as to form a single unit.
The port 4 of an embodiment of the PCAD housing 2 is visible in FIG. 3 a . One or more sensors or other components (not shown) may be disposed within the port 4 . Placement of components within the port 4 allows easy access for maintenance, upgrades, removal or installation of components. In keeping with such uses, the port 4 may vary in size, shape and structure based on the types of components used, the level of accessibility desired, the need to maintain the integrity of the housing 2 under various internal pressures, and other considerations.
Within the port 4 , may be mounted an interface 20 . This interface 20 permits communication between external components (not shown) of the sensing system, and internal components, such as coils and internal sensors (not shown), as will be discussed in detail. Furthermore, the interface 20 itself may include one or more sensory components. This interface 20 may be inset, so that it does not protrude beyond the housing 2 . Mounting of the interface 20 in such an inset fashion protects it from damage and external elements. Furthermore, if a larger interface 20 is needed, it may protrude beyond the external housing. One or more wires (shown at 6 in FIG. 2 ) may connect to or through the interface 20 .
FIG. 3 b shows a PCAD with the interface 20 removed. One or more seals 26 , if present, are visible through the unobstructed port 4 . One or more holes 24 may be disposed in the one or more seals 26 , for connection of the interface 20 . The seals 26 may comprise magnetic or non-magnetic materials, and may be stacked, as will be described in detail with regard to FIG. 5 .
FIG. 4 is a top-down perspective of an embodiment of a PCAD. In the embodiment of FIG. 4 , the housing 2 is circular in shape; however, other shapes may also be desired and implemented in various embodiments of the invention. An inner passage 12 is located within the housing 2 . Anomalies of a tube (not shown) or other structures passing through this inner passage 12 may be detected by one or more sensory components (not shown) disposed within the PCAD. An isolation sleeve 10 may be disposed between the housing 2 and inner passage 12 . The isolation sleeve 10 shown has a circular cross-section, however, the shape of the sleeve may vary depending on various considerations, such as the shape of the housing 2 . The isolation sleeve 10 may be plastic, or any other suitable material. It may be desirable that the material of the isolation sleeve 10 be non-conductive in order to minimize interference with the detection ability of the PCAD.
Also, disposed between the housing 2 and inner passage 12 and within the inner sleeve 12 if present, will be a pressure containing region (“PCR”) 40 . This PCR 40 may include one or more seals, a longitudinal sleeve, or other elements used in the art for containment of pressure within a defined space. In one or more embodiments, an isolation sleeve 10 is disposed between the PCR 40 and housing 2 . If the PCR 40 comprises a plurality of seals, these seals may be stacked within the housing as demonstrated in FIG. 5 .
In the embodiment of FIG. 5 , a series of stacked seals 26 disposed within the PCR 40 , form a barrier surrounding the inner passage 12 . The interior surface of the seals 26 forms the inner passage 12 , while the exterior surface of the seals 26 may be surrounded by an isolation sleeve 10 . Between each seal 26 and the next, a gasket 50 is disposed to contain the pressure within the inner passage. Gaskets 50 may comprise any material commonly used in the art. In one or more embodiments, the gaskets 50 comprise a metal. The stack of seals 26 may extend beyond the upper and lower ends of the housing 2 . Such a configuration allows the stack to be compressed when the housing 2 is fastened between various other components including BOPs, spools, adapters, tubes, pipes and spacers, such as may be used in oilfield applications.
The seals 26 may be of any magnetic or non-magnetic substance known in the art. In one embodiment, adjacent seals 26 within the stack will alternate between magnetic and non-magnetic composition. Certain of the seals 26 may be adapted to connect to the interface 20 , by means of connecting members 52 . Such adaptation may include holes for attachment by means of bolts, or similar connectors. However, the connecting members 52 may be of any type commonly used in the art. Connecting members 52 may also play a secondary role, such as the conduction of current to and from seals 26 and/or sensors.
Each seal 26 in a stack may be formed of discreet subparts, for instance an inner ring (not shown) proximal the inner passage 12 and an outer ring (not shown). Furthermore, seals 26 or the rings forming the seals 26 may comprise or contain coils or other components of a detection system. For instance, if induction balance technology is used in the sensor system, the outer ring of a seal 26 may comprise a transmitter coil while the inner ring comprises a receiver coil. However, the seals 26 and other components of the PCAD may be adapted for any type of sensor technology known in the art, including, but not limited to, pulse induction and beat-frequency oscillation technologies, as well as non-electrical or non-magnetic systems.
In one embodiment of a PCAD, entry of a tool collar, or other anomaly into the inner passage of the device will be detected by a sensory component nearest the anomaly and a signal will be transmitted to an indicator. As the anomaly nears the sensor, a stronger signal will be transmitted to the indicator. The use of various sensory components and configurations will allow for increased accuracy and directional detection. Such components may be of any type known in the art. Because a PCAD creates a protected environment for the disposition of sensory components, more sensitive components may be used.
In one embodiment of the PCAD, shown in FIG. 6 , a tubular member 60 may be disposed between the inner passage 12 and the housing 2 . In one or more embodiments, the tubular member 60 is non-magnetic. A recess 62 may be formed in the tubular member 60 . A coil (not shown) or other sensory component may be disposed at least partially within this recess 62 . Alternatively, a coil (not shown) or other sensory component may be integrated into the tubular member 60 itself. Interior and exterior walls of the tubular member may be configured in any fashion based on the need to accommodate sensory components, and other considerations, including manufacturing costs. Furthermore, the tubular member 60 may contain spaces or hollows (not shown) in order to accommodate sensory components, or lower manufacturing costs. The tubular member 60 may extend beyond the top or bottom of the housing 2 , in such fashion that it will be compressed by other components (not shown) attached to the housing 2 .
As shown in the embodiment of FIG. 7 , the recess 62 may also be formed in the housing 2 , either alone, or in combination with a recess 62 in the tubular insert ( 60 in FIG. 6 ) or a recess 62 formed in a series of stacked sections 70 . Any number of sections 70 may be used to form the stack. Furthermore, metal gaskets 50 may be disposed between the stacked sections 70 , ensuring the pressure containing integrity of the stack. In one or more embodiments, the sections 70 are non-magnetic, however, sections 70 may comprise any material known in the art. In an alternative embodiment, adjacent sections 70 may have differing compositions. Sections 70 may contain internal spaces or hollows (not shown) in order to lower manufacturing costs, or provide for the disposition of sensory or other components of the PCAD.
Although the invention has been described with reference to oilfield applications, such an apparatus may be used in any field where it is desirable to detect the presence, position, or movement of an anomaly within a longitudinal space. The protective advantages of the housing 2 , and PCR 40 , although useful in oilfield and similar applications where it is necessary to contain pressure within the housing 2 , may be similarly useful in applications where it is necessary to prevent the entry of external materials into a controlled environment existing within the housing 2 .
Advantages of embodiments of the present invention may include one or more of the following. Embodiments of the present invention provide the ability to use more sensitive detection components and protect them from damaging conditions. Embodiments of the present invention provide the ability to operate in a sub-sea or other harsh environments. The sensitivity of anomaly detection can be increased because sensory components may be mounted closer to the path of an anomaly. Ease of repair or replacement is increased for the few elements that are exposed to the environment (e.g., the wires or interface). Embodiments of the invention may also provide a more economical approach to anomaly detection because standard materials may be used in construction of the housing while the more expensive, non-conductive structural compositions can be limited to internal structures.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
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An anomaly detector, used to sense the presence of tool collars, tool joints and other structures within a longitudinal space, that includes a protective housing. Sensory components are disposed within the protective housing and a port is provided for communication between internal and external components of the sensory system. A pressure containing region within the housing prevents the loss of pressure from within the detector, and protects the various components of the system from fluids and other materials constrained within the longitudinal space.
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BACKGROUND
[0001] The concept of a tool holding either a front or back motorcycle wheel immobile while either installing or removing (hereafter simply changing) it is a new concept and doesn't appear to have been attempted in any of the prior art review that has been accomplished. In the observance of the act of changing wheels during a motorcycle race, the mechanic and/or two mechanics race out of the garage or pit area with a wheel and the related spacers to the motorcycle that has been raised either on a rear wheel bike stand or front wheel bike stand or both. Then one mechanic attempts to install the axle through the front forks or back swing arm while holding the spacers in place, while the second mechanic holds the wheel in place with his foot and/or hands which usually results in the failure to align the axle correctly, thereby causing multiple attempts and sometimes ultimate failure to install and/or damage to the wheel. In the home mechanics garage or the professional mechanics shop, the same event occurs, but without the time constraints of changing a wheel during a race. A tool that will allow for much shorter changing procedures both during a race and in a garage or shop situation is needed.
BRIEF SUMMARY
[0002] The Motorcycle Tire/Wheel Changing Tool includes a motorcycle wheel changing tool that engages and immobilizes the front or back wheel along with a front speedometer cable gear unit assembly, disc brake(s) (hereafter simply “wheel”), and spacers or back wheel spacers/disk brake/sprocket (hereafter simply “wheel”) in place on a rolling carriage that can be rolled around a garage, shop, or racing paddock and then be placed at the front or back wheel (in conjunction with any front of back wheel motorcycle lifting stand that is either double or single sided) to allow easy installation of the entire tire/wheel/spacer assembly (hereafter simply “wheel”) with a knockout rod (in place of the actual wheel axle).
[0003] It is the object of this disclosure to provide an easy means of holding a motorcycle wheel in place and immobile whether it be the front or back wheel in the process of changing the wheel.
[0004] It is a further object of this disclosure to provide ease of use for either the home or professional mechanic in the adjustment of this tool so that a motorcycle wheel can be installed in a timely manner and by one individual.
[0005] Additionally, a further object of this design is for the relative ease of construction of the tool. The Motorcycle Tire/Wheel Changing Tool can be disassembled to fit in a compact shipping or mailing container for subsequent assembly of the parts by the end user, whether that is a home mechanic or professional mechanic or a racing team.
[0006] Another object of the design is to have the entire Motorcycle Tire/Wheel Changing Tool have the ability to move as one unit. The handle steel swingarms fold down on the side of the knock-out axle steel swingarms and are held in place by a thumbscrew mechanism on one end that allows the steel swingarms to be held at a desired angle and at the other end by L-shaped brackets that are attached to the side angles to hold both sets of steel swingarms firmly in place. Additionally, there are PTO clips that can be inserted through designated holes in both sets of steel swingarms that keep the steel swingarms in place while moving the unit around the garage, shop, or paddock. These PTO clips are secured by a chain to the side steel angles so that they are attached to the rest of the Motorcycle Tire/Wheel Changing Tool. Additionally, there are spring clips attached to the PTO clips to secure the PTO clips to the side steel angles when the handle and knockout axle steel swingarms are raised and in use. Also, the two knockout axles (small for the front wheel and larger for the back wheel) are attached to the Motorcycle Tire/Wheel Changing Tool by means of metal straps with rubber surrounds that secure the knockout axles in place and allow them to be removed for use with the knockout axle swingarms.
[0007] The initial adjustment of the Motorcycle Tire/Wheel Changing Tool relates to the height of the center of the axle when it is placed on a particular motorcycle stand. An initial measurement of the centerline of the axle to the floor will give the dimension needed to set the tool up to allow the knockout axle rod to be placed in the wheel at the same height. When the tool and wheel are in place, then the actual axle can be inserted on one side of the front forks or rear swingarm and pushed through, ejecting the knockout axle rod while keeping the spacers in position. The tool allows for multiple adjustments to allow for the multitude of tire and wheel sizes that are used on different motorcycles.
[0008] One of the adjustments available is the variable height of the rolling wheels that can be moved up or down by turning the wheel assembly either counter clockwise to lower the tool or clockwise to raise the tool. The wheels then can be locked in place at that particular height with a wing nut and wave lock washer or allowed to swivel while moving the Motorcycle Tire/Wheel Changing Tool around. Another adjustment is to push together or pull apart the right and left steel angle frame of the tool that adjusts to the wheel width and immobilizes the wheel. There is a scale with ½″ increments along the inner edges of the end steel angles that allow for coordination of widths of both ends of the Motorcycle Tire/Wheel Changing Tool. Additionally, there are thumb screws and lock washers that lock the left and right and front and back steel angles in place. An additional adjustment is in relation to the eye hooks that lower clockwise and raise counter clockwise to further adjust the motorcycle wheels at the correct height for the axles. Another adjustment is the knockout steel axle arms that can be raised or lowered on an axis that allows for the different size of wheels and tires. These arms have multiple holes that allow the insertion of the knockout axle at several different heights. These arms are locked in place by thumb screws and lock washers to immobilize the arms and/or handle. Additionally, there is a spring provided that is stored by stretching it across either the left or right side eye hooks. Then when the spring is needed, it holds the two knockout steel axle rod swingarms in place, thereby immobilizing the spacers in place as well.
[0009] The entire assembly can be prepped prior to a race for easy installation of the wheel during a race. The utilization of two of these tools can be utilized for both the front and back wheels per race bike. The same two tools can be set up for the home or professional mechanic per a particular motorcycle. Additionally, axle heights, tire widths, and wheel widths can be recorded per bike with a particular bike stand that allows easy installation of the front or back wheels in a timely manner. An additional advantage is that the Motorcycle Tire/Wheel Changing Tool can be used by one individual rather than the need for at least two to change a wheel.
[0010] In one embodiment, an apparatus for changing a motorcycle wheel includes a carriage including four angles providing support for a motorcycle wheel, the carriage configured to allow expansion and contraction of the base to fit with different sized wheels and tires to be installed on either the front fork or back swingarm of a motorcycle while the motorcycle is supported by a motorcycle lift stand at one end of the motorcycle or both. In one alternative, the apparatus includes a first and second flat swingarm supported by two of the four angles at the right and left sides, the first and second flat swingarm having an outer position and configured to serve a handle, the first and second flat swingarm engaged with the two of the four angles at the right and left sides at a rotating joint allowing the first and second flat swingarms to be rotated 180 degrees, the first and second flat swingarms including slots that allow the handle to be compressed or expanded without any adjustment to the handle, the swingarm handle including thumbscrews for locking the swingarm handle in place. Optionally, the two of the four angles at the right and left sides support third and fourth flat swingarms, the third and fourth flat swingarms attached using a pivot configured to allow the swingarms to be pivoted 180 degrees and hold knockout axle rods that fit through knockout axle rod holes through the third and fourth flat swingarms. The third and fourth flat swingarms are held by a tension spring that is tensioned from the third flat swingarm to the fourth flat swingarm. Alternatively, the third and fourth flat swingarms are configured to be locked in place using thumbscrews. In another alternative, the first, second, third, and fourth swingarms fold down to a parallel position with the four angles. Optionally, the two of the four angles at the right and left sides support four eye-hooks configured to be raised and lowered by turning the eye-hooks clockwise or counter clockwise using sockets, and each eye-hook is secured using a wing nut and wave lock washer. Alternatively, the two side angles support four caged sets of two rollers each that can be raised and lowered using sockets and then locked using wing nuts and wave lock washers at the upper side of the angle. In one alternative, the apparatus further includes PTO clips supported by the two side angles inserted through holes in the two side angles and through the first and second swingarms to secure the swingarms in place, the PTO clips tethered to the two steel side angles using a chain, the PTO clips having a spring clip allowing them to attach to the two side angles when the two sets of swingarms are in use so that they do not interfere with the use of the apparatus. In another alternative, the apparatus further includes metal straps interconnected with the two different length knockout axle rods secured to the metal straps. In one alternative, the apparatus further includes cutout grating supporting the wheel and assisting in setting the wheel when in place in preparation to be changed and protecting threaded rods that span the longitudinal length of the tool.
[0011] In another embodiment, an apparatus for changing a wheel of a motorcycle includes a base; a first and second arm extending from the base, the first and second arm pivotally mounted on the base; a knockout axle inserted through an axle aperture in the wheel, the knockout axle inserted through a first and second aperture in the first and second arms respectively, such that the first and second arms are on either side of the wheel and the wheel is suspended in the air at a height proper for mounting the wheel on the motorcycle; and a retaining spring oriented between the first and second arm, engaging the wheel such that the wheel is held in place. Optionally, the first and second apertures are apertures of a plurality of apertures oriented in the first and second arms, such that the location of the knockout axle is adjustable. Alternatively, the apparatus further includes a replacement axle, the replacement axle sized to fit through the first and second apertures and push the knockout axle out of the first and second apertures when the motorcycle is positioned to receive the wheel and the replacement axle, therefore mounting the wheel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The foregoing objects, advantages, and features, as well as other objects and advantages, will become more apparent with reference to the description and drawings below, in which like numerals represent like elements and in which:
[0013] FIG. 1 is a perspective view of one embodiment of a Motorcycle Tire/Wheel Changing Tool shown from the front right corner showing a motorcycle wheel in place ready for changing;
[0014] FIG. 2 is a perspective view of the Motorcycle Tire/Wheel Changing Tool of FIG. 1 shown from the front left corner showing a motorcycle wheel in place ready for changing;
[0015] FIG. 3 is a perspective view of the Motorcycle Tire/Wheel Changing Tool of FIG. 1 shown from the back right corner showing a motorcycle wheel in place ready for changing;
[0016] FIG. 4 is a plan view of the Motorcycle Tire/Wheel Changing Tool of FIG. 1 shown from above showing a motorcycle wheel in place ready for changing, the arrows designating the horizontal range of adjustment;
[0017] FIG. 5 is a right elevation side view of the Motorcycle Tire/Wheel Changing Tool of FIG. 1 showing a motorcycle wheel in place ready for changing and the arc of the handle and knockout axle rod swingarms, the arrows designating the horizontal range of adjustment;
[0018] FIG. 6 is a plan view of the Motorcycle Tire/Wheel Changing Tool of FIG. 1 shown from below showing a motorcycle wheel in place ready for changing, the arrows designating the horizontal range of adjustment;
[0019] FIG. 7 is a left elevation side view of the Motorcycle Tire/Wheel Changing Tool of FIG. 1 showing a motorcycle wheel in place ready for changing and the arc of the handle and knockout axle rod swingarms, the arrows designating the horizontal range of adjustment;
[0020] FIG. 8 is a back elevation view of the Motorcycle Tire/Wheel Changing Tool of FIG. 1 showing a motorcycle wheel in place ready for changing, the arrows designating the horizontal range of adjustment;
[0021] FIG. 9 is a front elevation view of the Motorcycle Tire/Wheel Changing Tool of FIG. 1 showing a motorcycle wheel in place ready for changing, the arrows designating the horizontal range of adjustment;
[0022] FIG. 10 is a longitudinal section as identified on FIG. 3 showing a motorcycle wheel in place ready for changing; and
[0023] FIG. 11 is a transverse section as identified on FIG. 3 showing a motorcycle wheel in place ready for changing.
DETAILED DESCRIPTION
[0024] Certain terminology is used herein for convenience only and is not to be taken as a limitation on the embodiments of a Motorcycle Tire/Wheel Changing Tool. In the drawings, the same reference letters are employed for designating the same elements throughout the several figures.
[0025] The words “right”, “left”, “front”, and “back” designate directions in the drawings to which reference is made. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the motorcycle tire/wheel changing tool and designated parts thereof. The terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import.
[0026] Like reference numerals designate like or corresponding parts throughout the various views and with particular reference to each of FIGS. 1-11 as delineated below.
[0027] FIGS. 1-3 show one embodiment of a Motorcycle Tire/Wheel Changing Tool and delineate perspective views from several angles that show the two main steel angles 1 and 2 running longitudinally and the two identical end steel angles 3 running at 90 degrees to the main steel angles. Steel angles 1 and 2 are not interchangeable, since there is a pivot at the back end that allows the two sets of steel swingarms 9 and 12 to pivot on that point. The end steel angles 3 are interchangeable. The side steel angles 1 and 2 have one flat side horizontal and the other side vertical at the perimeter of the Motorcycle Tire/Wheel Changing Tool. The vertical portion of the steel side angles 1 and 2 hold the pivots for the two steel swing arms 9 and 12 , as well as a place to insert the PTO clips that secure the steel swingarms 9 and 12 while transporting the tool or when the steel swingarms 9 and 12 are raised and in use to install a wheel. The horizontal portion of the steel side angles provides for the thumb screws located at the four corners of the tool that allow the steel side 1 and 2 angles and the end 3 steel angles to be locked in place to secure the wheel in place, hold the carriage wheels 5 to allow the motorcycle wheels to be raised or lowered in the tool to allow for different sizes of motorcycle wheels, hold the eye bolts 6 to be raised or lowered to adjust for the different wheel sizes, the steel angles 8 at one end of the tool that hold the steel swingarms 9 and 12 in place and in line with the steel side angles 1 and 2 , and the chain 20 to be held at one end of the chain by the nuts and bolts 21 to secure the chain to the tool undercarriage.
[0028] The steel end angles 3 hold the threaded steel rods in place that ensures the tool is square. The threaded rods 4 are installed through threaded, imbedded, and compressed (hereafter TICS) aluminum sockets. The threaded rods 4 are covered with four rubber end pieces to ensure that the threads are not damaged and that they do no damage to the motorcycle. The horizontal portion of the steel end angles 3 are positioned under the two steel side angles 1 and 2 , and the vertical portion of the steel end angles 3 are the portion where the threaded rods 4 are threaded through the TICS and are secured with nuts and lock washers. The vertical portions of the steel end angles 3 hold metal straps with a rubber covering 7 that secure the two knockout axle rod sizes at each end of the Motorcycle Tire/Wheel Changing Tool.
[0029] The steel side angles 1 and 2 hold the long thumb screws 10 that secure the steel side angles 1 and 2 in place. The long thumb screws 10 are threaded through TICS and locked in place under the end angles 3 with wing nuts and lock washers. The TICS extend though the steel side angles 1 and 2 and the end angles 3 to act as guides to allow the steel side angles 1 and 2 to slide over the steel end angles 3 to expand and contract the tool. Washers are placed under the steel end angles 3 that secure the TICS from jumping out of the slots that run from each side of the steel end angles 3 towards the center of the steel end angles 3 . The second washer at each location provides a surface for the lock washer to rest and be secured by the wing nut. Additionally, there is a smooth surface at the horizontal portion on the inner and upper side of the end angles 3 that has ½″ increments to allow the accurate movement and securement of the steel side angles 1 and 2 to the end angles 3 . On the under side of the horizontal portion, the surface is knurled to provide friction that will secure all the steel angles 1 , 2 , and 3 in place while installing the motorcycle wheel.
[0030] Spanning between the steel end angles 3 is a slightly curved expanded steel grating 15 with diamond-shaped openings that are secured by the steel end angles 3 with bolts, nuts, washers, and lock washers 16 , as well as rubber covers over the ends of the bolts to protect the tire from damage. The expanded steel grating 15 holds the wheel in place and additionally protects the threaded rods 4 below it and provides additional stability to a Motorcycle Tire/Wheel Changing Tool.
[0031] The flat steel swingarms 12 that are placed outside the knockout axle rod flat steel swingarms 9 act as the fold away handle and utilize a rubber coated end handle 13 that slides inside slots that are in the end flat steel L-shaped that is bent at right angles to the flat steel swingarms 12 portion that is secured by the short thumb screws at the back end of the side steel angles 1 and 2 . This allows the end handle 13 to slide when the tool either expands or contracts to allow for different size wheel widths. Additionally, there is a small C-shaped clip 17 that allows the handle portions of the flat steel swingarms to slide together in line to keep the handle 13 at a right angle to the end flat steel 12 . Note that the flat end steel 12 will also bend back towards the center of the tool, allowing the end handle 13 to be more compact and rest between the two steel side angles 1 and 2 .
[0032] When fully expanded, the steel side angles 1 and 2 are approximately 8″ from the outside of the vertical portion of the angles. When fully compressed towards the center of the tool, the side angles are approximately 4.75″ from the outside of the vertical position of the angles. The variability of the width of the Motorcycle Tire/Wheel Changing Tool allows the installation of wider back wheels and narrower front wheels by the same tool. The total length of the Motorcycle Tire/Wheel Changing Tool is less than 21″ from the outside of the threaded rods 4 and less than 18.5″ from the outside of the steel end angles 3 to create a compact motorcycle wheel changing tool.
[0033] The four large eye hooks 6 that are placed within and on top of the horizontal portion of the two steel side angles 1 and 2 are able to be moved up or down through the TICS that secures them to the side angles 1 and 2 . Large wing-nuts, washers, and wave lock nuts below the horizontal portion of the side angles 1 and 2 allow the large eye hooks 6 to be locked in place at the desired and required height to install the axle in the front or back wheel.
[0034] The two flat steel swingarm combinations 9 and 12 rest flat along side the steel side angles 1 and 2 and are held in place by a thumb screw with TICS that is secured by two washers and a wave lock washer between them on each side of the tool. This allows the two flat steel swingarm combinations 9 and 12 to swing through an arc of +180 degrees. At the other end of the tool, the two flat steel swingarm combinations 9 and 12 rest on angles 8 that are secured with bolts, nuts, washers, and lock washers to the steel side angles 1 and 2 .
[0035] The inner flat steel swingarms 9 swing through the arc to align one of the twelve holes on either side with the wheel axle hole and to allow the knockout axle rod to be placed through the steel swing arm 9 holes through the wheel. After the insertion of the knockout axle rod through both sides of the steel swingarms 9 holes and the wheel, a spring 11 is attached to both of the steel swingarms through one hole on each side of the tool to secure the wheel in place on the tool to enable wheel installation. When the spring 11 is not in use, it will be stored stretching between two of the eye hooks 6 that are on one side or the other of the tool.
[0036] The PTO clips 18 that can be utilized at the opposite end of the swing arms 9 and 12 are placed through the third holes from the front end of the tool through the steel swingarms 9 and 12 , as well as steel side angles 1 and 2 . This aligns the PTO clips 18 through the open center of the wing nuts that secure the front Motorcycle Tire/Wheel Changing Tool wheels 5 in place when the tool is transported. Additionally, when the steel swingarms 9 are released to secure the wheel 22 in place, the PTO clips are removed, but stay with the tool by means of chains that are held at one end by a bolt and nut combination 21 and can be hooked to the steel side angles 1 and 2 by means of spring clips 19 through one of the holes in the steel side angles 1 and 2 . Thus, all parts of the tool are attached to and with the Motorcycle Tire/Wheel Changing Tool at all times, avoiding the loss of parts.
[0037] Exemplary listings of parts that may be used in the construction of the Motorcycle Tire/Wheel Changing Tool are listed below:
1. 1.25″×1.25″ 12 Gauge Steel Angle—Right Side with 0.375″ø Holes @ 1″ On Center; 2. 1.25″×1.25″ 12 Gauge Steel Angle—Left Side with 0.375″ø Holes @ 1″ On Center; 3. 1.25″×1.25″ 12 Gauge Steel Angle With 0.375″ø Holes @ 1″ On Center 2 2.5″ Long×0.5625″ Wide Slot With Rounded Ends @ Each End—Front and Back; 4. 0.375″ø×22.5″ Long Threaded Rod With 0.375″ø I.D. Aluminum Threaded, Imbedded, and Compressed Socket, 0.375″ø Regular Lock Washer, 0.375″ Nut and, 0.375″ Rubber End Cover; 5. 0.875″ø×1.5″ Long Nylon Roller Wheels With Rivets, 0.3125″ø×1″ Long Threaded Post, 0.3125″ø I.D. Aluminum Threaded, Imbedded, and Compressed Socket, 0.375″ø I.D./0.875″ø O.D. Washer, 0.375″ø I.D./0.625″ø O.D. Wave Washer, and 0.3125″ø Wing Nut; 6. 0.375″ø×4″ With 2″ Threaded Eye Hook With 0.375″ø I.D. Threaded, Imbedded, and Compressed Socket, 0.4375″ø I.D./0.875″o O.D. Wave Locknut, 0.4375″ø I.D./⅞″ø O.D. Washer and 0.375 Wingnut; 7. #10×0.75″ Long Panhead Bolt With Locknut, 0.25″ Steel Spacer and x″ø Aluminum C Clamp With Rubber Encasement To Hold 0.5″ø×6.5″ Long Front Axle Rod At One End and 0.5″×8.5″ Long Back Axle Rod Knockout At One End; 8. 1.5″×1.5″×0.5″ Wide Angle With 2.125″ø Holes Per Angle Side With #10×0.5″ Long Panhead Bolts With 0.1875″ø I.D./1″ø O.D. Washer, and 0.1875″ø I.D. Lock Washer and Nut; 9. 18″ Long×1.125″ Wide 12 Gauge Flat Steel With 11.125″ø Holes and 12×0.5625″ø Holes with 1″ Long×0.3125″ o Thumb Screw With 0.3125″ o Aluminum Threaded, Embedded, and Compressed Sockets With 0.125″ø I.D./2.825″ o O.D. Washers, and 0.3125″ø I.D. Regular Lock Washer; 10. 0.3125″ø×2.5″ Long Thumb Screw With 0.3125″ o Aluminum Threaded, Embedded, Compressed Insert With Longer Compression Extended Into Slot With 0.5625″ø I.D./1.025″ o O.D. Retaining Washer, 0.125″ø I.D./0.825″ o O.D. Washer and 0.375″ø I.D./0.625″ o O.D. Wave Lock Washer and 0.3125″ o Wing Nut; 11. 0.75″ø×8.5″ Extended and 3.5″ Un-extended Length Retaining Spring; 12. 1.125″×18″ 12 Gauge Flat Steel With 0.275″ø Holes @ 1″ O.C. With #10×0.375″ Long Bolt With 0.625″ø O.D. Washer, Lock Washer, and Bolt To 1.125″×5″×5.5″ 12 Gauge Angle With ×0.5625″ Wide×4.25″ Long Slot For ½″ø×6.25″ Long×3.75″ Wide Hitch Pin Rubber Coated Handle With ×0.5625″ø I.D.×2 1.125″ O.D./1.125″ø O.D. Heavy Duty Washers With Heavy Duty Cotter Pin; 13. #10×0.125″ Long Bolt With 0.625″ø O.D. Washer, Lock Washer, and Bolt; 14. 6″ Scale With 0.5″ Divisions To Allow Accurate Adjustment Of Tool To Hold Tire/Wheel; 15. 2.5″×18″×0.25″ Curve Expanded Steel Grating With Diamond 0.5″ Openings; 16. #8×1″ With 4.625″ O.D. Washers, 2.125″ O.D. Washer, Nut, and Lock Washer; 17. 0.25″ Wide×1″ Long C-Shaped Clip With #8×,5″ Bolt With 2.125″ Washers, Bolt, and Locknut; 18. PTO Pin—2″×2″; 19. 0.25″ Spring Link; 20. 1/16″×0.125″×0.625″×6″ Chain Link; 21. #8×0.75″ Bolt With 0.15625″×0.875″ Washer With, 0.25″ Rubber Grommet and Lock Washer With 0.125″ O.D. Washer; and 22. Motorcycle Tire/Wheel—Not Part Of Tool.
[0060] While specific embodiments have been described in detail in the foregoing detailed description and illustrated in the accompanying drawings, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure and the broad inventive concepts thereof. It is understood, therefore, that the scope of this disclosure is not limited to the particular examples and implementations disclosed herein, but is intended to cover modifications within the spirit and scope thereof as defined by the appended claims and any and all equivalents thereof.
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A motorcycle wheel changing tool is presented that utilizes a rolling carriage that immobilizes the front or back wheel utilizing flat steel swing arms and a tension spring that holds the wheel in place with a knockout retaining rod through the wheel. The entire unit can be rolled and/or lifted in place to work in conjunction with a motorcycle stand. There is a folding handle that expands or contracts to accommodate different size tire/wheel widths and can pull the unit. The rolling wheels can be raised or lowered for different motorcycles depending on the height of the bike in relation to the wheel stand. Additionally, four large eye hooks can be raised or lowered to secure the wheel. Two threaded rods are utilized that secure both angle ends in place to secure the unit so that it is perpendicular to the wheel and keeps the unit from flexing.
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Application Ser. No. 12/017,425 is a reissue of application Ser. No. 10/236,766, which has a U.S. Pat. No. 7,066,856.
FIELD OF THE INVENTION
The present invention relates to a protector for chain rings on bicycles and the like. In particular, it includes a mounting bracket operably secured to the bottom bracket sleeve with a durable guard extending therefrom and detachably secured thereto.
BACKGROUND OF THE INVENTION
Wheeled vehicles and especially in-line, two-wheeled vehicles such as bicycles, motorcycles, scooters, and the like, are popular forms of transportation, exercise, and sport. More recently, such vehicles are being used in particularly rugged environments including operating over unimproved roads and rough terrain, and for stunt riding over stairs and the like. For example, a form of bicycle commonly known as a mountain bike is specifically intended for off-road operation.
Most two-wheeled vehicles are propelled by a chain operably extending between two or more sprockets. One sprocket, commonly known as a chain ring, is driven by a power source such as a crank and pedal assembly. In bicycles, the chain ring is operably secured to a lower hub of the bicycle's frame which is commonly known as the lower bracket sleeve. The crank and pedal assembly usually have an axis of rotation centered along a centerline extending through the lower bracket sleeve.
Chain rings are usually planar disks with teeth along their outer diameter for engaging the chain. In order for the chain ring to operate effectively, it must remain substantially planar and the teeth must remain intact during operation of the vehicle. However, portions of most chain rings remain exposed and extend below the bicycle frame. Accordingly, chain rings are susceptible to bending and damage caused by inadvertent impact with objects.
This susceptibility is increased with off-road and stunt riding of the vehicle. For example, a rider of a mountain bicycle may frequently attempt to jump small objects such as rocks and fallen trees. If the rider executes a jump and in the process lands the bicycle such that a large rock straddles the front and rear wheels, the chain ring can impact the rock causing damage to the chain ring.
Attempts to protect the chain ring from inadvertent impacts have had limited success. For example, U.S. Pat. No. 5,320,583 to van Wingen born Looyen teaches securing a circular disk to the exterior planar surface of a chain ring such that the circular disk and chain ring are substantially parallel to each other and rotatable on the same axis or rotation. As a rider pedals, the chain ring and circular disk rotate about the axis of rotation. The circular disk contacts some objects approaching the chain ring first, thereby protecting the chain ring to a certain degree. However, since the circular disk is directly connected to the chain ring and drive shaft, any bending or damage of the circular disk caused by the impact will likely also bend the attached chain ring or drive shaft. Moreover, such circular disks offer negligible protection from impacts to the chain ring arising from contact with objects positioned toward the inside surface of the chain ring.
Inventors have also attempted to extend a chain ring protector directly from the bicycle's frame. For example, U.S. Pat. No. 5,067,930 to Morales teaches extending a trough-type protector from forward and aft struts mounted to the frame. The curved trough-type protector extends below the chain ring, thereby protecting it from inadvertent impact. A first clamp for securing the forward strut is positioned on a rail of the frame extending forward from the mounting bracket sleeve. A second clamp for securing the aft strut is positioned on rear wheel forks extending rearward from the mounting bracket sleeve. In an effort to allow the through-type protector to accommodate different bicycle designs, a swivel is provided between the first clamp and front strut.
Despite the benefits of the Morales design, it has several drawbacks. For example, a large amount of hardware, such as the first and second clamps, pivot structure, and struts, is required to support the protector, thereby increasing the expense of the structure and time required to mount and align it properly. Similarly, not all bicycles have the frame structure stemming from the mounting bracket sleeve as shown in Morales. Accordingly, the first and second clamps and orientation taught in Morales may not be operable when attempting to install the Morales protector on these different frame structures.
In addition, the length of the struts determines the size of the chain ring that may be used with it. Despite the limited adjustability provided by the swivel, if the struts are too short, a trough-type protector will not extend below the chain ring. Also, if the struts are too long, the trough-type protector can interfere with operation of the bicycle. In addition, under some impacts on the trough-type protector, the swivel structure can actually allow the trough-type protector to deflect into to the chain ring, thereby damaging it, or at least forcing the rider to stop to realign the protector.
SUMMARY OF THE INVENTION
Accordingly, despite the benefits of the known chain ring protectors, there remains a need for a simple, cost effective, easy to install and adjust, chain ring protector that can be operably secured to a large number of vehicles independent of a particular frame design, and that can effectively protect any sized chain ring operably installed on a vehicle without interfering with operation of the vehicle. In addition to other benefits that will become apparent in the following disclosure, the present invention fulfills these needs.
The present invention is a substantially planar mounting bracket operably secured to the bottom bracket sleeve of a vehicle with a durable guard extending therefrom. The durable guard has a substantially arcuate outer edge sized to approximate the outer diameter of a chain ring, and it is operably secured to the planar mounting bracket such that the outer edge extends slightly beyond the outer diameter of the chain ring in which it is protecting.
Preferably, the durable guard is detachably secured to the mounting bracket, and the mounting bracket includes a plurality of mounting portions thereon, thereby allowing a large variety of possible mounting configurations for the durable guard. More preferably, the guard includes parallelly aligned slots extending therethrough for operably engaging the mounting portions, thereby allowing the outer edge of the durable guard to be adjusted simply by sliding the durable guard along the slots toward or away from the bottom bracket sleeve.
Since the durable guard is detachably secured to the mounting bracket, the durable guard may be replaced easily if it becomes damaged or worn, or if a different sized durable guard is desired.
In an alternative embodiment, a second chain ring protector can be installed on the opposite side of the bottom bracket sleeve, and the two chain ring protectors can be operably secured together with a stabilizing bracket extending therebetween.
Additional objects and advantages of the present invention will be apparent from the detailed description of the preferred embodiment thereof, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric front, right view of a bicycle having a chain ring protector installed thereon in accordance with an embodiment of the present invention.
FIG. 2 is an enlarged, fragmentary, exploded, isometric view of the chain ring protector shown in FIG. 1 .
FIG. 3 is a sectional view taken along line 3 - 3 of FIG. 1 .
FIG. 4 is a side view of the chain ring protector showing a possible orientation with respect to a chain ring.
FIG. 5A is a first sectional view of an alternative configuration showing a possible use of two chain ring protectors in accordance with an alternative embodiment of the present invention.
FIG. 5B is a second sectional view of the alternative configuration of FIG. 5A .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A simple, cost effective, easy to install and adjust, chain ring protector 10 operably secured to the lower bracket sleeve 12 of a vehicle, such as a bicycle 14 , is shown in FIGS. 1-5B .
Referring to FIG. 1 , the bicycle 14 includes a frame 16 having a front wheel 18 , back wheel 20 , handle bars 22 , seat 24 , and the lower bracket sleeve 12 operably secured thereto. Preferably, the lower bracket sleeve 12 is reverse threaded to accept the threads of a conventional lower bracket spindle 26 ( FIG. 2 ) therethrough. The lower bracket spindle 26 is a common, commercially available product, and includes a shaft 28 operably received within a housing 30 . The shaft 28 rotates about a longitudinal centerline 32 . Usually, bearings (not shown) are sealed within the housing 30 to facilitate rotation of the shaft 28 .
Preferably, the housing 30 includes the reverse threads 34 toward one end 36 with a lip 38 adjacent to those threads 34 . More preferably, the housing 30 also includes a recess 40 and spaced-apart notches 42 to allow a mating wrench portion (not shown) to be detachably secured thereto. According, the mating wrench portion may be used to tighten and loosen the lower bracket spindle 26 to the lower bracket sleeve 12 .
Left and right cranks 44 , 46 , respectively, are operably secured to the ends 48 a, 48 b of the lower bracket spindle shaft 28 with a pivoting pedal 50 secured at the opposite ends of each crank 44 , 46 . At least one sprocket having teeth 52 extending radially therefrom is secured to the lower bracket spindle and positioned on one side of the lower bracket sleeve 12 . This sprocket is also commonly known as a chain ring 54 . Usually, the chain ring 54 is also secured to one of the cranks 44 , 46 .
A continuous loop chain (not shown) encircles the chain ring 54 and operably engages the teeth 52 of the chain ring 54 . The chain also engages a second sprocket (not shown) operably secured to one of the front and rear wheels of the bicycle 14 . Accordingly, when an operator pedals the bicycle by alternatingly urging the left and right cranks 44 , 46 , respectively, to spin the shaft 28 , the chain ring 54 urges the chain to spin one of the wheels of the bicycle.
As best shown in FIGS. 2 and 3 , the chain ring protector 10 is operably secured to the lower bracket sleeve 12 . For example, the chain ring protector 10 can include a substantially planar mounting bracket 60 with an impact resistant and durable guard 62 extending therefrom. The mounting bracket 60 includes a central bracket mounting hole 64 for receiving the lower bracket spindle 26 therethrough. It can be appreciated that by tightening the lower bracket spindle 26 on the threads of the lower bracket sleeve 12 , the mounting bracket 60 operates much like a conventional washer and is thereby secured in place when the lip 38 of the lower bracket spindle housing 30 tightens against the mounting bracket 60 .
The mounting bracket 60 includes a plurality of guard mounting holes 70 a-i thereon. Preferably, the mounting bracket 60 has two arms 72 , 74 extending from the central bracket mounting hole 64 and a substantially circular outer edge 76 extending from the central bracket mounting hole 64 opposite the arms 72 , 74 as best shown in FIG. 2 . Each of the arms 72 , 74 has a guard mounting hole 70 a, 70 b, respectively, thereon. Also, a plurality of guard mounting holes 70 c-i are aligned along the circular outer edge 76 .
The guard 62 has a substantially planar mounting portion 80 with an opening 82 to prevent it from interfering with the lower bracket spindle 26 . A substantially arcuate outer edge 84 extends radially from the opening 82 as best shown in FIG. 2 . The mounting portion 80 includes a plurality of mounting slots 86 a-c, which are preferably parallelly aligned and spaced-apart from each other. Each slot 86 a-c is positioned to align with one guard mounting hole 70 a-c on the mounting bracket 60 . For example, slot 86 a aligns with mounting hole 70 a, slot 86 b aligns with mounting hole 70 b, and slot 86 c aligns with mounting hole 70 c.
Connectors 90 extend through each aligned mounting hole and slot combination. Preferably, each connector includes a screw 92 being operably received into an internally threaded shaft 94 with a resilient washer 96 operably engaging the guard 62 and a lock washer 98 holding the screw 92 in place. More preferably, the internally threaded shaft 94 has a tapered head 100 and is recessed within the guard mounting hole ( 70 a shown in FIG. 2 ) when the screw 92 is tightened.
Preferably, the mounting slots 86 a-c are aligned to allow the substantially arcuate outer edge 84 to move toward or away from the lower bracket spindle 26 when the guard 62 is mounted to the mounting bracket 60 . As shown in FIG. 4 , the mounting slots 86 a-c allow the position of the arcuate outer edge 84 of the guard 62 to extend past the outer radius 102 of the chain ring 54 . Moreover, the mounting slots 86 a-c allow the guard 62 to be individually adjusted for any particular chain ring 54 size, without necessarily requiring different guards 62 to protect different sized chain rings 54 .
The guard 62 and mounting bracket 60 are constructed of durable, impact resistant materials. One known preferred guard material is Ultra-High Molecular Weight polyethylene or plastic, which is commonly known in the materials industry as “UHMW.” One known acceptable mounting bracket material is aluminum, and more preferably a type of aluminum known as “6061 Aluminum.”
As shown in FIG. 3 , the chain ring protector 10 of the present invention can be used concurrently with a conventional chain ring-mounted protector 106 . In such case, the chain ring protector 10 remains fixed to the lower bracket sleeve 12 to protect the chain ring 54 from impacts arising from contact with objects positioned toward the inside surface of the chain ring 54 .
It can be appreciated that a plurality of chain rings 54 a-c ( FIG. 3 ) can be positioned on the lower bracket spindle shaft 28 . In such case, the guard 62 is preferably positioned to extend beyond the outer radius 102 of the largest chain ring 54 c ( FIG. 3 ) on the shaft 28 as shown in FIG. 3 .
Referring to FIG. 2 , if desired, an anti-rotation mount 110 can be secured to the guard mounting holes 70 d-i on the mounting bracket 60 . The anti-rotation mount 110 extends from the mounting bracket 60 toward the frame 16 and is preferably wedged adjacent to one or two frame members 112 extending from the lower bracket sleeve 12 . Preferably, the anti-rotation mount 110 includes a notched recess 114 sized to operably engage the frame members 112 . The large number of guard mounting holes 70 c-i along the substantially circular outer edge 76 allow the anti-rotation mount 110 to be effectively installed on a wide variety of frame styles and sizes. An installer mounts the anti-rotation mount 110 with bolts 111 extending through one or more of the mounting holes 70 c-i on the mounting bracket 60 . The installer simply selects the particular mounting holes 70 c-i ( FIG. 2 shows mounting holes 70 f and 70 g being used) that best fit that particular frame.
When the chain ring protector 10 is installed on the bicycle 14 , the chain ring 54 is protected from inadvertent impacts with an object 11 . The mounting bracket also assists with preventing the chain from inadvertently falling off the chain ring. Moreover, the chain ring protector 10 is operably secured directly to the lower bracket sleeve 12 , one of the strongest elements of the frame 16 . In addition, no portion of the chain ring protector 10 contacts or otherwise engages the chain ring 54 so it will not likely also damage the chain ring 54 in the process of protecting it. Accordingly, should the chain ring protector 10 become damaged during use, it can be easily replaced without removing the mounting bracket 60 from the lower bracket sleeve 12 . Since the chain ring protector is secured primarily in place on the lower bracket sleeve using a conventional lower bracket spindle, which is already needed to enable operation of the bicycle, the need for additional mounting hardware beyond the mounting bracket is greatly reduced over the structure disclosed in U.S. Pat. No. 5,067,930 to Morales.
In view of the wide variety of embodiments to which the principles of the invention can be applied, it should be apparent that the detailed embodiments are illustrative only and should not be taken as limiting the scope of the invention. For example, and as best shown in FIGS. 5A & 5B , two chain rings protectors 10 , 10 ′ can be installed on a lower bracket sleeve 12 . One chain ring protector 10 is positioned between the lower bracket sleeve 12 and chain ring 54 as previously described. The other chain ring protector 10 ′ is operably secured to the opposite end of the lower bracket sleeve 12 as shown. Preferably, the opposite end of the lower bracket sleeve 12 includes a threaded portion 120 with a mating threaded mount (not shown) having a lip (not shown) for engaging the mounting bracket 60 of the second chain ring protector 10 ′. If desired and as shown in FIG. 5B , the anti-rotation mount 110 can extend between the two mounting brackets, thereby securing them in place on the bicycle 14 .
Accordingly, the claimed invention includes all such modifications as may come within the scope of the following claims and equivalents thereto.
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A chain ring protector having a substantially planar mounting bracket operably secured to the bottom bracket sleeve of a vehicle with a durable semi-circumferential guard extending therefrom is disclosed. The durable guard has a substantially arcuate outer edge sized to approximate the outer diameter of a chain ring, and it is operably secured to the planar mounting bracket such that the outer edge extends slightly beyond the outer diameter of the portion of the chain ring extending below the bottom bracket sleeve.
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The present invention relates to processing image data, wherein displayed picture points are relocatable in response to manual operation of an interface device.
INTRODUCTION
Systems for processing image data in response to manual operation of a control device are known, in which image data is stored as an array of pixel values. Each pixel value may represent a luminance level or, in a full color system, pixel values may be stored for color components such as additive red, green, blue components, subtractive cyan, magenta, yellow and black components or, particularly in video systems, luminance plus chrominance color difference components.
In addition to application in television post production facilities, systems of this type are being used increasingly for the production of cinematographic film, where the information content for each frame of film is substantially higher. Film clips are scanned on a frame-by-frame basis producing large volumes of image data for subsequent manipulation. Pixel data may be processed under program control to produce visual effects and a system of this type is produced by the present applicant and distributed under the trade mark "FLAME". Thus, in addition to manipulating images as part of a post production process, it may become necessary to make manual modifications to image data, possibly to remove unwanted items from an image or to change or add color etc.
Traditionally, in order to make manual operations, each frame must be examined to allow manual modifications to be made to the image data on a frame-by-frame basis. This takes a considerable amount of time and limits the extent to which techniques of this type may be implemented for particular productions.
In particular, in a function known as "warping", a grid or mesh is superimposed over an area of an image on a display device, and selected points of that mesh are translated, rotated, or reduced in size, with the effect that the whole mesh is correspondingly translated, rotated or reduced.
During warping operations, control points on an image frame are moved on a frame by frame basis. Since an image contains a large number of pixels, it is not feasible to manually move each pixel on a frame by frame basis. In these situations, processes are applied by which a region of an image can be warped by identifying a few control points, typically at the periphery of a desired image portion, in order to define a mesh covering the image portion. A warp function is applied to the mesh which moves the remaining pixel portion of the image in accordance with movements of the mesh. However, such warping techniques, although allowing a warp to be carried out in a relatively short time, introduce distortions particularly at the edges of the warped image portion. Such edges need to be "smoothed out" to reduce the visual distortions and visible discontinuities on the resultant warped image.
Presently, it is known to make manual operations to each frame for smoothing out the edges of a warped region. However, each frame requires much work and, as an example, to produce five seconds of warped film footage having discontinuities smoothed out, can take up to three weeks of work. Film Directors are therefore reluctant to make heavy use of warping techniques due to the high cost of post production procedures involved.
SUMMARY OF THE INVENTION
According to the first aspect of the present invention there is provided a method of processing image data, wherein displayed picture points are relocatable in response to manual operation of an interface device, comprising steps of moving an identified picture point in response to said manual operation; and moving other picture point data by a displacement which differs from the displacement of said identified pictured point and which varies in proportion to distance from the identified picture point.
Preferably, the identified picture point is identified by a displayed cursor and said cursor may be moved in response to movement of a stylus or a mouse.
In a preferred embodiment, a picture point is identified as a transition between image colours.
According to a second aspect of the invention, there is provided an image data processing apparatus, including display means for displaying picture images in the form of a plurality of picture points; a manually operable interface device; and processing means configured to relocate the position of said picture point in response to manual operation of said interface device, wherein said processing device is configured such that the movement of a first picture point in response to operation of said manual device results in the movement of other picture point data by displacements which differ from the displacement of an identified picture point and which vary in proportion to distance from said identified picture point.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows in general view an editing suite for editing film clips, video images or computer generated images;
FIG. 2 shows a general layout comprising the editing suite of FIG. 1;
FIG. 3 shows a display device comprising the editing suite of FIG. 1;
FIG. 4 shows a control panel feature of the display device of FIG. 3;
FIG. 5 shows an Ith image frame displayed on the display device, in which a group of vertices are translated as a whole from a first position to a second position;
FIG. 6 shows the vertices of FIG. 5 in the second position;
FIG. 7 illustrates a method of moving the group of vertices individually one by one, between an initial position and positions intermediate between an initial position and a final position, in order to perform a "smoothing" operation;
FIG. 8 shows the resultant smoothed image of FIG. 7;
FIG. 9 shows the image of FIG. 7 in a successive I+20th frame;
FIG. 10 shows the I+20th frame after having a smoothing operation as carried out in FIGS. 7 and 8;
FIG. 11 shows a successive I+Nth frame;
FIG. 12 shows the I+Nth frame after the individual smoothing operation;
FIG. 13 shows schematically a method of smoothing a group of vertices in accordance with a preferred method of the present invention;
FIG. 14 shows the group of vertices in smoothed form;
FIG. 15 shows the image of FIG. 13, in and I+20th frame;
FIG. 16 shows the smoothed image of FIG. 15 in the I+20th frame;
FIG. 17 shows a portion of the image in an I+Nth frame;
FIG. 18 shows the smoothed image in the I+Nth frame;
FIG. 19 illustrates a proportionality distribution function according to a preferred method of the present invention;
FIG. 20 shows a second proportionality distribution function;
FIG. 21 illustrates smoothing of an edge feature in accordance with the preferred method of the present invention;
FIG. 22 shows a third proportionality distribution function as may be applied in FIG. 21;
FIG. 23 shows a fourth proportionality distribution function as may be applied in FIG. 21;
FIGS. 24 shows a second example of smoothing in accordance with the preferred methods of the present invention;
FIG. 25 illustrates a further proportionality distribution function as applied in the smoothing of FIG. 24.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 of the accompanying drawings, a film, video or computer generated image editing suite comprises an image display device 103 e.g. a high resolution video monitor; a control key pad 106; and a graphics tablet 103 and stylus 104 for applying modifications to the displayed image.
FIG. 2 shows in schematic form features comprising the image processing apparatus. There is provided a central processing unit 201, a random access memory 202, a graphics hardware device 203, a hard disk storage unit 204, and a graphics interface 205.
In the example of the preferred embodiment a post production process will be considered in which source material, in the form of a film clip, has been recorded and is being processed prior to a final on-line editing operation being performed.
A post production facility is illustrated in FIG. 1, in which a video artist 101 is seated at a processing station 102. Images are displayed to the artist via a visual display unit 103 and manual modifications to displayed images are effected in response to manual operation of a stylus 104 upon a graphics touch tablet 105. In addition, a conventional keyboard 106 is provided to allow alpha-numeric values to be entered directly. The monitor 103, tablet 105 and keyboard 106 are interfaced to an image processor 107, which may be based substantially upon a graphics workstation executing the UNIX operating system.
Image data is supplied to the image processor 107 via a digital video tape recorder 108, which may be configured to supply full bandwidth broadcast quality video data to the image processor at video rate. Alternatively, general purpose data storage tape drives may be used and image frames substantially larger than video frames, such as image frames derived from cinematographic film, may be received and processed within the system.
Image processor 107 is detailed in FIG. 2. The processor includes a central processing unit 201, arranged to receive program instructions from an addressable random access memory 202. The processing unit 201 may also access a hardware graphics card 203, provided as part of the UNIX environment, allowing computationally extensive operations to be effected at very high speed.
Image data is held within the random access memory 202 as modifications are taking place and large data volumes are held on a disk store 204, preferably taking the form of an array of concurrently accessible disks. The processing unit 201 communicates with the display unit 103, the graphics tablet 105, the keyboard 106 and the video recorder 108 via interface circuits 205 and additional interface circuits may be provided, such as an SCSI interface etc., to allow communication with conventional data manipulation and storage devices etc.
In response to program instructions read from RAM 202, the CPU 201 generates image data which is in turn displayed on the display unit 103. Display unit 103 is a twenty inch non-interlaced visual display unit. Display unit 103 is detailed in FIG. 3. A displayed image 301 may be considered as being made up of two component parts, taking the form of a working "canvas" 302 and a control panel 303. Image data is displayed in the region of said canvas 302 either as individual frames or as a moving video/film clip.
While an image is being displayed on the canvas 302, pixel data may be modified in response to manual operations of the stylus 104 upon the touch tablet 105. The position of the stylus 104 is identified to the artist 101 by means of a cursor 304, which tracks the position of the stylus 104 as it is moved over the touch tablet 105. The monitor 103 includes a control panel 305 for the control of monitor variables, as is well known in the art.
In addition to effecting interactive modification to displayed images, by positioning the cursor within region 302, control operations are similarly effected by moving said cursor into region 303. Control region 303 is detailed in FIG. 4.
New data objects are stored with reference to particular data layers in which a first layer may be considered as background image data, with a second layer of data taking priority over said first and a third layer of data taking priority over the second. This arrangement of layers is substantially similar to the layering of video source material in on-line mixing systems, in which images are combined using smooth keying or matting signals so as to achieve a smooth blending to create realistic-looking composites. In operation, modifications may be made within any of these layers and an appropriate layer is selected, layer 1, layer 2 or layer 3, by placing the cursor 304 over a respective layer "button" 401, 402, 403 and placing the stylus 104 into pressure.
The system may be used to display moving video clips, with soft controls being provided substantially similar to those known within video tape recorders etc. Thus, the control display includes a fast rewind button 404, a reverse button 405, a stop button 406, a play button 407 and a fast forward button 408.
Processes are selectable using process selection buttons 409, 410 and 411. Button 409 selects the color mode of operation, in which manual modifications may be made through pixels displayed within the canvas 302. Button 410 allows layer information to be considered and in particular it allows various constructed objects to be allocated to particular layers. Button 411 allows visual effects to be controlled. Upon selection of button 409, 410 or 411 associated process parameters are displayed in a modifiable fashion within region 412. Region 413 allows geometric shapes to be selected, such as circles, ellipses, squares and rectangles, which are then generated automatically at locations within the canvas 302 identified by the cursor 304.
Consideration may now be made to the initial problem, of the smoothing out of the periphery of warped images.
To illustrate a first method of producing a warp, reference will be made to FIGS. 5 and 6 of the accompanying drawings.
Points a to e of an image frame I undergo a translation as part of the warp, such that points a and e remain in their original positions, and points b, c and d are translated to new positions b1, c1, d1. The result of the warp translation is shown in FIG. 6. However, since the points b, c, d are selected as a group and translated as a group, there is a perceived discontinuity around an edge of a warped image, which in the finished film clip or video clip leads to lack of realism as perceived by a viewer.
Referring to FIGS. 7 and 8, the warp translation may be improved by, rather than moving selected points b, c, d as a group in a single translation, individually moving selected points b, c, d to respective new positions b2, c2, d2 as shown in FIG. 7. This may result in a "smoothing out" of the discontinuity as compared with the warp method of FIG. 5. An illustrative result of individually moving the points b, c, d is shown in FIG. 8.
It will be appreciated that individual movement of specific points of an image, using the apparatus described with reference to FIGS. 1 to 4 of the accompanying drawings, is a time consuming operation. For each frame of film clip or video clip, a large number of individual points must be relocated using the touch tablet 105 and the stylus 104. For a clip of film or video having a number N individual frames, an image will generally move from frame to frame, and the warp may need to be effected on a frame by frame basis. Consequently, smoothing of the warp also may need to be effected on a frame by frame basis leading to a large number of individual manual point movements using the stylus 104 and touch tablet 105.
FIGS. 9 and 10 show illustratively an I+20th frame of the clip before and after warping and manual post warp smoothing, and FIGS. 11 and 12 show respectively an illustrative I+Nth frame both before and after warping and manual post warp smoothing.
An example of the specific method according to the present invention will now be described.
In the following discussion, movement of points of an image are described. It will be understood that where movement of a "point" is described, this relates to movement of one or more pixels on display screen 103 or the graphics tablet 105. Corresponding pixel data and image data is modified in accordance with movements of pixels, and so where movement of parts of an image frame to new positions within the image frame are described, corresponding processing of image data occurs in the image processor 107.
Referring to FIG. 13 of the accompanying drawings, an image characterized by individual points V,W,X,Y,Z at initial positions v, w, x, y, z is to be warped to a new position at points v, w1, x1, y1, z. A point, e.g., point X, is identified as a source point by manipulation of a cursor on the visual display unit 103 in response to manual operation of an interface device, for example the stylus 104 and the touch tablet 105. Using the stylus and touch tablet, the point X is dragged to a new position x1.
The central processing unit 201 identifies points related to the identified source point X, in this case related points V, W, Y and Z. The processor applies a proportionality distribution function in order to move the related points V,W,Y and Z in accordance with a predetermined distribution, which is proportional to the distance which the source point X has been moved from its source position to its destination position. For example, in FIG. 13 source point X is translated from its original position within the frame (its source position) to a new position x1, its destination position.
Related points V, W, Y and Z are translated to respective destination positions v, w1, y1, z.
In FIG. 13 in the case of the points V and Z, the source positions of these related points are the same as their destination positions, i.e. the points V and Z stay where they are in relation to the frame. However, points W and Y are moved from their initial source positions to new destination positions w1, y1. The resultant destination positions of points V to Z are shown in FIG. 14.
Referring to FIGS. 15 and 16, in the I+20th frame of the clip, the image has moved compared to the Ith frame and so the source point X20 needs to be moved from its source position in the I+20th frame to its destination position x20 as shown in FIG. 16. The line in FIG. 16 illustrates the destination positions of related points V20, W20, Y20, Z20. Similarly, in the I+Nth frame, the image has moved relative to the frame even further, and again the image needs to be identified with reference to a source point XN, which is moved from a source position to a destination position XN.
Thus, for each frame an identified feature of an image may be moved by identifying a source point of that image data, the source point of the image data from a source position to a destination position, and by moving further related points of the image move automatically under control of the central processing unit and in accordance with a predetermined proportionality distribution function by an amount relative to the distance between the source point and the destination point, the amount being determined by the proportionality distribution function.
Referring to FIG. 19 of the accompanying drawings, an example of a proportionality distribution function is shown with reference to a "+" electronic cursor 600. The cursor is shown as moving in a vertical direction with reference to the frame. The proportionality function is defined as having a y axis in the direction of movement of the cursor, in this case vertically with reference to the frame, and an x axis in a direction transverse to the movement of direction of the cursor. In this case, the x axis of the function happens to be perpendicular to the direction of movement of the cursor, but is not necessarily so.
In the case shown in FIG. 19, the proportionality function comprises a substantially gaussian function. The maximum extent of the gaussian function in the y direction is preferably set, such that it corresponds to the distance moved between the source point and the destination point by the cursor. At positions either side of the cursor, related points are moved to a lesser extent, being a proportion of the distance moved by the cursor.
The width of the gaussian function may be determined, to enable related points within a predetermined distance from the source point to move with the source point. Selection of the width of the proportional distribution function determines the fineness or coarseness of the smoothing effect.
Referring to FIG. 20, movement of the cursor is made diagonally across a frame. In this case the proportional distribution function is defined in the y direction as being in a direction diagonally across the frame and in the x direction, transverse to the y direction.
Related points may be identified by way of intensity, color, or their initial unwarped position.
Referring to FIG. 21 of the accompanying drawings, there is illustrated a source point S at a source position s, which is moved to a destination position s1. The effect of applying a proportional distribution function as shown in FIG. 22, having a relatively narrow width (trace a) and another proportional distribution function as shown in FIG. 23, having a relatively wide width (trace b) as shown in FIG. 21.
The maximum magnitude of the proportionality function in the y direction is the distance s-s1, in FIG. 21, and at x positions either side of the maximum value, the value of the proportionality function is less than the distance s-s1. The maximum magnitude of the proportionality function may be varied or preset as a percentage of the distance between the source point and the destination point.
Referring to FIG. 24 herein, another identified source point T at source position t is moved to a destination position t1. In this case, a proportional distribution function having a partially negative effect, as shown with reference to FIG. 25 is applied. The function extends over a distance in the x direction of width d transverse to the direction of the movement t-t1.
The effect on the image feature, denoted by the line in FIG. 24, is that movement of the source point T to the destination position t1 results in the trace c as shown in FIG. 24, in which a portion of the image feature corresponding to related points actually moves away from the destination point t1 as the source point T is translated from position t to t1.
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Displayed picture points are re-locatable in response to manual operation of an interface device such as a stylus or a mouse etc. The interface device is activated, by being placed into pressure or by clicking, and an identified picture point is subsequently moved in response to manual operation of the interface device. In response to said picture point being moved, other picture points are also moved by a displacement which differs from the displacement of the identified picture point and which varies in proportion to the original distance of the other picture point from the identified picture point.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to pipe connection joints, particularly but by no means exclusively for sea-bed pipework.
2. Description of the Prior Art
There is frequently a requirement for a non-weldable but permanent pipe connection joint in both subsea and surface applications. In addition, for subsea applications in particular, it is desirable that a pipe connection joint should also possess the capability of telescoping to allow disconnection of an adjacent connector.
In the installation of a subsea template or manifold system on the sea-bed, sea-bed flowlines have to be laid from either a platform or a land installation. With a deep water application it is usual, because of the complexity of the operation, to pull a line into its final position and, after retaining it at the junction, to effect the final connection to the manifold or template pipework in a separate operation. This final connection can be effected in a number of ways, but in all cases it is usual to spread the pipe ends apart in order to interpose seals or a seal carrier and then to pull them together and pressure clamp the pipe ends.
Thus provisions have to be made to allow for spreading apart of the pipe ends when the final connection is made. For this purpose telescopic joints have in the past been proposed, and although such joints are inherently attractive they have attracted severe criticism on two main grounds. Firstly, the resilient seals which have been necessary to prevent leakage could not be guaranteed to remain effective over long periods and, secondly, the joints generally had to be restrained to prevent end pressure parting.
The present state of the art relating to subsea installations generally avoids the problems with telescopic joints by utilising either flexible pipe spools or flex loops within the manifold pipework structure which deflect appropriately to allow spreading of the pipe ends to be connected. As will be appreciated this requires large pipe bends to be incorporated to accommodate the required deflection without over-stressing of the pipe loops. The desired result can be achieved with outboard sea-bed flowline deflection, and although this reduces the size of the template and manifold structure the successful deflecting back of the flowline to make the final connection is not predictable, and indeed the success of this operation cannot be guaranteed.
SUMMARY OF THE INVENTION
The present invention has for its object to provide a metal sealing pipe connection joint which, for subsea applications, can be designed as a telescopic pipe connection joint which successfully overcomes the foregoing criticisms of prior telescopic joints for such applications.
To this end, according to the invention, a pipe connection joint comprises two coaxial tubular joint members which are telescopically engaged one within the other with an interference fit which provides both a seal against leakage from the joint and a friction lock precluding relative axial separation of the joint members under the intended working pressure conditions, one of the joint members incorporating an externally connectible duct leading to the interface of the joint members whereby fluid under pressure can be introduced to relieve said friction lock and allow relative telescopic movement of the joint members.
The interference fit of one of the joint members within the other may be pressure assisted, with an increase in the internal working pressure tending to expand the inner joint member at the interface and thus increasing both the sealing efficiency and the friction lock.
Seals may be fitted at each end of the interface region which provides the interference fit. These seals contain the fluid pressure introduced via said duct to relieve the friction lock, and they may be elastomeric or metallic seals. In the latter case the seals or sealing surfaces may be machined from the joint members themselves. Such seals but not the plain sealing surfaces are incidental during normal working operation of the joint when the interference seal is operative.
Preferably the outer joint member is counterbored with a stepped counterbore which receives the inner member.
With a joint which is not intended to be telescopically extendable for connection and contractible for disconnection, substantially the entire length of the counterbore preferably provides the interference fit, with the inner joint member having a complementary fitting outer surface. In this case the stepped formation facilitates initial assembly of the joint, as the inner and outer members may be partly interengaged before interference occurs, and said seals are preferably respectively provided at the inner end of the inner joint member and the outer end of the outer joint member.
When the joint is telescopically variable in length, when an appropriate fluid pressure is externally applied via said duct, an outer portion of the counterbore in the outer joint member may provide the required interference fit with the inner joint member having a reduced diameter inner end sleeve portion which is a free sliding fit in an inner portion of the counterbore. This enables the parts of the bores of the two joint members exposed when the joint is fully compressed to be of a common diameter, and provides in the working extended condition an almost continuous bore which allows pigs to be passed through the joint without losing the pig total motive seal contact with the bore. A wiper and protection sealing ring is preferably fitted to prevent ingress of solids between the counterbore and said sleeve portion, and a secondary wiper and protection sealing ring may be disposed at the inner end of said interface region.
Other features of the invention will be apparent from the following description, drawings and claims, the scope of the invention not being limited to the drawings themselves as the drawings are only for the purpose of illustrating ways in which the principles of the invention can be applied. Other embodiments of the invention utilising the same or equivalent principles may be used and structural changes may be made as desired by those skilled in the art without departing from the present invention and the purview of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a telescopically extendable pipe connection joint, especially suitable for use in a subsea installation /and
FIG. 2 illustrates a non-extendable pipe connection joint suitable for use in subsea and surface installations.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The top half of FIG. 1 illustrates the pipe connection joint shown therein fully compressed, whereas the bottom half shows the joint in a fully extended working condition.
This joint comprises two coaxial tubular joint members 1 and 2 which are telescopically engaged, one within the other. The outer joint member 1 has a bore 3 of the same diameter as that of the pipeline with which the joint is to be used, and the inner joint member 2 has a through bore 4 of the same diameter. A stepped counterbore of the joint member 1 presents an intermediate diameter portion 5 and a larger diameter outer end portion 6. This counterbore formed in the member 1 is relieved over an intermediate annular groove 7.
The inner joint member 2 has an outer surface of complementary stepped form. Inwardly of a relief groove 8 the joint member 2 has a sealing portion 9 which is an interference fit within the outer counterbore section 6, and this fit provides both a seal against leakage from the joint and a friction lock which normally precludes relative telescopic movement of the joint members 1 and 2. In particular, it prevents the internal working pressure from blowing the joint apart.
At each end of the interface region 10 which provides the interference fit resilient seals 11 and 12 are provided between the joint members 1 and 2, the inner seal 11 being let into the joint member 1 and the outer seal 12 being let into joint member 2. The inner joint member 2 has an inner end sleeve portion 13 which is a free sliding fit in the intermediate diameter portion 5 of the outer joint member 1. This enables the normally exposed bore portions--see lower half of FIG. 1--to present an almost continuous bore which allows pigs to be passed through without losing the pig motive seal contact with the bores 3 and 4, as the thin sleeve portion 13 bridges the groove 7.
A wiper and protection seal 14 is provided between the sleeve portion 13 and outer joint member 1 at the outer end of the bore portion 5. This seal 14 is let into the outer joint member 1 and positioned so that it is disposed close to the inner or free end of the sleeve portion 13 at the full joint extension, as shown in the bottom half of FIG. 1. A second wiper and protection seal 15 which is let into the outer joint member 1 close to, and on the inner side of, the seal 11 provides secondary protection for the interface region 10.
A duct 16 in the inner joint member 2 has an external connection at 17 and leads to a port 18 which communicates with a peripheral groove 19 in the interface region 10. This duct 16 can thus be supplied with pressure fluid which forces the joint members 1 and 2 apart at the interface region 10, thereby relieving the interference fit and allowing relative telescopic `stroking` movement of the joint members 1 and 2, the full extension range or stroke of the joint being indicated by reference S.
The described pipe connection joint is intended to be fabricated into a sea-bed pipework arrangement close to the inboard/outboard sealed connection of a subsea template or manifold system. On installation one of the joint members 1 and 2 is welded to the template of manifold pipework, and the other to the corresponding connecting flange or hub. It is probable that the inboard pipework will require to be retracted when pulling in the outboard side flowline. With the outboard hub locked down a connection tool can be run to place and locates on both inboard and outboard hubs, at the same time plugging into a hydraulic stroking probe receiver. This receiver, which is not illustrated, can be permanently piped to the joint pressure stroking connection 17.
Although this joint is designed primarily for use in deep-sea locations as a diverless remote connection, it can also be used in shallower waters in conjunction with diver assistance.
To allow stroking of the joint a suitable high pressure is applied to the stroking port 18, causing the joint members 1 and 2 to be pressured apart thus allowing free relative telescopic movement out to the extended position. Once the pipe connection is finally coupled up the pipe joint can be pressure tested by pressuring through the stroking port 18 to a pressure equal to the working internal pressure. As the interference fit is maintained through to the resilient stroking seal 12, the pipe joint pressure containment is tested on faces adjacent the stroking inlet port groove 19. Further peripheral grooves 20 are provided in the joint members 1 and 2 at the interface region 10. These assist distribution of the pressure fluid in this region and thus act as anti-locking grooves to equalise pressure when unlocking the joint by application of external pressure to the connection 17.
It will be appreciated that in an installation it is likely that both the inboard and the outboard pipework will be positively locked down. In that case the friction lock resistance provided by the interference fit between the joint members 1 and 2 has only to cater for the difference in pressure area of the pipe bore and sliding interface diameter, and not the total bore pressure area plus the inner tube differential area.
Although the joint of FIG. 1 has been described as installed in a template or manifold system, it will further be appreciated that it also provides advantages for the mid-connection of sea-bed flowlines. In this case the joint allows tow out of complete lengths of pipeline, which lengths can be joined remotely on the sea-bed without the use of large expanding pipe loops.
Apart from its general simplicity the joint provides considerable flexibility which allows the final operating position to be within a considerable tolerance band whilst still working effectively. Any tendency for the pipe to move under pressure end load will only enhance the presetting load of the flowline connection. As compared with the present normal practice in the art, the joint of the invention takes the place of an equivalent 360° bend having a diameter at least four times the length of the present joint.
A flexible boot 21 is fitted to protect the surface of the joint member 2 which enters the member 1 during stroking of the joint and which would otherwise be exposed. This avoids encrustation deposits on that surface which would impede stroking after a period in service on the sea-bed. The boot 21 is clamped at one end around the joint member 1 by a clamp ring 22, and at the other end around the joint member 2 by a clamp ring 23.
The embodiment of FIG. 2 is fundamentally similar to that of FIG. 1 but is simplified by the omission of the capability of telescopic extension under pressure. Similar basic parts of this embodiment are identified by the same reference numerals as those used in FIG. 1 but increased by `100`. The outer and inner joint members 101 and 102 have through bores 103 and 104 of common diameter matching that of the pipeline in which the joint is to be fitted. In the assembled condition which is illustrated the inner end of the member 102 abuts a step 130 in the outer member 101 at the inner end of the stepped counterbore 105,106 in the latter. In this case the intermediate groove 7 of FIG. 1 is omitted, and the members 101 and 102 are an interference fit over the full length of the counterbore, that is over both portions 105 and 106 thereof.
Thus the resilient seals 111 and 112 which are respectively positioned at the ends of the interface region providing the interference fit are comparatively widely spaced. The inner seal 111 is now mounted on the inner member 102 at the inner end thereof, and the outer seal 112 is mounted in the outer member 101 at the outer end thereof. The counterbore portions 105 and 106 are of substantially equal effective length and the comparatively short radial duct 116 and external connection 117 are formed in the outer member 101 and positioned centrally of the counterbore portion 106. The peripheral groove in the interface region, with which the duct 116 communicates, is accordingly now formed in the outer joint member 101. The further spaced grooves 120 which assist distribution of externally applied fluid pressure at the interface region are now formed some in the counterbore portion 106 and some on the now-fitting smaller diameter inner end portion 113 of the inner joint member 102.
To assemble the connection joint the inner member 102 is partially inserted into the outer member 101 until the inner seal 111 enters the counterbore portion 105, when the outer seal 112 also operatively engages the inner member 102. Fluid pressure is now applied externally, through the connection 117 and duct 116 between the members 101 and 102. This pressure is contained by the seals 111 and 112 and spreads the engaged tubular portions of the joint members radially apart, expanding the member 101 and contracting the member 102. This allows the members to be pushed fully together to the normal operative position illustrated in FIG. 2, and on release of the applied pressure a permanent metal sealing joint is obtained, providing a metal seal and friction lock by utilising a compound tubular arrangement with an interference fit in accordance with the invention.
The joint once assembled can be pressure tested through the external connection 117 at a lower pressure than that required to separate the joint members, that is at the internal working pressure of the joint. A pressure assisted seal is obtained, as with the internal working pressure applied a greater pressure sealing and friction lock is provided by the action of increasing the hoop stress in the tubular portion of the outer member 101 which surrounds the inner member 102.
If the joint is subsequently required to be broken, fluid pressure is applied via the external connection 117 to force the joint members 101 and 102 apart radially, thus allowing them to be separated axially. Apart from simplified construction, this connection joint possesses the general advantages of speed of connection (and disconnection), the ability to pressure test the joint externally, and a dimensionally low profile.
In either of the described embodiments the inner resilient seal 11 or 111 may if desired be omitted. In this case application of a test pressure to the external connection 17 or 117 provides a positive check, if the joint "holds" this pressure, of the integrity of the interference seal between the joint members 1 and 2. If suited to installation procedures, the duct 16 of the first embodiment may alternatively be provided by a radial bore through the outer joint member 1, as with the corresponding duct 116 of the embodiment illustrated in FIG. 2.
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A pipe connection joint comprises two coaxial tubular joint members which are telescopically engaged, one within the other. The outer joint member has a bore, and the inner joint member a through bore, of the same diameter as that of the pipeline with which the joint is to be used. The inner joint member is received in a counterbore in the outer joint member, being an interference fit therein over an interface region to provide both a seal and a friction lock precluding relative axial separation of the joint members under internal working pressure. One of the joint members incorporates an externally connectible duct which leads to the interface region, whereby fluid under pressure can be introduced through the duct to relieve said friction lock.
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BACKGROUND OF THE INVENTION
[0001] The invention relates in general to display devices and more specifically to an apparatus and method for displaying a picture or postcard or other aesthetic article.
[0002] Picture display devices such as picture frames allow the presentation of a photograph or other planar item for easy viewing. Many picture frames can be placed on a flat surface such as table or desk such that the displayed item is positioned at a pleasing viewing angle. Conventional display devices, however, have several limitations. For example, many conventional designs partially obscure the displayed item with a frame or clip. Further, many conventional display devices are heavy, bulky, and relatively expensive. Many picture frames in include a glass panel to protect the displayed device and, therefore, may pose a danger if dropped or otherwise broken.
[0003] Postcards provide a mechanism for mailing a message along with a selected picture. Although the selected image may be attractive, humorous, or otherwise entertaining, available images are limited and are not personalized. Often the sending party would prefer to send a personal photograph rather than a generic postcard. Conventional techniques for mailing personal photographs include using an envelope, using a framed postcard device, and applying a sticker to the back of the photograph. Conventional mailing techniques, however, are limited in several ways. For example, some conventional techniques are limited in that the photograph is partially or completely obscured by the article used to mail the photograph. When a photograph is mailed in an envelope, the entire image is covered until the recipient opens the package. Other devices include a frame that covers a portion of the custom photograph or picture. In addition, conventional mailing products are limited in that the photograph or other displayed item can not be easily positioned for display. Mailed photographs must often be displayed by securing the photograph to vertical surface using tacks or magnets or by placing the photograph in a picture frame.
[0004] Accordingly, there is need for an apparatus and method for efficiently displaying a displaying a planer display item.
SUMMARY OF THE INVENTION
[0005] A display device, comprising a clear-front envelope formed by foldable blank including at least one backing flap folded around a transparent sheet leaving an opening for receiving the planar displayed item, such as a photo; postcard; etc. The opening is at least partially closed when a sealing flap integrally formed with said foldable blank is secured to the backing flap. A support flap is integral with the sealing flap, the support flap being configured to fold at fold line adjacent to the backing flap and having an end for resting on a horizontal surface to support the clear-front envelope at a viewing angle to the horizontal surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is an illustration of an exploded perspective view of an unsealed display device in accordance with the exemplary embodiment of the invention.
[0007] FIG. 2 is an illustration of a perspective view of the display device of FIG. 1 shown in a sealed state.
[0008] FIG. 3 is an illustration of a perspective view of the display device in use in a landscape orientation in accordance with the exemplary embodiment of the invention.
[0009] FIG. 4 is a diagram of a side view of the display device in use in a landscape orientation in accordance with the exemplary embodiment of the invention.
[0010] FIG. 5 is an illustration of a perspective view of the display device in use in a portrait orientation in accordance with the exemplary embodiment of the invention.
[0011] FIG. 6 is a diagram of side view of the display device in use in a portrait orientation in accordance with the exemplary embodiment of the invention.
[0012] FIG. 7 is an exploded perspective bottom view of an unsealed display device in accordance with the exemplary embodiment of the invention.
[0013] FIG. 8 is a perspective bottom view of a partially sealed display device in accordance with the exemplary embodiment of the invention.
[0014] FIG. 9 is an additional perspective bottom view of a partially sealed display device in accordance with the exemplary embodiment of the invention.
[0015] FIG. 10 is a perspective view of a sealed display device in accordance with the exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] According to this invention, a foldable support flap is affixed to a backing flap of an envelope having a main window portion to form a photograph display device. A user encloses a photograph, postcard or other thin, planar item to be displayed into a pocket formed between the main window portion and the foldable paper backing by folding side flaps and sealing flap relative to the main window portion. A transparent sheet may be disposed at the main window portion. Any combination of indicia such as advertisements, decorative marking, and instructions may be included on either side of the transparent front sheet, the main window portion, the foldable paper backing, and/or the support flap. In the exemplary embodiment, the display device includes postcard indicia such a stamp placement square and address lines allowing the display device to be used as a personalized postcard for mailing photographs or other display items. The foldable blank is typically partially sealed to create the pocket or envelope for receiving a photograph or postcard. As such, a user can easily insert a photograph, seal the display device and mail the display device. In addition to minimizing production costs, an efficient, integrated construction provides a durable display device that requires minimal manipulation and assembly by the user. Although the device may be used for mailing display items, the display device may be used solely as a safe, lightweight, and inexpensive picture frame that allows full view of the display item.
[0017] FIG. 1 is an illustration of a perspective view of an unsealed and unfolded display device 100 in accordance with one embodiment of the invention. The display device 100 includes at least one support flap 104 and at least one foldable backing flap 106 connected to a main window portion 108 . Further, a pair of side flaps 107 , 109 may be disposed along opposite edges of the main window portion 108 . Disposed adjacent the main window portion 108 is a protective transparent plastic sheet 112 . The foldable backing flap 106 and the support flap 104 are formed from paper stock and connected to the main window portion 108 through respective living hinges 106 a , 122 a . Likewise, side flaps 107 , 109 are connected to the main window portion 108 via living hinges 107 a , 109 a.
[0018] FIG. 2 shows the display device of FIG. 1 in the folded in sealed state. Although in the exemplary embodiment the display device 100 has a rectangular shape, the display device 100 may be square, triangular, oval, circular or any other suitable, preferably planar, shape.
[0019] FIG. 3 is an illustration of a perspective view and FIG. 4 is an illustration of a side view of the display device 100 in use in a landscape orientation in accordance with the exemplary embodiment of the invention. Where the display device 100 is designed to display rectangular display items, the display device 100 displays the display item in a landscape orientation by placing a long side 202 of the display device parallel to a horizontal flat surface 300 such as a desk or table. Neither of the short sides 204 , therefore, rests on the horizontal surface 300 when the display device 100 is in the landscape orientation. The support flap 104 is folded back to the appropriate distance from the paper backing by the user to set the desired viewing angle, α, 302 of the display item. As the support angle, β, 304 is increased, the viewing angle, α, 302 also increases allowing the display item to be more easily viewed form higher elevation above the horizontal surface 300 .
[0020] FIG. 5 is an illustration of a perspective view and FIG. 6 is a side view of the display device 100 in use in a portrait orientation in accordance with the exemplary embodiment of the invention. Where the display device 100 is designed to display rectangular display items, the display device can be used to display the display item in a portrait orientation by placing either of the short sides of the display device parallel to the horizontal flat surface. Neither of the long sides, therefore, rests on the flat surface when the display device is in the portrait orientation. The support flap 124 has a shape that allows the display device 100 to present the displayed item at an esthetically pleasing viewing angle, θ, 504 where the viewing angle, θ, 504 is the angle formed between the front face of the display item 100 and the horizontal surface 300 . Although any viewing angle between 180 degrees and 90 degrees can be used, an example of a suitable viewing angle is 100 degrees. The viewing angle, θ, 504 is determined by the support flap cut angle, φ 502 . In the exemplary embodiment, the support flap 124 is symmetrically cut at each edge to form support flap cut angle, Φ, 502 of approximately 11 degrees relative to the short side of the display device 100 .
[0021] FIG. 7 is a perspective view of the display device 100 in the unfolded condition. As discussed above, the display device 100 may have any one of several shapes. In the exemplary embodiment the display device has a shape configured to display a standard size photograph such as for example, 3 inch by 5 inch, 4 inch by 6 inch, 5 inch by 7 inch, and 8 inch by 10 inch photographs. Accordingly, a display device may be manufactured for each of the standard photograph sizes. The dimensions of the paper backing are slightly larger that the dimensions of the intended display item. The main window portion 108 should be sized to allow the display item to be easily inserted or otherwise disposed adjacent the transparent plastic sheet 112 while having dimensions small enough to minimize any movement of the display item after it is sealed. Also, the dimensions should be chosen such that amount of paper backing bordering the display item is minimized. An example of suitable dimensions is having a length and width that is approximately one millimeter larger than the intended display item. In some circumstances the dimensions may be selected to cause the front clear panel to bow slightly outward.
[0022] As discussed above, the support flap 124 is cut and angle, Φ, that allows the display device 100 to have an appropriate viewing angle when positioned in the portrait display position. In the exemplary embodiment, the angles on the both sides of the support flap 124 are the same. In some circumstances, however, the angles may be different allowing the display device to have different viewing angles depending on which short side 204 is placed on the horizontal display surface.
[0023] As will be described below with reference to FIGS. 7-10 , the folding and sealing method employed by this invention will now be described. Starting with the flat panel or blank 100 shown in FIG. 7 , the transparent plastic sheet 112 is first disposed adjacent the main window portion 108 of flat foldable panel 100 and secured in place by adhesive or other suitable fastening means known to those of skill in the art. Next, the side panels 107 , 109 are folded along fold lines (living hinges) 107 a , 109 a to the positions shown by arrows A, B in FIG. 8 . Then, the foldable backing flap 106 is folded to secure the side flaps 107 , 109 in place as shown by arrow C in FIG. 8 ; the backing flap 106 is preferably secured by adhesive of other suitable retention system to retain the display device 100 in the shape shown in FIG. 9 .
[0024] By following this methodology, a clear front envelope assembly shown in FIG. 9 is formed by folding the plurality of foldable flaps 106 , 107 and 109 relative to the main window portion 108 and around the transparent plastic sheet 112 . Suitable adhesive or any other fastening mechanism adheres the transparent sheet 112 and the foldable flaps 106 , 107 and 109 relative to the main window portion 108 .
[0025] With the configuration of FIG. 9 , a photograph, postcard or other aesthetic display item may be inserted into the envelope arrangement shown in FIG. 9 .
[0026] As will be apparent to those of skill in the art, the sealing flap 118 is not adhered to the paper backing 116 until after a photograph or other display item is inserted into the clear front envelope or pocket defined by the foldable flaps 106 - 109 .
[0027] At least one sealing strip 120 may be disposed on the connection portion 122 of the support flap 104 and/or backing flap 106 to allow the user to peal off a protective tape, fold the support flap 104 and adhere the connection portion 124 of the support flap 104 to the backing flap 106 to seal the display item (e.g., photo, postcard or other item) inside the clear front envelope or pocket 133 of the display device 100 . Once the support flap 104 is adhered to the backing flap 106 , the display item is retained in the display device 100 and the article assumes the configuration shown in FIG. 2 .
[0028] The transparent sheet 112 may be adhered to the flaps 106 , 107 , 109 with adhesive that is applied at least along the perimeter of the main window portion 108 and/or the transparent sheet 112 . It is also contemplated by this invention that the transparent sheet is retained within the envelope or pocket without the use of adhesive.
[0029] In use, the connection portion 122 meets the stand portion 124 at a fold line 126 . The stand portion 124 is folded away from the backing flap 106 when the display device 110 is used to display the display item on a horizontal surface (not shown). The display device 100 may be used to display the display item in a portrait or in a landscape position.
[0030] As described above, a plurality of edges 106 , 110 of the transparent sheet 112 is adhered to the back 114 of the backing flap to form a clear front envelope 102 . An adhesive, such as a spray adhesive, is applied the back of the main window portion 108 and edges of the transparent sheet 112 are attached by the adhesive. A pocket 133 is formed between the front of the backing flap 106 and the transparent sheet 112 . A display item such a photograph is inserted into the pocket 133 .
[0031] In the exemplary embodiment, a section or peal of adhesive tape forms the adhesive strip 120 on one or both of the connecting portion 122 or backing flap 106 . Accordingly, the user removes a protective strip from the adhesive strip and presses the connecting portion 122 of the support flap 104 to the paper backing. User instructions in the form of printed indicia are included on the display device to assist the user in properly using the display device 100 as a display device and a personalized postcard mailer. The instructions may include directions on applying the sealing flap to the backing flap 106 and not to the support flap 104 .
[0032] FIG. 10 shows one example of the display item in the final sealed state with a display article mounted in the pocket 133 at the window frame defined by the window portion 108 .
[0033] FIG. 2 is an illustration of a perspective view of a sealed display device 100 with indicia indicating the appropriate location for postage 1102 is printed on the connection portion 122 of the support flap 104 . In some situations, the postage may be provided on the display device 100 . In addition to postcard indicia, the display device includes other indicia on one or more components of the display device 100 in the exemplary embodiment. For example, indicia such as advertising indicia, decorative indicia, logos, letters, numbers, symbols, or other types of printed or etched items may be included on the transparent sheet 112 , the paper backing 116 , the sealing flap 118 , or the support flap 104 . When included on the back side of the display device 100 , the indicia may be printed on the connection portion 122 of the support flap 104 , on the stand portion 124 of the support flap, or on the paper backing 114 as well as on any portion of the sealing flap 118 or the transparent sheet edges 106 , 108 , 110 . In some circumstances, the indicia may be included on the transparent sheet 112 such that it can be viewed when the display item is sealed with the clear front envelope 102 . Etching techniques may be used to form a logo, lettering or other design on the front face of the clear front envelope to allow the display item to be viewed with minimal interference. In some circumstances, the indicia may be included on the front of the paper backing 116 such that it can be viewed through the clear front envelope before a display item is inserted. For informational or decorative purposes, the display item 100 may include other features by using particular materials such as colored paper stock or colored transparent sheets 112 .
[0034] The indicia may be a generic decorative designs or images such as representations, for example, of historical or natural landmarks, seasonal or holiday depictions, or religious symbols. The representations may include any level of complexity and color and may be full color photos such as traditional photos found on postcard or may be single color sketch. For example, the back of the display device 100 may include a full color photograph of a beach or may simply include a single color image of a palm tree to express a vacation theme. Examples of holiday and seasonal indicia include depictions of Christmas trees, Santa Claus, hearts, clovers, snowmen, flags, winter scenes, flowers, witches, pumpkins, turkeys, colored leaves, as well as text. In some situations the indicia may express an invitation to an event such as a party or wedding and may include customized information. For example, the indicia may include date, time, location and other event specific information.
[0035] The display device may be used as a promotional mechanism or for advertising. For example, company logos, names, slogans, trademarks and other company identifiable symbols may be etched or printed in the clear envelope or on the back of the display device 100 . The promotional aspects of the exemplary display device 100 may be particularly useful at theme parks where symbols or marks may indicate the source of the picture. For example, an image of famous whale may be included on the display device to indicate that a photograph contained in the display device was taken at an aquatic adventure park. Further, famous cartoon characters may enhance the attractiveness of the display device when sold or otherwise provided at a well known theme park associated with those characters.
[0036] In some circumstances, a thin planer magnet is attached to the display device 100 to allow the display device to be mounted on a metal surface such as a refrigerator. A suitable technique for attaching a magnet includes sealing a strip of thin, planar magnetic material between the paper backing and the connection portion of the support flap 104 .
[0037] The display device 100 , therefore, allows a display item such a photograph to be displayed in either a landscape or portrait orientation. The clear front envelope formed by the paper backing and the transparent sheet secures the display item without obscuring the image with a frame. The display device 100 is easy to use as an inexpensive, safe picture frame and also as a convenient envelope for forming a personalized postcard.
[0038] Clearly, other embodiments and modifications of this invention will occur readily to those of ordinary skill in the art in view of these teachings. The above description is illustrative and not restrictive. This invention is to be limited only by the following claims, which include all such embodiments and modifications when viewed in conjunction with the above specification and accompanying drawings. The scope of the invention should, therefore, be determined not with reference to the above description, but instead should be determined with reference to the appended claims along with their full scope of equivalents.
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A display device, comprising a clear-front envelope formed by foldable blank including at least one backing flap folded around a viewing window and leaving an opening for receiving the planar displayed item, such as a photo; postcard; etc. The opening is at least partially closed when a sealing flap integrally formed with said foldable blank is secured to the backing flap. A support flap integral with the sealing flap, the support flap configured to fold at fold line adjacent to the backing flap and having an end for resting on a horizontal surface to support the clear-front envelope at a viewing angle to the horizontal surface.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0001] FIG. 1 shows a considerably enlarged longitudinal cross-sectional view of an electromagnetic valve including a one-part deepdrawn valve housing 1 of thin-walled design that accommodates a separate retaining collar 2 seated on the outside periphery of the valve housing and attached by means of laser welding, said retaining collar being made by non-cutting shaping, e.g. as a cold-heading part. The outside periphery of the substantially disc-shaped retaining collar 2 is configured as a calking punch so that it is press-fitted with its undercut extending along the periphery with the ready-made valve housing 1 in a stepped accommodating bore of a block-shaped valve carrier 4 . The soft material of the valve carrier is displaced during the pressing operation into the undercut for fastening and sealing purposes. Above the retaining collar 2 , the open end portion of the sleeve-shaped valve housing 1 is closed by means of a plug 14 additionally assuming the function of a magnet core. Likewise plug 14 is a low-cost cold-heading part that is manufactured with a sufficient rate of precision and laser-welded at its outside periphery with the valve housing 1 . Disposed below the plug 14 is a magnet armature 15 being manufactured equally very inexpensively from a round or many-sided profile by means of cold-heading or extruding operations, respectively. Magnet armature 15 , under the effect of a compression spring 16 , closes in the valve's basic position a first valve passage 5 arranged in a second valve closure member 8 by means of the first valve member 7 that is fitted to the tappet-shaped extension of the magnet armature 15 . To this end, the first valve closure member 7 is expediently fitted as a hemisphere at the tappet portion that is attached in a bore of the magnet armature 15 by means of self-calking. The second valve closure member 8 is substantially designed as a bowl-shaped deepdrawn part acted upon in the valve's closing position of the first valve closure member 7 by the effect of a spring 17 .
[0002] However, due to the effect of the compression spring 16 interposed between the plug 14 and the magnet armature 15 , the bottom of the bowl-shaped second valve closure member 8 acting as a valve closure means remains in the valve's basic position shown in the drawings on a second valve passage 6 provided in the bottom end of the valve housing 1 . The cross-section of said valve passage that can be opened in response to the hydraulic differential pressure is considerably larger than the opening cross-section at the first valve passage 5 that can be opened electromagnetically.
[0003] Spring 17 is supported at an edge of the second valve closure member 8 configured as a sleeve-type piston and being horizontally penetrated by punched transverse bores 22 .
[0004] To accommodate and seal the valve housing 1 in the bore step 11 , the valve housing 1 is decreased in diameter in the area of the bore step 11 and equipped with a sealing ring 10 so that between the valve housing 1 and the bore step 11 , leakage flow is prevented between the pressure fluid inlet 13 opening horizontally into the valve housing 1 and the pressure fluid outlet 19 arranged below the valve housing 1 . The pressure fluid inlet 13 , which is basically illustrated as a transverse channel in the valve carrier 4 , is continued through the annular filter 12 disposed in the hollow space 20 of the valve carrier 4 to the punched transverse bore 21 in the valve housing 1 so that pressure fluid on the inlet side is applied directly to the second valve closure member 8 , whose transverse bores 22 arranged in the horizontal plane to the transverse bore 21 ensure a low-resistance flow route without any rerouting and, hence, leading directly to the first valve member 7 .
[0005] In addition, the electromagnetic valve is characterized in that the spring 17 is arranged outside the flow route that can connect the pressure fluid inlet 13 to the pressure fluid outlet 19 . For this purpose, stop 3 is inserted remote from the flow route into the valve housing 1 , at which stop the end of spring 17 remote from the second valve closure member 8 is supported. Consequently, spring 17 is not arranged in the flow route but above the transverse bores 21 , 22 at stop 3 . Stop 3 is secured to a housing step 19 of the valve housing 1 to this end. Said housing step 19 is arranged above the transverse bore 21 extending through the valve housing 1 . Stop 3 is designed as a sleeve bowl widely opened in the bowl bottom and having an opening in which the second valve closure member 8 is guided and centered in the direction of the valve seat member 27 . The one end of spring 17 is supported on the bowl bottom of stop 3 . The bowl edge remote from the bowl bottom is angled off towards the inside wall of the valve housing 1 . The result is that an annular chamber 25 accommodating spring 17 is positioned between the outside periphery of the sleeve bowl and the inside wall of the sleeve-shaped valve housing 1 and constitutes a permanent pressure fluid communication between the pressure fluid inlet 13 and a magnet armature chamber 26 by way of pressure compensating openings 18 arranged in the valve housing 1 and at the periphery of the sleeve bowl. Stop 3 and valve sleeve 1 consist of a deepdrawn thin sheet wherein the pressure compensating openings 18 are punched or impressed. Especially small valve parts that can be manufactured at low cost and with precision are achieved thereby.
[0006] The one-part valve housing 1 is designed as a stepped, thin-walled drawn sleeve whose open end remote from the second valve passage 6 is closed by a plug 14 effective as a magnet core and being designed as a cold-heading or extruded part allowing low-cost and precise manufacture. For the mechanical relief of the valve housing 1 , the second valve passage 6 is provided in a disc-shaped or sleeve-shaped valve seat member 27 which is retained in a snug fit on the inside wall of the valve housing 1 . The valve seat member 27 is composed of a wear-resistant metal. Its total height is chosen such that the second valve closure member 8 with its diametral transverse bores 21 rests at the level of the diametral transverse bores 22 of the valve housing 1 , irrespective of whether the valve closure member 8 , being in its closing position according to the drawing, closes the large second valve passage 6 or is lifted therefrom. Therefore, the two transverse bores 22 in the valve housing 1 are increased in their diameter compared to the passages of the transverse bores 21 positioned in the second valve closure member 8 at least by the stroke of the second valve closure member 8 so that the transverse bores 21 are always overlapping the transverse bores 22 even in the hydraulically initiated open position of the second valve closure member 8 for the purpose of a flow routing that is without any deviation and has a low resistance to the greatest degree possible.
[0007] The second valve closure member 8 is configured as a sleeve bowl whose bowl bottom accommodates the first valve passage 5 cooperating with the second valve closure member 7 . Close to the bowl bottom, transverse bores 22 penetrate the peripheral surface of the sleeve bowl and are positioned in the horizontal plane of the transverse bore 21 to provide a flow route that is free from rerouting, if possible. Opposite to the bowl bottom, an edge is provided at the sleeve bowl that is angled-off in the direction of the sleeve-shaped stop 3 and on which the second end of spring 17 remote from stop 3 is supported. Designing the stop 3 as a sleeve portion radially spaced from the inside wall of the valve housing 1 includes the advantage that the forces that act from the retaining collar 2 on the valve sleeve 1 during the press fit operation of the electromagnetic valve are accommodated by the annular chamber 25 in the case of a deformation of the valve housing 1 and do not act on the second valve closure member 8 . This prevents the second valve closure member 8 from being damaged and jammed, even if relatively significant tolerance variations occur. The sleeve bowl is of light weight, small and inexpensive, and is manufactured preferably by deepdrawing from a thin sheet.
[0008] Different from FIG. 1 , FIG. 2 discloses another suitable design of some component parts. The electromagnetic valve according to FIG. 2 differs basically from the valve construction according to FIG. 1 by the second valve closure member 8 and the valve seat member 27 being configured as solid turned parts and/or cold-heading parts. FIG. 2 shows the second valve closure member 8 as a slim piston part that is conically turned at its bottom end and manufactured inexpensively from free-cutting steel. Said conical end normally bears against the conical sealing seat of the hollow-cylindrical valve seat member 27 which, when required, exactly as the valve closure member 8 can be furnished with a surface hardening in the area of the sealing surfaces. Accommodation of the tappet portion within the second valve closure member 8 (cf. FIG. 1 ) is deliberately omitted in the design of the electromagnetic valve according to FIG. 2 because this would necessitate an unnecessary quantity of metal removed for manufacturing the valve closure member 8 .
[0009] Even if not all the features shown in FIG. 2 have been explicitly described in the previous paragraph, they correspond to the features explained in FIG. 1 .
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The present invention relates to an electromagnetic valve, the spring thereof being arranged outside the flow route that can connect the pressure fluid inlet to the pressure fluid outlet in order to reduce the flow resistance, to what end a stop is inserted in the valve housing remote from the flow route, on which stop the end of spring facing away from the second valve closure member rests.
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FIELD OF THE INVENTION
The invention relates to a measuring system for controlling a self-propelled, unmanned, controllable aerial vehicle using a measuring unit according to the preamble of claim 1 and a method for controlling the aerial vehicle, according to claim 8 .
BACKGROUND
These days, unmanned aerial vehicles are used in many fields of technology as a result of flexible employability, be it to reach terrain sections that are difficult to access, for example when fighting fires or in disaster zones, or to carry out an image-supported examination of large objects. In order to capture terrain information, such instruments can be equipped with sensors, e.g. with cameras, and relatively large terrain sections can be recorded contiguously therewith from the air. Furthermore, corresponding drones can be employed for military purposes, e.g. for monitoring, target acquisition, as combat unit or transport means.
In principle, an unmanned aerial vehicle can be controlled or moved manually by means of a remote control by a user or in a completely autonomous or semiautonomous fashion, usually on the basis of GNSS position information.
In general, it is possible to modify four from six degrees of freedom when moving the aerial vehicle, e.g. a helicopter-like aerial vehicle, i.e. the aerial vehicle can be moved forward and backward, left and right and up and down. Moreover, the alignment of the aerial vehicle can be modified by a rotation about the vertical axis. The remaining two degrees of freedom are fixed by the substantially horizontal position of the aerial vehicle.
Precise positioning in a predetermined position or precise movement, e.g. along a predefined axis or flight route, was found to be difficult for a user in the case of manual control. Particularly if the aerial vehicle is exposed to external influences, such as e.g. wind, and the deviations created thereby have to be compensated for with quick reactions, a required accuracy can often not be maintained in the case of such a manual control.
Furthermore, the field of application for an autonomous GNSS-based control is limited to locations at which a sufficient number of satellite signals can be received for determining the position. Hence, in general, a use in e.g. closed rooms or tunnels is not possible. The use in heavily built-up areas can also be difficult if buildings shield GNSS signals.
In order to control an aerial vehicle in such a built-up area, EP 1 926 007 proposes a first flyby over the relevant area, during which images are taken and GPS information is stored with each image. The images are subsequently combined to form an overview image with GPS position information. In order to navigate the aerial vehicle, the images which are recorded at a lower altitude than the ones recorded in advance can now be compared to the overview image and a respective position of the aerial vehicle can be derived on the basis of the stored GPS information. Disadvantages in this procedure can emerge if the first overview image does not comprise all areas of the buildings and the spaces between the buildings and it proves impossible to find correspondence in the case of an image comparison. Positional determination can also be impaired by changes in the surroundings captured at first, for example by movement of vehicles depicted in the image or if light conditions change. Furthermore, this method is limited by the resolution of the camera capturing the surroundings.
EP 1 898 181 discloses a further system and method for controlling an unmanned aerial vehicle, wherein GPS signals, measurement data from inertia sensors and images captured by a camera are used for determining or estimating a position of the aerial vehicle. The captured signals and data can be fed to a computer unit and the position can be determined therefrom. By using the camera, carrying out this determination of the position can supply more reliable results compared to systems without a camera and enable an increased accuracy. However, this method is also limited by the resolution of the camera or can possibly only be carried out to restricted extent as a result of changes in the captured surroundings.
In the case of an autonomous control, the route can furthermore be prescribed to the aerial vehicle in the form of a trajectory, for example it can be defined by several waypoint positions. EP 2 177 966 describes a navigation method for a aerial vehicle on the basis of a predetermined flight route, wherein, for the purposes of controlling the aerial vehicle, pictures of the flight surroundings can be taken by a camera and the flight route can be adapted on the basis thereof. In order to control the aerial vehicle on the flight route, specific intended positions or waypoint positions can be compared to a current actual position of the aerial vehicle, which can, for example, be determined by the GNSS signals. Control signals for the movement of the aerial vehicle can thus be determined from the differences in position and, as a result thereof, a deviation of the actual position with respect to the target position can successively be reduced.
What is common to the aforementioned methods or systems is that the position of the aerial vehicle, in particular the vertical position, can only be determined to an accuracy of up to 2-5 cm by means of GNSS sensors. This uncertainty subsequently has a great limitation on the accuracy when determining the position of the aerial vehicle and on the accuracy when controlling the aerial vehicle.
SUMMARY
Accordingly, an object of the present invention is to provide an improved, more robust system or method for controlling an unmanned aerial vehicle, by means of which the aerial vehicle can be positioned and moved in a more user-friendly and precise manner and with a higher degree of automation. A special object of the invention is to make in possible to carry out this positioning and movement of the aerial vehicle independent of being able to receive GNSS signals.
These objects are achieved by the realization of the characterizing features of the independent claims. Features which develop the invention in an alternative or advantageous fashion can be gathered from the dependent patent claims.
The system for controlling the unmanned aerial vehicle (UAV) has e.g. a theodolite, a total station, a laser tracker, a laser scanner or a rotational laser and a control unit. By means of control signals, the control unit can bring about a positioning or movement of the aerial vehicle, by virtue of e.g. a rotational speed of the rotors, of which, in particular, there are four, of the aerial vehicle or a respective alignment of the rotors being able to be set in a defined fashion. Here, the respective measuring instrument is in contact with the aerial vehicle, for example by a laser beam emitted by the measuring instrument and/or by radio signals. By means of the laser beam and a reflector attached to the aerial vehicle, a distance between the aerial vehicle and the measuring instrument can be determined by reflection of the beam and reception at the measuring instrument. Furthermore, a vertical and horizontal angle of the emitted beam, i.e. an emission direction, can be captured by angle measurement units on the measuring instrument and this can be used in conjunction with the determined distance to determine, precisely in geodetic terms, a position of the aerial vehicle with respect to the measuring instrument in a relative coordinate system.
Furthermore, the laser beam, e.g. in a combined aerial vehicle/rotational laser, can be received on the part of the aerial vehicle by a laser beam reception unit. By means of this unit, it is possible to determine an angle of incidence of the laser beam relative to the reception unit and, from this, a relative alignment of the aerial vehicle with respect to the laser beam (actual state of the aerial vehicle) can be derived by an evaluation unit. Moreover, it is possible to determine an offset of the beam from a defined zero position of the reception unit and, from this, a relative position of the aerial vehicle with respect to the laser beam can in turn be derived. Correction parameters can be established from the respective offset and/or the angle of incidence, which correction parameters serve to control the aerial vehicle in such a way that an intended position and intended alignment are reached, wherein, when the intended state is reached, the offset or the relative angle of incidence respectively assume the zero position, i.e. have no deviation from an intended value.
Using such a reception unit, the aerial vehicle can moreover be coupled to a laser beam. By way of example, this beam can be emitted by a laser scanner and the aerial vehicle can be controlled by a user with a remote control in such a way that the laser beam impinges on the reception unit. As soon as the beam is received, a computer unit in the aerial vehicle can then at least partly assume the control. In a control group, the current position, the orientation, the velocity and flight direction of the aerial vehicle can be established continuously and thereby be compensated for or corrected such that the laser beam impinges centrally, i.e. without deviating from the zero position, on the reception unit. Using the remote control, the user can now move the aerial vehicle along the laser beam, i.e. with one remaining degree of freedom. In this configuration, the aerial vehicle can now be guided, additionally or alternatively, by realignment or by pivoting of the emitted beam. If e.g. a rotational laser is employed in place of the laser scanner, it can be used to span a laser plane and the aerial vehicle can be “put” onto this plane. Here, the user is also able to move the aerial vehicle—now with two degrees of freedom—in the plane or parallel thereto. By way of example, the plane or beam can be aligned horizontally and thereby bring about a horizontal movement of the aerial vehicle. Moreover, these can be aligned at any angle or vertically, in particular wherein, in the case of a vertical alignment, the altitude of the aerial vehicle above the ground can remain freely selectable. By way of example, such an application can be useful in the case of work along a building façade or for measuring the latter.
Depending on the embodiment of the laser beam reception unit, the angle of incidence range to be detected can be restricted to a range between e.g. 0° and 180°, in particular between 0° and 45°. As a result of this, the arrangement of the reception unit on the aerial vehicle must be adapted to the respective alignment of the laser beam or the laser plane in order to ensure continuous reception of the beam. In the case of a horizontal beam alignment, the laser beam reception unit can, for example, be attached laterally to the UAV; in the case of a vertical alignment, it can, for example, be arranged on the underside of the UAV. For universal use of the aerial vehicle, the laser beam reception unit can furthermore be attached to the aerial vehicle in such a pivotable manner that the reception unit can, depending on the alignment of the laser beam, be pivoted in a particular angular position and thereby receive the beam within the detection region, which is predetermined by the design. In order to determine the beam offset, it is also possible, depending on the beam alignment, to adapt the arrangement of the reception unit or align a main detection direction of the reception unit in a pivoting fashion with respect to the beam.
In principle, an actual state of the aerial vehicle in the relative coordinate system, i.e. a state which, for example, at least in part describes a current position, a current alignment, a velocity or a flight direction of the aerial vehicle, can be determined continuously for controlling the UAV by an interaction with the measuring unit. Moreover, an intended state for the aerial vehicle can be predetermined with information content in the measuring system, which information content, in composition and form, corresponds to the actual state. On the basis of the actual state determined thus and on the basis of the defined intended state to be reached by the aerial vehicle, correction values can be established by comparing the state, by means of which correction values the targeted control of the aerial vehicle to the intended state can be realized. It is therefore possible to derive control data from the corrections and provide said control data to the aerial vehicle, for example for actuating the rotors. The correction or control data can be established by the control unit, wherein the control unit can in this case be associated with the measuring unit, the aerial vehicle or the remote control or can furthermore be designed as a structurally independent unit.
It is furthermore possible to prescribe an individual point, a trajectory, an axis and/or a plane to the system as intended state or intended position and the aerial vehicle can be positioned and moved in accordance with the respective prescription, in particular by a continuous comparison of intended and actual values and iterative repositioning. A trajectory or a flight route can, for example, be set by a start point and an end point, wherein the aerial vehicle can in this case be guided along a straight connecting line from the start point to the end point in a manual, autonomous or semiautonomous fashion, i.e. the aerial vehicle moves substantially independently, but a user can intervene in the movement procedure and for example temporarily interrupt the latter. Further waypoints can be defined between the start point and end point and the flight route can be adapted, in particular automatically, in such a way that the waypoints lie on the route. Furthermore, the flight route to be flown can be defined independently of start, end and waypoints, by the position of a movement axis. In the case of a defined flight route, a comparison of the route profile with the current actual state of the aerial vehicle can be undertaken for controlling the aerial vehicle and said comparison can be used to establish the respective correction values or control data. Here, in order to optimize the flight movement of the aerial vehicle in the case of a necessary positional correction toward the flight route, there can be an optimized correction movement, e.g. taking into account the current flight direction and velocity of the aerial vehicle, instead of a direct movement, i.e. instead of a movement along the shortest connection between actual position and flight route.
In addition to measurements of the measuring instrument and/or the laser beam reception unit, measurements from a sensor unit arranged on the aerial vehicle can also be used for determining the alignment of the aerial vehicle and/or the velocity in the relative coordinate system in order to determine corrections. To this end, the sensor unit can detect inertia values, e.g. by means of an accelerometer, and a geographic alignment, e.g. by a magnetometer. The corrections can likewise be converted into control signals for the aerial vehicle and thereby bring about a change in the position, the alignment, the velocity and/or the flight direction.
Furthermore, in order to determine the alignment of the aerial vehicle, markings, e.g. defined patterns, pseudo-random patterns or luminous means, can be applied to the aerial vehicle at a specific position and arrangement and an external detection unit can detect these markings. The detection unit, in particular a camera, can, to this end, be arranged on the measuring instrument or be designed as an independent unit. The position of at least some of the markings in an image captured by the camera can then allow deductions to be made in respect of the alignment of the aerial vehicle in the relative coordinate system. Furthermore, the aerial vehicle can be captured by a RIM camera (range imaging camera) and, as a result thereof, it is possible to capture an image with point-resolved distance values from the RIM camera to the aerial vehicle. Hence, the distance and, if the shape of the aerial vehicle is known, the alignment of the aerial vehicle can be likewise be derived from this data.
Moreover, further applications can be made possible with distance measuring sensors arranged on the aerial vehicle. Here, the aerial vehicle can, for example, be controlled in such a way that a distance to an object can be kept constant, e.g. at 40 cm, in particular in order to avoid collisions or to maintain an optimum measurement distance for an additional data detection sensor (e.g. scanner or camera). By way of example, it is hence possible to carry out a reliable control of the aerial vehicle in surroundings with a restricted amount of available space, by virtue of it being possible to detect possible obstacles by the distance sensors and fly around these or to be able to measure spatial restrictions continuously, for example in the case of a flight through a pipe, a pipeline or a tunnel, and adapt the position of the aerial vehicle accordingly. In the case of such a spatially restricted movement, the aerial vehicle can, in particular, be coupled to a laser beam and be guided on the basis of this beam. Using such a combination of distance measurement and guidance on the basis of a beam, it is furthermore possible, for example in a case of a horizontal alignment of the guide beam, movement of the aerial vehicle along this beam and a continuous distance measurement from the flown-over terrain, to generate a terrain profile or a terrain section by linking respective distance measurements and respective aerial vehicle positions.
In particular, it is possible for the position of the measuring unit, i.e. the setup point thereof, to be predetermined by a known point and an alignment to be determined by measuring a known target point or by means of an inclination sensor and a magnetometer. Moreover, the position and alignment can be determined by sighting at least three target points, in particular if the setup point is unknown. As a result of this procedure, it is possible to determine the position and the coordinates of the measuring unit and the orientation of the measuring unit in a global coordinate system, which is superordinate to the relative coordinate system. Furthermore, the direction of the movement axis can be given in the global coordinate system. With this knowledge, it is now possible to reference the relative coordinate system to the global coordinate system, e.g. by a coordinate transform. As a result of this, it is possible to transfer the position and alignment of the UAV, determined in the relative coordinate system, into the global coordinate system and, for example, it is possible to specify an absolute position and alignment of the UAV in this superordinate coordinate system.
The invention relates to a geodetic measuring system with a geodetic measuring unit, in particular a total station, theodolite, laser tracker or laser scanner, with a beam source for emitting a substantially collimated optical beam, a base, a sighting unit which can be pivoted by motor about two axes relative to the base for aligning an emission direction of the optical beam and angle measurement sensors for determining the alignment of the sighting unit, and, in particular, with a ranging functionality. Moreover, the measuring system comprises a self-propelled, unmanned, controllable aerial vehicle with an optical module, wherein the aerial vehicle is designed in such a way that the aerial vehicle can be moved in a controlled fashion and positioned at a substantially fixed position. Moreover, provision is made for an evaluation unit, wherein the evaluation unit is configured in such a way that it is possible to determine an actual state of the aerial vehicle in a coordinate system, determined by a position, an alignment and/or a change in position, from an interaction of the optical beam with the optical module. The measuring system comprises a control unit for controlling the aerial vehicle, wherein the control unit is configured in such a way that, on the basis of an algorithm depending on the actual state, which can in particular be determined continuously, and a defined intended state, control data can be produced and the aerial vehicle can be brought into the intended state, in particular into a defined tolerance range about the intended state, in an automatically controlled fashion by means of the control data.
The sighting unit of the geodetic measuring unit can, in one embodiment, be designed as an emission unit (with telescopic unit) having the beam source. In particular, such an embodiment can be realized for designing a total station or a theodolite.
In respect of the design of laser trackers or laser scanners, the beam source can be provided in e.g. a support, which is designed such that it can pivot relative to the base about a standing axis defined by the base, or in the base, wherein the emitted radiation can be guided to the sighting unit by means of optical beam guiding elements. In this context, the sighting unit can be designed as e.g. beam deflection element (e.g. mirror).
In the geodetic measuring system according to the invention, it is possible to take account of an actual position, an actual alignment and/or an actual velocity of the aerial vehicle when determining the actual state and/or it is possible to take account of an intended position, an intended alignment and/or an intended velocity when defining the intended state.
A state of the aerial vehicle, e.g. the position, the alignment, the flight velocity or flight alignment, can be determined continuously in such a system. To this end, the measuring unit can emit a laser beam, which can interact with a sensor or reflector on the aerial vehicle. The state of the aerial vehicle can then be established on the basis of this interaction. Moreover, it is possible to define an intended state for the aerial vehicle, for example a position at which the UAV should be positioned, and there can be such a control of the aerial vehicle on the basis of a comparison between the established actual state of the aerial vehicle with this intended state that the aerial vehicle is moved or aligned to the intended state and assumes the intended state, i.e. that, for example, the actual position corresponds to the intended position. For this regulation process, control data for controlling the aerial vehicle are produced on the basis of an algorithm. Here, the produced measurement data or the actual position and actual alignment of the aerial vehicle can be supplied to e.g. a Kalman filter and the control data can be generated from the sum of the data, taking into account a defined intended state. Moreover, in order to establish the control data, averages can be derived from the measurement variables. Furthermore, a difference can be formed continuously between individual intended/actual variable pairs and a direction and distance to the intended position can be determined e.g. on the basis of a difference in position determined thus and the control data in relation to flight direction, flight path and flight velocity can be derived. As a result, the rotors of the aerial vehicle can, for example, be actuated in such a way that, particularly as a result of different rotational speeds, there is a controlled movement of the aerial vehicle to the intended position. Moreover, there can be continuous reevaluation and calculation of the control data within the scope of the algorithm from a continuous comparison between the actual position and the intended position, as a result of which the position of the aerial vehicle can continuously be readjusted by means of such a control loop.
In particular, it is possible for the optical module of the geodetic measuring system according to the invention to be embodied by a reflector which specifies the actual position of the aerial vehicle and for the beam to be able to be reflected by means of the reflector, wherein a distance from the measuring unit to the aerial vehicle can be determined and the actual position of the aerial vehicle can be derived, in particular continuously, from the distance and the emission direction of the beam.
By virtue of the reflector on the aerial vehicle being sighted by e.g. a laser beam, the actual state, in particular the actual position, of the aerial vehicle can be established by the measuring unit, e.g. by a total station. To this end, the reflected beam for the distance measurement, detected at the measuring instrument, and the detected angles at which the beam is emitted are used to determine the direction and a position and alignment of the aerial vehicle relative to the position of the measuring unit can be derived therefrom.
Furthermore, the optical module of a geodetic measuring system according the invention can be embodied by a beam detection unit and the optical beam can be received by the beam detection unit, wherein a beam offset from a zero position and/or an angle of incidence of the beam can be determined, in particular continuously, by means of the beam detection unit for at least partly determining the actual state, and the control unit is configured in such a way that the aerial vehicle can be positioned and aligned, depending on the beam offset and/or the angle of incidence of the beam. Moreover, the aerial vehicle, in particular, can be coupled to the beam by the beam detection unit and can be guided along the beam and/or by a change in the emission direction of the beam.
Within the scope of the invention, a guide plane, in particular a laser plane, in particular in the horizontal, can be defined by a rotation of the beam and the aerial vehicle can be positioned and/or guided by means of the beam detection unit in a defined fashion relative to the guide plane, in particular in the guide plane or parallel to the guide plane.
As an alternative to reflecting the beam at the UAV, the former can be received at the corresponding detection unit and a state of the aerial vehicle relative to the measuring unit can be determined from a determinable angle of incidence of the beam and/or a possible deviation from a zero position of the impact point on a detector in the detection unit. On the basis of the variables which can be established thereby, the aerial vehicle can in turn be controlled—by an actual/intended comparison—and the aerial vehicle can be brought into the intended state. Using such an arrangement, the UAV can moreover be coupled to the beam. To this end it is possible, likewise depending on the determined deviations of the beam incident in the beam detection unit, to control the UAV in such a way that the deviations are continuously compensated for and the beam remains aligned to the beam detection unit or the UAV. In particular, the UAV can then moreover be controlled by virtue of modifying the alignment of the beam, wherein the aerial vehicle moves in correspondence with the alignment change. The degrees of freedom in which the aerial vehicle can be moved in the case of coupling can be defined by means of the beam configuration, i.e., for example, an aligned beam or a plane defined by rotation of the beam. Hence the aerial vehicle can also be coupled to a spanned plane and be moved in the latter, wherein, in this case, there is not a continuous contact between beam and detection unit, but rather said contact is ongoing, interrupted depending on a rotational frequency of the beam.
According to the invention, the geodetic measuring system can be embodied in such a way that the beam detection unit can be pivoted on the aerial vehicle in such a defined fashion that the beam can be received. By way of example, in the case of an oblique alignment of the beam, this can make it possible to establish contact between beam and beam detection unit and thereby open up universal employability for the system or a broad spectrum of application for the aerial vehicle control.
Moreover, according to the invention, the aerial vehicle can have a sensor unit for determining the actual alignment and/or the actual velocity of the aerial vehicle in the coordinate system, in particular an inclination sensor, a magnetometer, an accelerometer, a rate sensor and/or a velocity sensor, in particular a GNSS module. Moreover, the aerial vehicle can have a marking specifying the actual alignment, in particular a defined pattern, pseudo-random pattern, a barcode and/or a light-emitting diode, and the measuring system can have a detection unit, in particular a camera, for detecting the marking and for determining the actual alignment of the aerial vehicle in the coordinate system from the position and arrangement of the marking. Moreover, the measuring system can have a distance image detection unit, in particular a RIM camera, for taking an image of the aerial vehicle, wherein a contour and/or pixel-dependent distance data in respect of the aerial vehicle can be derived from the image and the actual alignment and/or the distance to the aerial vehicle in the coordinate system can be determined therefrom.
The alignment and/or the flight velocity, in particular the position, of the aerial vehicle can be determined by means of one of the above-described arrangements and hence it is possible to establish the actual state of the aerial vehicle. Moreover, a GNSS module can be arranged on the aerial vehicle in a supportive manner and the actual position, a flight direction and hence the actual alignment of the aerial vehicle can be determined from, in particular continuously, received GNSS signals. Hence, if the position of the measuring unit is known, it is possible, for example, to determine the distance thereof to the aerial vehicle and take this information into account when establishing the actual state and the control data. Moreover, the measuring unit can be equipped with a GNSS module (for receiving GNSS signals) and it can be used to establish the position of the unit or a positional relation to the aerial vehicle.
In particular, the control unit can, according to the invention, be configured in such a way that the aerial vehicle can be moved depending on the actual state and a specific flight route, wherein the flight route can be determined by a start point and an end point and/or by a number of waypoints, in particular automatically, and/or by a defined position of a flight axis, in particular wherein a movement of the aerial vehicle can be optimized taking into account the actual state, and in particular wherein information relating to the actual state, in particular the actual position, the actual alignment, the actual velocity, the angle of incidence, the beam offset and/or the distance to the measuring unit, can be fed to a Kalman filter and the movement of the aerial vehicle can be controlled taking into account parameters calculated by the Kalman filter. The flight route can furthermore be defined taking into account the surroundings of the aerial vehicle and can, in the process, take into account e.g. obstacles or directional changes in narrow surroundings. By way of example, the route can be adapted in a pipe in such a way that it is ensured that collisions with the pipe wall are avoided. Moreover, it is possible for e.g. the flight route to be defined depending on a terrain model, in particular a CAD model.
Furthermore, the aerial vehicle of a geodetic measuring system according to the invention can have a sensor for measuring, in particular continuously, an object distance to an object, wherein the object distance can be taken into account when controlling the aerial vehicle and/or wherein the respective object distance can be linked with the respective actual state, in particular the actual position, in the case of a guide, in particular a linear horizontal guide, of the aerial vehicle in such a way that an object surface profile, in particular a terrain section, can be determined. Using such an embodiment, the aerial vehicle can, taking into account the sensor measurements, be controlled in such a way that obstacles are once again identified and it is possible to avoid a collision with the latter. Moreover, the sensors can detect or measure objects along which the aerial vehicle is guided.
Moreover, the aerial vehicle can be controlled in such a way that the aerial vehicle can be guided constantly at a specific intended distance from the object depending on the measurement of the object distance. By maintaining a predetermined distance from an object, a possible collision with an obstacle can therefore be avoided. Moreover, the UAV can be coupled to a laser plane and thus be moved in the horizontal, e.g. in the case of a horizontal alignment of the plane defined by a rotating laser beam, wherein a constant distance to e.g. a tunnel wall can be maintained.
Furthermore, within the scope of the geodetic measuring system, a position and alignment of the measuring unit can be predetermined in a global coordinate system, wherein the position can be predetermined by a known setup point of the measuring unit and/or the position and alignment can be determined by calibration on the basis of known target points, in particular wherein the coordinate system can be referenced with the global coordinate system such that the actual state of the aerial vehicle can be determined in the global coordinate system. As a result, the aerial vehicle can be controlled in relation to the superordinate, global coordinate system and the actual state can likewise be determined in respect of this system.
In a geodetic measuring system according to the invention, state information, in particular actual state information, intended state information and/or the distance between the measuring unit and the aerial vehicle, can be transmitted between the measuring unit and the aerial vehicle for producing control data and/or the control data, in particular wherein the state information can be transmitted by radio link, in a wired fashion and/or modulated onto the beam. Furthermore, the measuring system can have a remote control unit for controlling the aerial vehicle, wherein the state information and/or the control data can be transmitted between the remote control unit and the measuring unit and/or the aerial vehicle, in particular by means of radio link or via a cable. Hence measurement data can be interchanged between the system components, collected on a component and the control data can be produced on this component. By way of example, in the case of coupling of the aerial vehicle to the laser beam, the information, e.g. the distance or the actual state, can be transmitted on the basis of a signal that is modulated onto the laser beam. As a result, there can be direct interchange of the measurement data and, for example, the control of the aerial vehicle by a control unit in the aerial vehicle can occur on the basis of a comparison of the respectively provided actual state with the intended state.
The invention furthermore relates to a method for controlling a self-propelled, unmanned, controllable aerial vehicle, wherein the aerial vehicle is moved in a controlled fashion and/or positioned at a substantially fixed position, with a geodetic measuring unit, in particular a total station, theodolite, laser tracker or laser scanner, with a beam source for emitting a substantially collimated optical beam, a base, a sighting unit which can be pivoted by motor about two axes relative to the base for aligning an emission direction of the optical beam and angle measurement sensors for determining the alignment of the sighting unit, and, in particular, with a ranging functionality. The measuring unit is used to bring about an emission of a substantially collimated optical beam in an emission direction. The optical beam interacts with the aerial vehicle in such a way that the former is reflected or received at the aerial vehicle, wherein an actual state of the aerial vehicle in a coordinate system is determined from the interaction, which actual state is determined by a position, an alignment and/or a change in position. Furthermore, control data are produced depending on the actual state, which is in particular determined continuously, and a defined intended state and the aerial vehicle is brought into the intended state, in particular in a defined tolerance range about the intended state, in an automatically controlled fashion by means of the control data.
Within the scope of the method, an actual position, an actual alignment and/or an actual velocity of the aerial vehicle can be taken into account when determining the actual state and/or an intended position, an intended alignment and/or an intended velocity can be taken into account when defining the intended state.
Furthermore, according to the invention, a distance from the measuring unit to the aerial vehicle can be determined by means of reflecting the beam at the aerial vehicle and the actual position of the aerial vehicle can be derived, in particular continuously, from the distance and the emission direction.
In the method according to the invention, a beam offset can be determined, in particular continuously, from a zero position and/or an angle of incidence of the beam when receiving the beam at the aerial vehicle for determining the actual state and the aerial vehicle can be positioned and aligned, depending on the beam offset and/or the angle of incidence of the beam, in particular wherein the aerial vehicle can be coupled to the beam and guided along the beam and/or by a change in the emission direction of the beam.
Moreover, within the scope of the method according to the invention, a guide plane, in particular a laser plane, in particular in the horizontal, can be defined by rotating the beam and the aerial vehicle can be positioned and/or guided in a defined fashion relative to the guide plane, in particular in the guide plane or parallel to the guide plane.
Moreover, according to the invention, the actual alignment of the aerial vehicle can be determined in the coordinate system in the pitch, roll and yaw directions, in particular wherein determination takes place by means of an internal sensor unit associated with the aerial vehicle, in particular by means of an inclination sensor, magnetometer, accelerometer, rate sensor and/or velocity sensor. Moreover, the actual alignment in the coordinate system can be determined by means of an interaction of a marking, which is associated with the aerial vehicle and specifies the actual alignment, in particular of a defined pattern, of a pseudo-random pattern, of a barcode and/or of a light-emitting diode and a detection, in particular by means of a camera, of the marking for determining the actual alignment from a position and arrangement of the marking. Furthermore, the actual alignment can be determined in the coordinate system by taking an image of the aerial vehicle, wherein a contour and/or pixel-dependent distance data in respect of the aerial vehicle are derived from the image.
Within the scope of the method according to the invention, the aerial vehicle can be moved dependent on the actual state and a specific flight route, wherein the flight route can be determined, in particular automatically, by a start point and an end point and/or by a number of waypoints and/or by a defined position of a flight axis, in particular wherein a movement of the aerial vehicle can be optimized taking into account the actual state. Alternatively, or in addition thereto, information in respect of the actual state, in particular the actual position, the actual alignment, the actual velocity, the angle of incidence, the beam offset and/or the distance to the measuring unit, can be fed to a Kalman filter and the movement of the aerial vehicle can be controlled taking into account parameters calculated by the Kalman filter.
Furthermore, according to the invention, an object distance from the aerial vehicle to an object can be measured, in particular continuously, wherein the object distance can be taken into account when controlling the aerial vehicle and/or wherein the aerial vehicle ( 20 ) can be controlled in such a way that the aerial vehicle ( 20 ) is guided constantly at a specific intended distance from the object ( 81 , 85 ) depending on the measurement of the object distance.
Furthermore, in the method according to the invention, a position and alignment of the measuring unit can be predetermined in a global coordinate system, wherein the position can be predetermined by a known setup point of the measuring unit and/or the position and alignment can be determined by calibration on the basis of known target points, in particular wherein the coordinate system can be referenced with the global coordinate system such that the actual state of the aerial vehicle can be determined in the global coordinate system.
The invention furthermore relates to a geodetic measuring unit, in particular a total station, theodolite, laser tracker or laser scanner, for a system according to the invention, with a beam source for emitting a substantially collimated optical beam, a base, a sighting unit which can be pivoted by motor about two axes relative to the base for aligning an emission direction of the optical beam and angle measurement sensors for determining the alignment of the sighting unit, and, in particular, with a ranging functionality. Furthermore, the measuring unit is embodied in such a way that control data for controlling a self-propelled, unmanned, controllable aerial vehicle can be generated and transmitted to the aerial vehicle.
The invention moreover relates to a computer program product, which is stored on a machine-readable medium, or computer data signal, embodied by an electromagnetic wave, with program code for producing control data depending on an actual state, which in particular is determined continuously, of an aerial vehicle and of a defined intended state for automatically controlling the aerial vehicle into the intended state, in particular if the program is carried out in an electronic data processing unit.
BRIEF DESCRIPTION OF THE DRAWINGS
The method according to the invention and the system according to the invention are described in more detail below in a purely exemplary manner on the basis of specific exemplary embodiments which are illustrated schematically in the drawings, wherein further advantages of the invention are also mentioned. In detail:
FIGS. 1 a - c show a positioning movement, according to the invention, of the aerial vehicle from an actual state to an intended state;
FIG. 2 shows a first embodiment of a measuring system according to the invention, with an unmanned aerial vehicle and a total station;
FIG. 3 shows a second embodiment of a measuring system according to the invention, with an unmanned aerial vehicle and a laser scanner;
FIGS. 4 a - b respectively show a third embodiment of a measuring system according to the invention, with an unmanned aerial vehicle and a rotation laser; and
FIGS. 5 a - c show three embodiments for an aerial vehicle controlled by a measuring system according to the invention.
DETAILED DESCRIPTION
FIG. 1 a schematically shows a positioning process according to the invention for an aerial vehicle. Here, the aerial vehicle is in an actual state, which is defined by an actual position 12 , an actual velocity and/or an actual alignment, and should assume an intended state. The intended state of the aerial vehicle is predetermined by an intended position 11 and a flight velocity (intended velocity), which should equal zero at the intended position 11 . Moreover, an intended alignment of the aerial vehicle can be set within the scope of the intended state, wherein the aerial vehicle can be equipped with a measuring sensor for determining the alignment and hence be able to carry out a defined self-alignment. Depending on the intended state and the actual state, it is now possible to determine a correction 13 , i.e. the actual state of the aerial vehicle can be compared to the intended state and a difference for the respective state variable (position, velocity, alignment) can be calculated therefrom. Furthermore, control data or control signals can be derived from these state differences and transmitted to the motors of the rotors for controlling the aerial vehicle. On the basis of the corrections 13 , the aerial vehicle can now be controlled with a specific velocity and alignment, proceeding from the actual state, in particular from the actual position 12 , in such a way that there is e.g. an iterative approach to the intended state or to the intended position 11 . In the process, the actual state of the aerial vehicle is continuously compared to the intended state and a respective correction 13 is derived therefrom. This correction 13 of the actual state of the aerial vehicle can occur until the actual state of the aerial vehicle corresponds to the intended state or the difference comes to rest below a predefined threshold such that a correction 13 no longer needs to be carried out.
FIG. 1 b shows positioning according to the invention of an aerial vehicle on a predetermined trajectory 17 . The trajectory 17 or flight route for the aerial vehicle is in this case limited by a start point 14 and an end point 15 and the profile thereof is defined by further waypoints 16 a , 16 b . The aerial vehicle is in an actual state, which, in turn, can be defined by an actual position 12 , an actual velocity and/or an actual alignment of the aerial vehicle. Here, the actual state can be determined by means of an evaluation unit. In this arrangement, the intended state (intended position 11 ) of the aerial vehicle is determined by the profile of the trajectory 17 . Here corrections 13 are also established by comparing the actual state with the intended state, which corrections are converted into control signals for the aerial vehicle and transmitted to the latter. During the calculation of a positional correction 13 , the current alignment or the flight direction and the velocity can be taken into account here, wherein the aerial vehicle is not necessarily directed to the trajectory 17 on the shortest distance, but rather is controlled in an optimized direction and with an optimized velocity to the flight route. By way of example, this can avoid strong deceleration and acceleration of the aerial vehicle and an abrupt change in direction. Moreover, an optimized reduction in the flight velocity can be prescribed at e.g. those waypoints 16 a , 16 b , 16 c at which there is a change in direction of the flight path.
FIG. 1 c shows an alignment and positioning, according to the invention, of an aerial vehicle on a predetermined axis 18 . It is possible to calculate the corrections 13 taking into account the actual state, inter alia the actual position 12 , and control signals transmitted by a user, which control signals can bring about a forward and backward movement of the aerial vehicle along the axis 18 . Analogously to the positioning as per FIG. 1 b , the movement of the aerial vehicle from the actual position 12 to the intended position 11 can be optimized in such a way that, in particular, the flight velocity or control commands, such as e.g. a movement direction 19 , additionally entered by a user are taken into account in the correction movement 13 and, as a result thereof, the flight path is not along the shortest path between actual position 12 and axis 18 . In the shown case, the correction movement 13 of the aerial vehicle 20 can be in the direction 19 to the right-hand side due to a control command.
FIG. 2 shows a measuring system 1 according to the invention, with an unmanned aerial vehicle 20 and a total station 30 , which represents a measuring unit.
The actual state of the aerial vehicle 20 , in particular the actual position, can in this case be detected by measurements from the total station 30 or a laser scanner (not shown here). The total station 30 is equipped with an emission unit 31 , which can be pivoted about two axes, as a result of which an emission direction can be aligned with the aerial vehicle 20 . The precise alignment can be detected by angle measurement sensors on the total station 30 . Additionally, a distance measuring module, which renders it possible to carry out a measurement of a distance to a reflector 22 on the aerial vehicle 20 , is integrated into the emission unit 31 . An actual position or actual coordinates of the aerial vehicle 20 can be determined from the measured angles and the distance. In order to determine the actual alignment, there can be on the part of the measuring instrument, e.g. by a camera integrated in the emission unit 31 or by an external camera, the field of view of which can be aligned to the aerial vehicle 20 , in particular via a mirror, wherein a marking, e.g. several LEDs or defined patterns, can be observed and detected at a known position on the housing of the aerial vehicle 20 . Moreover, measurement data in respect of the actual state can also be detected by a sensor unit 21 , which for example has an accelerometer, rate sensor, magnetometer, inclination sensor and/or a velocity sensor.
All measurement data can be transmitted to a control unit 60 e.g. via cable or radio link, which control unit is situated in the total station 30 in this embodiment but can alternatively be arranged in a remote control or in the aerial vehicle 20 . An algorithm, e.g. a Kalman filter, can be used to calculate the actual state (position, velocity, alignment) of the aerial vehicle 20 from the measurement data.
In the process, the measurement data can be detected with different measurement frequencies. Thus, the total station 30 can detect e.g. the angles and the distance with a measurement frequency of e.g. 1 Hz, while the accelerometer can determine the accelerations acting thereon with a frequency of e.g. 100 Hz or more. By a suitable combination of the sensors, the position can thus be determined by the Kalman filter with a frequency of e.g. 100 Hz or more and thus have a positive effect on regulating the aerial vehicle. All measurements, e.g. angles and distance and/or accelerations, inclines and/or rates, from the sensor unit can be fed to the Kalman filter, which continuously calculates positional coordinates, a velocity vector and/or an alignment angle as well as possible sensor-specific parameters, e.g. the bias of the accelerometer, of the aerial vehicle with a frequency of e.g. 100 Hz or more.
Corrections can be derived from the actual state and control signals, which, for example, are entered into the system 1 by a user via a remote control, wherein these corrections are transmitted directly or in the form of further control signals to the motors of the aerial vehicle 20 and can bring about a corrected positioning of the aerial vehicle 20 .
In this first embodiment shown here, the measurement data for determining the actual state of the aerial vehicle 20 can be detected by the total station 30 and a sensor unit 21 . The emission unit 31 of the total station 30 can be aligned continuously to the reflector 22 on the aerial vehicle 20 by an automatic target detection function and, as a result, track the aerial vehicle 20 . In the case where the automatic target tracking loses the connection to the target (reflector 22 ), e.g. due to a visual obstacle, an approximate position can be transmitted by radio link to the measuring instrument 30 on the basis of measurements of the sensor unit 21 and/or of a GNSS module on the aerial vehicle 20 . On the basis of this information, the measuring instrument 30 can find the target again, reestablish the connection and once again carry out automatic target tracking. Furthermore, if the connection is lost thus, the aerial vehicle 20 can be detected by a camera and e.g. a contour of the aerial vehicle 20 can be derived by image processing and the measuring unit 30 can be newly aligned with the UAV 20 on the basis thereof. The distance measuring module and the angle sensors, which are arranged on the total station 30 , can be used to measure the distance to the reflector 22 and the alignment of the emission unit 31 and hence the direction of a beam 32 , in particular a measurement beam, emitted by the emission unit 31 . The measurement data can then be transmitted on to the control unit 60 in the total station 30 .
At the same time, the alignment of the aerial vehicle 20 can be determined by a sensor unit 21 . To this end, use can be made of measurements from an accelerometer, a rate sensor, a velocity sensor, an inclination sensor and/or a magnetometer, which can be arranged in the sensor unit 21 onboard of the aerial vehicle 20 . The measurement data determined thereby can be transmitted to the control unit 60 via e.g. radio link.
The actual state of the aerial vehicle 20 can be calculated in the control unit 60 from the measurement data established by the total station 30 and by the sensor unit 21 , and it can be compared to the predetermined intended state. From this, it is possible, in turn, to derive the corrections which can be transmitted to the aerial vehicle 20 by radio link and, there, can be transmitted as control signals on to the rotors 23 for positioning and alignment purposes.
FIG. 3 shows a second embodiment of a measuring system 1 according to the invention, with an unmanned aerial vehicle 20 and a laser scanner 40 as measuring unit.
In this case, a movement axis 43 is prescribed on the part of the laser scanner 40 for the aerial vehicle 20 by emitting an optical beam 42 . To this end, the beam 42 , in particular a laser beam, is, using a rotatable mirror 41 in an emission unit, emitted in a direction in which the aerial vehicle 20 should be moved. When the aerial vehicle 20 is coupled to the laser beam 42 , a lateral positional deviation and an angular deviation of the aerial vehicle 20 from the predetermined axis 43 is determined by a beam detection unit 25 . Additional measurement data, such as e.g. the inclinations of the aerial vehicle 20 , can, in turn, be detected by the sensor unit 21 . By way of example, the aerial vehicle 20 can be coupled to the beam 42 by virtue of a user 100 moving the aerial vehicle 20 to the laser beam 42 by means of a remote control unit 70 or by virtue of the laser beam 42 being directed to the detection unit 25 , the aerial vehicle 20 being coupled on and the beam 42 then being aligned in a defined direction, with the aerial vehicle 20 remaining coupled on and being moved along accordingly with the realignment of the beam 42 .
The measurement data to be detected in order to determine the actual state can in this case be detected on the aerial vehicle 20 by means of the beam detection unit 25 . By way of example, this beam detection unit 25 can consist of a reception optical unit and an image sensor, wherein the laser beam 42 can be imaged as laser point in the recorded image and a beam offset or an angle of incidence can be detected.
Depending on the design of the reception optical unit, it is possible to determine the lateral positional deviation or the angular deviation of the laser beam 42 from an optical axis of the reception optical unit from the position of the laser point in the image. The angular deviation can be detected by means of a collimator associated with the reception optical unit. A detection unit 25 which can detect both the lateral positional deviation and the angular deviation with two reception optical units is also feasible.
All measurement data can be transmitted to the control unit 60 on the aerial vehicle by a wire connection or by means of a radio link and can be used there to calculate the actual state of the aerial vehicle. Additionally, control data, which can bring about a forward or backward movement of the aerial vehicle along the axis 43 , can be transmitted from the user 100 to the control unit 60 via the remote control unit 70 . From a comparison of the actual state with the intended state, it is possible to calculate corrections while taking into account the user-defined control data, which corrections can be transmitted to the rotors of the aerial vehicle 20 as control signals and can bring about an alignment and positioning of the aerial vehicle 20 on the laser beam 20 , i.e. a correspondence of the predetermined direction of the movement axis 43 with an optical axis of the beam detection unit 25 . Moreover, the lateral beam offset and the angular offset can be fed to the Kalman filter, which, in particular, is embodied in the control unit 60 .
In this embodiment, it is also possible to realize a semi-autonomous control of the aerial vehicle 20 in such a way that the movement axis 43 , along which the aerial vehicle 20 should move, is prescribed to the system 1 as intended state. Using this system 1 , which operates by the interaction of laser beam 42 , beam detection unit 25 and optionally additional measurement data from the sensor unit 21 , the aerial vehicle 20 can automatically be kept on the movement axis 43 . The forward and backward movement along the axis 43 , i.e. a movement of the aerial vehicle 20 with one degree of freedom, can therefore be brought about in a simple manner by the user 100 by means of the remote control unit 70 .
If the aerial vehicle 20 should moreover be positioned on the predetermined movement axis 43 at a predetermined distance from the laser scanner 40 , the actual distance can be measured by a distance measurement using the laser scanner 40 . By comparing this actual distance with the predetermined intended distance, it is once again possible to calculate corrections, which are transmitted to the aerial vehicle 20 as control signals for actuating the rotors 23 and can bring about a positioning of the aerial vehicle 20 at the predetermined intended distance. Since the alignment of the beam 42 emitted by the laser scanner 40 and the distance to the aerial vehicle 20 in this beam direction are known, the position of the aerial vehicle 20 can moreover be determined exactly or the coordinates can be derived in respect of a relative coordinate system of the laser scanner 40 .
FIGS. 4 a and 4 b respectively show a third embodiment of a measuring system 1 according to the invention, with an unmanned aerial vehicle 20 and a rotation laser 50 , and are therefore described together here. In these embodiments, the rotation laser 50 or a rotating emission of a laser beam 52 from the rotation laser 50 can predetermined a guide plane 53 or an intended movement plane in the horizontal ( FIG. 4 a ) or at a predetermined angle α to the horizontal H ( FIG. 4 b ) in order to keep and to move the aerial vehicle 20 at a constant altitude or to move it in a defined direction. In principle, such a plane can also be defined by a rotating sighting unit of a total station while emitting a measurement beam.
When using a total station, it is possible, depending on the horizontal position of the aerial vehicle 20 , to rotate the sighting unit about the vertical axis and thereby align the emitted measurement beam with the aerial vehicle 20 . In the case of the rotation laser 50 , the plane 53 can be spanned independently of the position of the aerial vehicle 20 by a laser beam 52 which is rotating quickly about an axis.
Using the beam detection unit 25 it is possible to detect the deviation of the aerial vehicle 20 from a position defined by the plane, e.g. in altitude. The incline and alignment of the aerial vehicle 20 can in turn be determined by the sensor unit 21 on board of the aerial vehicle 20 . These measurement data are transmitted via radio link to the control unit 60 , which is integrated in the remote control unit 70 , of the user 100 . There it is possible to calculate the actual state of the aerial vehicle 20 in this fashion. From a comparison between the actual state and the intended state, which in this case for example corresponds to a positioning and alignment of the aerial vehicle 20 on the defined laser plane 53 , corrections are calculated taking into account possible additional control data produced by the user 100 , which corrections are transmitted as control signals to the aerial vehicle 20 in order to actuate the rotors 23 and are able to bring about a positioning of the aerial vehicle 20 in the predetermined intended state, i.e. a positioning and/or movement of the aerial vehicle 20 in the guide plane 53 .
Hence, there can be an automatic continuous change in the altitude of the aerial vehicle 20 in such a way that it is positioned on the predetermined horizontal plane 53 ( FIG. 4 a ). The change in the position of the aerial vehicle 20 in the plane 53 can furthermore be brought about by the user 100 by means of the remote control 70 , which can be realized as Smartphone or tablet PC. The user 100 can therefore move the aerial vehicle 20 in the plane 53 , i.e. with two remaining degrees of freedom.
In the case of a non-horizontal alignment of the plane 53 in accordance with FIG. 4 b , the beam detection unit 25 can be arranged at a corresponding angle on the aerial vehicle 20 or the alignment of the detection unit 25 can be adapted by a pivot device to the angle α of the plane 53 . In the case of such an arrangement, the user 100 can freely move the aerial vehicle 20 with two degrees of freedom on this angled plane 53 —indicated by the arrow P.
FIGS. 5 a , 5 b and 5 c show three embodiments for an aerial vehicle 20 controlled by a measuring system according to the invention.
FIG. 5 a shows an aerial vehicle 20 , which has a beam detection unit 23 which is aligned to a laser beam 82 . With this, the aerial vehicle 20 can be guided along a movement axis 83 . The laser beam 82 is aligned coaxially to the axis of a pipe 81 , which therefore corresponds to the movement axis 83 . With this arrangement, the aerial vehicle 20 can be moved, for example in a narrow pipe 81 , by means of the continuous guide along the beam 82 provided by the beam detection unit 23 in such a way that the distance to the pipe wall can be kept constant and a collision with the pipe wall can be avoided. Moreover, the aerial vehicle 20 can comprise distance measuring sensors 26 a , 26 b , e.g. scanners, which continuously detect distances to the pipe wall and provide measurement data. This data can additionally be used to control the aerial vehicle 20 and can be taken into account when calculating correction values for changing the aerial vehicle state. A user can therefore very easily move the aerial vehicle 20 backward and forward and position said aerial vehicle manually in the pipe 81 , in particular by means of a remote control.
FIG. 5 b shows a further application for an aerial vehicle 20 which is controlled in a guided manner according to the invention. Here, terrain 85 should be measured. To this end, a laser beam 82 can once again be aligned in the direction of a horizontal axis 83 and the aerial vehicle 20 can be moved along this beam 82 by means of a beam reception unit 25 , in particular on the basis of the beam offset and/or the angle of incidence. Using an additional sensor 26 , which can be aligned downward in the vertical direction, it is possible to measure the distance to the terrain surface continuously while flying over the terrain 85 . From this, a distance can be derived in each case between the axis 83 and the terrain and, by linking these distance values with the respective actual position of the aerial vehicle 20 , it is possible to establish a terrain profile or terrain section.
FIG. 5 c shows a further application for an aerial vehicle 20 which is controlled according to the invention. The aerial vehicle 20 is in this case guided in turn in a vertical plane (not shown), defined by a measuring unit, by means of the beam reception unit 25 . Using the distance measuring sensor 26 , a distance to a surface of an object 85 is measured during the movement of the aerial vehicle 20 and used for determining a flight route 86 for the aerial vehicle 20 . As a result of this continuous measurement, it is possible to maintain a constant distance to the object 85 when the aerial vehicle 20 is moved and hence render it possible to avoid a collision with the object.
It is understood that these depicted figures only depict possible exemplary embodiments in a schematic manner. According to the invention, the various approaches can likewise be combined with one another and with systems and methods for controlling aerial vehicles and with measuring instruments from the prior art.
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A geodetic measuring system having a geodetic measuring unit having a beam source for emitting a substantially collimated optical beam. The measuring system also has an automotive, unmanned, controllable air vehicle having an optical module. An evaluation unit is also provided, wherein the evaluation unit is configured in such a manner that an actual state of the air vehicle, as determined by a position, an orientation and/or a change in position, can be determined in a coordinate system from interaction between the optical beam and the optical module. The measuring system has a control unit for controlling the air vehicle, wherein the control unit is configured in such a manner that control data can be produced using an algorithm on the basis of the actual state, which can be continuously determined in particular, and a defined desired state, and the air vehicle can be automatically changed to the desired state.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for the determination of glucose concentration in blood, especially in serum, such concentration is called the "blood sugar concentration". In particular, the present invention relates to a method for the quick determination of glucose concentration in whole blood with a minimum error.
2. Description of the Related Art
Determination of glucose concentration in blood is required in medical research and treatment of some medical conditions. Various methods for the determination of the glucose concentration in the blood have been proposed and are carried out.
Among these methods, the glucose concentration in the blood is generally determined with a biosensor. Such a method is called the Glucose Sensor Method. In the glucose oxidase biosensor method, a glucose oxidase (GOD) fixed membrane is used in combination with a hydrogen peroxide electrode.
The Glucose Sensor Method is widely used especially in diagnosis and monitoring of diabetes since the glucose concentration is detected with high sensitivity without any pretreatment of blood because of substrate specificity obtained by using the glucose oxidase as part of the detection method.
Such biosensor method used for the determination of the blood sugar concentration in the blood comprises steps of:
separating a supernatant (plasma or serum) from the blood by centrifugation,
diluting the supernatant with a suitable buffer solution,
reacting glucose, oxygen and water in the supernatant with the fixed glucose oxidase,
measuring an amount of hydrogen peroxide produced by the enzyme reaction in terms of an output (current) of the hydrogen peroxide electrode, and
determining a decomposition rate of glucose, that is, a production rate of hydrogen peroxide.
FIG. 1 schematically shows an apparatus used in the biosensor method for the determination of the glucose concentration in the serum. A cell 1 for the determination of the glucose concentration comprises a GOD fixed hydrogen peroxide electrode 2, and a liquid in the cell is thoroughly stirred with a stirrer 3 and a stirring member 4. A buffer solution is supplied in the cell through a valve 6 with a pump 5. After the determination, the liquid in the cell is discharged through a valve 8 with a pump 7. A sample to be determined is supplied in the cell with a sample 9.
The decomposition rate of glucose by the glucose oxidase is proportional to the glucose concentration in the buffer solution. However, the amount of the glucose decomposed is so small that the glucose concentration in the buffer solution is regarded to be constant. Thus, the hydrogen peroxide production rate is constant in a steady state. When the sample is supplied in the buffer solution, the output current from the hydrogen peroxide electrode is, for example, as shown in FIG. 2. The output current of the hydrogen peroxide electrode becomes constant after about 10 seconds from the sample supply.
A calibration curve is beforehand obtained which shows a relation between the glucose concentration and the output current of the hydrogen peroxide electrode after 10 to 20 seconds from the sample supply. Then, the glucose concentration the sample to be measured is obtained as follows: the output current of the hydrogen peroxide electrode with respect to the sample diluted with the buffer solution is measured; and the glucose concentration in the buffer solution which corresponds to the measured output current is read from the calibration curve. The glucose concentration in the diluted sample is converted to the glucose concentration in the undiluted sample by multiplying by the dilution ratio. This determination method is herein called the "Equilibrium Method".
When the glucose concentration in the sample is measured, the sample is usually diluted with the buffer solution as described above. The term "measured glucose concentration" is, hereinafter, intended to mean a glucose concentration which is the glucose concentration in the diluted sample. "Measured glucose concentration" is obtained from the measured output current by reading from a calibration curve plotted from output current measurements of some aqueous glucose solutions of known glucose concentration.
When the curve as shown in FIG. 2, namely, the curve which shows a relation between the output current (I) of the hydrogen peroxide electrode and time (t) is differentiated with respect to time (dI/dt), a curve as shown in FIG. 3 is obtained. A relative maximum value (i.e. a maximum changing rate of the hydrogen peroxide electrode output current) on the curve in FIG. 3 is proportional to the glucose concentration in the buffer solution. Thus, when a relation between the glucose concentration and the relative maximum value of dI/dt has been obtained beforehand as a calibration curve, the measured glucose concentration in a certain sample to be measured is obtained by measuring the relative maximum value of the changing rate of the output current of the hydrogen peroxide electrode immersed in the sample. This method to obtain the glucose concentration in the sample as described above is herein called the "First Differential Method". According to this method, the glucose concentration is obtained after 2 to 3 seconds from the supply of the sample into the buffer solution.
FIG. 4 shows a curve which results from a second order differentiation with time of the curve shown in FIG. 2 (d 2 I/dt 2 ). A relative maximum value on the curve shown in FIG. is also proportional to the glucose concentration in the buffer solution. Thus, the glucose concentration in the buffer solution can be determined from the relative maximum value as in the First Differential Method. This method as just described above is called the "Second Differential Method". According to this method, the glucose concentration can be advantageously obtained in a shorter time than in the First Differential Method.
Broken lines in FIGS. 2 and 3 and dashed lines in FIGS. 3 and 4 each indicate correspondency of time as shown with arrows.
The glucose concentration obtained by any of the methods as described above is that in a homogeneous solution, for example the buffer solution in which the serum is diluted. Therefore, the serum must be obtained by previously separating blood cells from the blood by centrifugation. It takes about 10 to 15 minutes to centrifugally separate the serum. As long as such separation is required, a quick determination of the glucose concentration is impossible.
The biosensor method is preferably applied to whole blood since the glucose concentration is quickly obtained. The following problems arise in the use of any of the methods described above.
The blood consists of the serum and the blood cells, and the blood cells contain a liquid component therein. The glucose concentration in the blood cells is the same as that outside the blood cells. A solid component of the blood is contributed by the blood cells. The amount of the solid component is generally 25 to 40% of the blood by volume.
For example, in the case where a whole blood sample is introduced into an isotonic buffer solution and then the glucose concentration is measured, glucose in the blood cells transfers into the buffer solution within about 10 seconds to form an equilibrium state in which the glucose concentration in the buffer solution is the same as that inside the blood cells. In this case, not only the serum of the blood but also the liquid component in the blood cells are diluted with the isotonic buffer solution. Then, all of the glucose in the whole blood is measured. However, a true glucose concentration (in which the solid component in the blood is taken into account) cannot be obtained since the ratio of the blood cell volume to whole blood volume is unknown, thus, the true dilution ratio is unknown. Correction of the concentration was proposed in 1980 by WHO (World Health Organization) by the use of an average ratio of the volume of the blood cells to the whole blood volume (blood cell ratio). However, the ratio of the blood cell volume to whole blood volume is highly variable among individuals. Thus, correction based on an average value introduces a rather large error.
When the First Differential Method is employed, equilibrium is reached within a short time, for example after 2 or 3 seconds from the time the sample is supplied. The glucose concentration measured by this method corresponds to that of the buffer solution which contains not only the glucose in the serum but also a small amount of glucose from the blood cells. Also in this case, the true glucose concentration cannot be obtained since the ratio of the volume of the blood cells to the whole blood volume is unknown. A corrected glucose concentration may be obtained using the average blood cell ratio (hematocrit value). Since the hematocrit value varies among individuals, the corrected glucose concentration includes a rather large error.
In the case where the Second Differential Method is employed, not only the glucose in the serum but also a smaller amount of glucose from the blood cells is measured. It is easily understood that the same problems as arise in the First Differential Method arise in this case.
The amount of glucose which is liberated from the blood cells in the Second Differential Method is less than that in the First Differential Method. Although in the method of the present invention, described below, the First Differential Method or the Second Differential Methods is used, the present method is not affected by the amount of liberated glucose since it is very small and the error is canceled when the measured glucose concentration is converted as described below.
As described above, the Glucose Sensor Method is an effective method to quickly measure the glucose concentration itself. However, the centrifugal separation to obtain the serum cannot be omitted as long as the blood cell volume to whole blood volume ratio is unknown. Therefore, the glucose concentration cannot be measured in the whole blood.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method for the quick and accurate determination of the true blood sugar concentration from a measured glucose concentration which is obtained from a whole blood sample by the biosensor method in which the problems caused by the individual variation in blood cell ratio as described above are overcome.
According to the present invention, there is provided a method for the determination of a glucose concentration in a whole blood sample comprising steps of:
1) obtaining two kinds of measured glucose concentrations in a whole blood sample to be measured by "Equilibrium Method" and a method selected from a group consisting of "First Differential Method" and "Second Differential Method",
2) estimating a ratio of blood cell volume to the whole blood volume from a ratio of one measured glucose concentration to the other on the basis of a previously established relation between the blood cell ratio and a function of the ratio of said two measured concentrations, whereby a conversion factor defined as a ratio of a true glucose concentration in the whole blood to the glucose concentration measured by on of said three Methods is obtained, and
3) converting said one measured glucose concentration with the obtained conversion factor to give the true glucose concentration as the glucose concentration in the whole blood.
The "Equilibrium Method", the "First Differential Method" or the "Second Differential Method" is, herein, the same Glucose Sensor Method as described in the background part of the present specification, in which method the combination of the fixed glucose oxidase with the hydrogen peroxide electrode is used.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows an apparatus with which a method of the present invention is performed by the Glucose Sensor Method.
FIG. 2 is a graph showing a curve obtained by Equilibrium Method.
FIG. 3 is a graph showing a curve obtained by First Differential Method.
FIG. 4 is a graph showing a curve obtained by Second Differential Method.
FIG. 5 is a graph showing a relation between a measured glucose concentration [Cx or Cy] and a ratio of serum volume to serum volume plus blood cell volume [X].
FIG. 6 shows a relation between a measured glucose concentration ratio [μ] and the ratio of the serum volume to the serum volume plus the blood cell volume [X].
FIG. 7 shows a relation between a conversion factor and the ratio of the blood cell volume to the serum volume plus the blood cell volume [1--X].
DETAILED DESCRIPTION OF THE INVENTION
The following definitions are used in the description of the invention below:
A=volume of an undiluted whole blood sample.
B=volume of a buffer solution used to dilute a whole blood sample.
a=volume of the solid component of a whole blood sample.
b=volume of the liquid component of the blood cell in the whole blood sample. p1 c=volume of serum component of a whole blood sample.
X=c/A
Co=true glucose concentration in a sample.
Cx=uncorrected glucose concentration in a sample, measured by the equilibrium method.
Cy=uncorrected glucose concentration in a sample, measured by a differential method.
Rx=Cx/Co.
Ry=Cy/Co.
μ=Rx/Ry=Cx/Cy.
The present invention is completed on the basis of following considerations:
If one of the Glucose Sensor Methods is applied, the measured glucose concentration deviates from the true glucose concentration (i.e. a blood sugar concentration in a liquid component of the blood) since the blood cells (or solid component) are present in the whole blood as described above. Therefore, when the deviation of the measured glucose concentration from the true glucose concentration has been previously known depending on the ratio of the volume of the blood cells (solid component) to the volume of the whole blood, conversely such ratio can be estimated from the deviation extent.
In the case where the blood sugar concentration is determined with the Glucose Sensor Method, a given amount of the whole blood [A] (for example 20 μl) is diluted with a given amount of the buffer solution [B] (for example 1.5 ml). Then, the apparent diluting ratio is equal to (A+B)/A. When the glucose concentration is to be measured in an unseparated blood sample [A], which consists of an amount of the serum [c] and the blood cells consisting of an amount of the solid component [a] and an amount of a liquid component [b] on the basis of volume, i.e. A=a+b+c, the apparent diluting ratio is equal to (A+B)/A but the true diluting ratio is equal to (b+c+B)/(b+c) since glucose in the serum [c] and in the liquid component [b] is to be measured. When there are no blood cells in the blood sample, that is, the sample consists only of the serum, the true diluting ratio is equal to the apparent diluting ratio, as a=0. Thus, in that case the measured glucose concentration is equal to the true glucose concentration.
When the First Differential Method or the Second Differential Method is applied, glucose only in the serum [c] is measured. Thus, the true diluting ratio is equal to (c+B)/c. Since the solid component in the blood is due to the blood cells, the measured glucose concentration can be converted to the true glucose concentration if the ratio of the volume of the blood cells to whole blood volume is estimated.
According to the present invention, the ratio of the blood cell volume to whole blood volume (i.e. (a+b)/A) or the ratio of the serum volume to whole blood volume (i.e. c/A) is estimated and then the conversion coefficient is obtained as described below. Therefore, the true glucose concentration is obtained by converting the measured glucose concentration with the conversion coefficient.
Now, the method for estimating the blood cell ratio will be described.
A blood sample containing glucose at a certain constant concentration is subjected to the Equilibrium Method while changing the ratio of the blood cells, whereby results as shown in FIG. 5 are obtained. In the graph shown in FIG. 5, the ordinate X indicates [serum/(serum+blood cells)]×100 (%) on the basis of volume, and the abscissa shows the measured glucose concentration.
It is clearly seen from the graph in FIG. 5 that the measured glucose concentration Cx is smaller than the true glucose concentration (except at X=100%) since the apparent diluting ratio is not changed in spite of increase of the true diluting ratio when the blood cell ratio increases, that is, [c] decreases, whereby the proportion of the solid component increases.
Then, with respect to the same samples as the Cx values are obtained in the above Equilibrium Method, the measured glucose concentrations are obtained by the First Differential Method, which are shown in terms of Cy in the graph in FIG. 5. In the case whereby the First Differential Method is applied, the relative maximum value of dI/dt is reached before the glucose in the blood cells is released into the buffer solution as described above. Then the glucose concentration is practically measured under the condition that glucose only in the serum is diluted.
Therefore, the measured glucose concentration Cy is smaller than that obtained by the Equilibrium Method, since the true diluting ratio is larger than that in the case of the Equilibrium Method since glucose in the liquid component of the blood cells [b] is not measured. Thus, the apparent diluting ratio is not changed and the amounts of the whole blood sample and the buffer solution are the same as those in the above measurement made using the Equilibrium Method. Therefore, as the blood cell ratio increases, the measured glucose concentration decreases, since the amount of glucose available to be measured that is contributed by the serum decreases because of the decrease of [c while the apparent diluting ratio is not changed in spite of the increase in the true diluting ratio.
Both measured glucose concentrations (Cx and Cy) deviate from the true glucose concentration Co (at X=100%). The extent of each deviation is Cx/Co (=Rx) in the case of the Equilibrium Method or Cy/Co (=Ry) in the case of the First Differential Method. A ratio (u) of such deviations is as follows:
μ=Rx/Ry=Cx/Cy
Thus, with respect to some standard samples each having different known ratio X of an amount of serum to a total amount of blood cells plus serum (X=c/[a+b+c]), Cx and Cy are determined and then a relation between X and μ is obtained as following equation:
X=fn(μ) (1)
wherein fn means a function.
When the relations between the measured glucose concentration Cx and X and between the measured glucose concentration Cy and X are expressed by linear relations, respectively, the relation between X and μ is expressed by a hyperbolic relation. If a more accurate relation is required, an approximate expression rather than the hyperbolic relation can be easily obtained by any suitable mathematical technique.
The relation between μ and X on the basis of the data as shown in FIG. 5 is indicated in a graph in FIG. 6. When the relation as indicated in FIG. 6 has been previously known, X is easily estimated by calculating μ from the data obtained by the Equilibrium Method and the First Differential Method.
In the method of the present invention, Cx and Cy are obtained with respect to a whole blood sample, and then μ is easily calculated. With the calculated μ, X is estimated from the equation (1) or the same curve as indicated in FIG. 6. When x is estimated, the conversion factor (Co/Cx) at the estimated X can be obtained from the data as shown in FIG. 7.
Since the relation between X and the conversion factor does not depend on the glucose concentration of the sample, such relation only has to be determined once. FIG. 7 is a graph which shows a relation between the logarithm of the conversion factor (a ratio of the glucose concentration in serum [Co] (i.e. the true glucose concentration) to the measured glucose concentration by the Equilibrium Method [Cx]), namely, log [Co/Cx], and the blood cell ratio (i.e. [volume of blood cells/(volume of serum+volume of blood cells)]×100[%]. understood from FIG. 7 that the relation is nearly linear.
From FIG. 7, the conversion factor is obtained. Since the abscissa indicates not the serum ratio but the blood cell ratio the conversion factor is obtained after estimation of the blood cell ratio from X. Then, the true glucose concentration is obtained by multiplying the glucose concentration measured using the Equilibrium Method by the conversion factor. In the case where the glucose concentration measured by the First Differential Method is multiplied, the same procedures as in the case of the Equilibrium Method are carried out except that Co/Cy is used instead of Co/Cx in the estimation of the conversion factor.
In the case where the Second Differential Method is used, the measured glucose concentration is affected by the blood cells as in the First Differential Method. Since the period from the sample supply into the buffer solution to the appearance of the relative maximum value in the Second Differential Method is shorter than that in the First Differential Method, the amount of glucose released from the blood cells is smaller and therefore the effect of the blood cells is more remarkable. However, such effect is proportional to the amount of the blood cells as in the First Differential Method. Thus, when a relation between the blood cell ratio and a ratio of the measured glucose concentration by the Equilibrium Method to the measured glucose concentration by the Second Differential Method has been previously obtained as in the case where the Equilibrium Method and the First Differential Method are used, the true glucose concentration is obtained from a curve as shown in FIG. 7.
Though in the basic principles of the present invention the procedures as described above should be followed, such procedures are easily programmed in software on the basis of the present invention and easily processed with a computer. Thus, when the calibration curve as shown in FIG. 7 has been previously obtained, the glucose concentration can be obtained in real time.
Conventionally, the determination of the glucose concentration has required the separation of the serum from the blood. According to the present invention, the determination of the glucose concentration in whole blood can be performed so that the separation of the serum from the blood is omitted in the determination of the glucose concentration. Thus, the time required for such separation is saved and the overall time for making the determination is remarkably shortened.
EXAMPLE
Preparation
In the example, a commercial apparatus used for the glucose concentration measurement (commercially available as GA-140 from Kyoto Daiichi Kagaku Co., Ltd., Kyoto, Japan) was modified as described below. The apparatus comprised a hydrogen peroxide electrode (commercially available as Type E-08 from Kyoto Daiichi Kagaku Co., ltd.) as a sensor to which a glucose oxidase fixed membrane was installed. To perform the measurement, a blood sample was automatically sucked from a sample cup on a turntable.
For each measurement, 1.7 ml of a buffer solution (phosphoric acid buffer solution of 0.075M, pH=6.7) and 20 μl of the blood sample were used. The apparatus was originally for the measurement of the glucose concentration by the First Differential Method and it was modified so that the Equilibrium Method was also performed and output data (current) from the hydrogen peroxide electrode was processed through an interface by a personal computer (commercially available as PC9801 from NEC Corp, Tokyo, Japan).
Before the measurement of a blood sample, a standard glucose solution of 150 mg-glucose/dl was subjected to measurements by the Equilibrium Method and the First Differential Method for calibration of each Method.
Then, a blood sample was divided into a blood cell sample and a serum sample by centrifugation. The glucose concentration in the serum sample was measured by the Equilibrium Method and the First Differential Method. The glucose concentration was measured to be 84 mg/dl by each method.
With the use of the serum sample and the blood cell sample which were prepared as described above, standard samples having a percentage of the blood cells by volume of 0, 20, 40, 60, and 80% were prepared and the glucose concentrations thereof were measured. The results on each standard sample by the Equilibrium Method and the First Differential Method are as shown in FIG. 5.
Then, the curve in the graph as shown in FIG. 6 was obtained by the calculation of μ=(the measured glucose concentration by the Equilibrium Method)/(the measured glucose concentration by the First Differential Method) in relation to the percentage of the serum, thus the blood cell ratio. In FIG. 6, the relation is shown in relation to the ratio of the serum volume to the whole blood volume.
FIG. 7 shows the graph which indicates the relation between the logarithm of the converted conversion factor (i.e. the glucose concentration in the serum (=84 mg/dl)/the measured glucose concentration in each standard sample by the Equilibrium Method) and the blood cell ratio.
Measurement of Sample
The glucose concentration in the whole blood was measured with respect to thirty blood samples as follows:
(a) Each sample was divided into two samples.
(b) One of the two divided samples was subjected to the separation by centrifugation, and the glucose concentration in the separated serum was measured by the First Differential Method.
(c) With respect to the other sample of the two divided samples, the glucose concentration was measured in the whole blood by the First Differential Method.
(d) The ratio (μ) was calculated on each sample from the measured glucose concentrations by the Equilibrium Method and the First Differential Method. Then, the percentage of the whole blood volume consisting of the serum [X], thus the blood cell ratio, in the whole blood was also estimated from the curve in FIG. 6.
(e) The conversion factor which corresponds to the estimated blood cell ratio was obtained from FIG. 7 and then the converted glucose concentration was obtained as the true glucose concentration by multiplying the glucose concentration measured by the Equilibrium Method by the conversion factor.
Results
A correlation between the measured glucose concentrations obtained in the step (b) and those obtained in the step (c)was evaluated by plotting the former along X axis and the latter along Y axis. The correlation was such that Y+0.904·X and a correlation coefficient γ=0.962.
Similarly, the correlation between the measured glucose concentrations obtained in the step (b) and those obtained in the steps (d and e) was evaluated by plotting the former along the X axis and the latter along the Y axis. The correlation was such that Y=0.998·X and the correlation coefficient γ=0.995.
Although the present invention has been described with reference to the above example, various modifications may be made within the concept of the present invention. For example, an oxygen electrode or a FET (field effect transistor) can be used as a sensor instead of the hydrogen peroxide electrode. The enzyme need not be fixed to the electrode but rather it may be present in the buffer solution. Further, although the First Differential method and the Second Differential Method are described in relation to the present invention in which a differentiation is used for the determination of the glucose concentration, a higher order differentiation can be applied to the determination of the glucose concentration.
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There is provided a method for the determination of a glucose concentration in a whole blood utilizing a biosensor. A correction of the measured glucose concentration for dilution error introduced by the solid component of blood cells is calculated based on the change in glucose concentration measured before and after significant glucose has diffused from blood cells into the buffer used to dilute the sample. Thus, the need to centrifuge blood samples to obtain a cell-free serum sample for glucose determination is eliminated.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to color television receivers and more specifically to comb filters utilized in these receivers to separate the transmitted luminance and chrominance information.
2. Description of the Prior Art
Standard color television systems transmit the luminance and chrominance information separately. Luminance information is line locked to the horizontal scan, while the chrominance information is transmitted on a sub carrier having a frequency of 3.579545 MHz (227.5 X f h ). This choice of sub carrier provide luminance signals Y that are in phase from horizontal scan line to horizontal scan line and chrominance signals C that are 180 degrees out of phase on adjacent horizontal scan lines. At the video level a composite signal is established that is Y+C for one horizontal scan line and Y-C for the next horizontal scan line. These sum and difference video signals are utilized to separate the luminance video from the chrominance video.
In the prior art the composite video signal is coupled to a comb filter wherein it is delayed one horizontal line time, the delayed signal then being added to and subtracted from the composite signal of the next horizontal line; the sum providing a luminance video Y, the difference providing the chrominance video C. The combed chrominance signal is coupled through a low pass filter and summed with the combed luminance to restore some of the lost luminance vertical detail components, and also coupled through a bandpass filter for further processing.
Filters utilizing one horizontal scan line delay (1-H comb filter) effectively separate the chrominance and luminance signals on vertically correlated video signals thereby eliminating cross color and dot crawl. When the signals are not vertically correlated, however, the 1-H comb filter does not completely separate the Y and C components. This causes "hanging dots" on strong vertical color transitions and cross color components on high frequency diagonal Y transitions, especially when the diagonal detail is angled close to 45 degrees. The "hanging dots" artifact of 1-H comb filters is particularly offensive, since the luminance bandwidth in receivers employing 1-H comb filters is increased approximately 1 MHz over the 3 MHz utilized in older TV receivers wherein a 3.58 MHz trap is used. If the overall amplitude response of the receiver is of the Murakami type for optimum transient response and the phase response is linear, the amplitude of signals at frequencies at 3.58 MHz vicinity are considerably peaked, thus aggravating the "hanging dots" problem by making the dots very visible.
SUMMARY OF THE INVENTION
In accordance with the principles of the present invention an adaptive comb filter for separating the luminance and chrominance information contained in a composite video signal selectively combines the composite signal on one line with the composite signal on either the line above or the line below for each sample on the line. The choice for each sample is determined by initially comparing the difference signal obtained by subtracting the composite signal on the line above from the composite signal on the line presently being processed with the difference signal obtained by subtracting the composite signal on the line below with composite signal of the line presently being processed and comparing these two difference signals. If the difference between the two difference signals is substantially equal to zero, implying identical luminance and chrominance information on the line above and line below, the chrominance and luminance output signal obtained with the line above processing are chosen. Should the difference between the line above difference signal and the line below difference signal not be equal to zero, the system determines if the difference signal for the line above is approximately equal to zero, implying identical luminance information with no chrominance information on both the line in question and the line above, making the proper choice the luminance and chrominance output signals obtained by processing with the line above. Should the difference signal obtained by subtracting the composite signal on the line above with the composite signal on the line in question not be equal to zero, the difference signal obtained by subtracting the composite video signal on the line below with the composite signal on the line in question is investigated. If this difference signal is approximately equal to zero, the chrominance and luminance signals obtained by processing with the line below are selected.
The two difference signals obtained by subtracting the composite video signals on the line above and the line below from the composite video signal on the line under consideration are also each coupled to a low pass filter to remove the chrominance components from the two difference signals. If the difference signal obtained with the line below processing is not equal to zero the filtered line above difference signal is investigated. If this signal is approximately equal to zero, indicating no vertical transition from the line above, the luminance and chrominance signal obtained with the line above processing is chosen. If the filtered line above difference signal is not equal to zero the filtered line below difference signal is investigated. If this signal is approximately equal to zero then the luminance and chrominance signals obtained with line below processing are chosen. If the filtered line below difference signal is not equal to zero the luminance and chrominance signals obtained with line above processing are selected.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a comb filter utilized in the prior art for separating the luminance and chrominance signals from a composite video signal.
FIG. 2 is a representation of the luminance and the chrominance signals in the composite video signal.
FIG. 3 is a block diagram of a preferred embodiment of the invention.
FIG. 4 is a flow chart of an algorithm that may be employed for the selection logic of FIG. 3.
FIG. 5 is a block diagram of a circuit that may be employed to implement the logic of FIG 4.
FIG. 6 is a representation of diagonal transitions of the luminance signals.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a comb filter 10 of the prior art, shown in FIG. 1, the composite video signal is delayed by delay line 11 for a time interval equal to the time required to complete one horizontal scan line. This delayed signal is coupled to summation network 12 which sums the delayed signal x(n-1) with the current signal x(n) at the input terminal 13 of the delay line 11 to obtain luminance signals. Chrominance signals are obtained by subtracting the delayed signal x(n-1) from the current signal x(n) at the input terminal 13. This chrominance signal is coupled through an amplifier 15 having an amplification factor of 0.5 and a band pass filter 16 to the receiver demodulator not shown. Luminance signals are coupled through an amplifier 17 having an amplification factor of 0.5 to a summation network 18 wherein the luminance signals are added to the chrominance signals passed through a low pass filter 19 to provide luminance signals to the demodulator, not shown, from the output terminals of the summation network 18 having vertical detailed components restored thereon previously removed by the filtering process. Filters of the prior art effective in completely separating the chrominance and luminance signals on vertically correlated video signals, thereby eliminating cross color and dot crawl. When the signals are not vertically correlated, however, these prior art filters do not completely separate the luminance and chrominance signals, causing "hanging dots" on strong vertical color transitions and cross color distortion on high frequency diagonal luminance transitions, especially when the diagonal detail is angled close to 45 degrees. This problem is illustrated in FIG. 2 wherein a luminance signal Y 1 without any chrominance is indicated on horizontal sweep line 2 and a luminance signal Y 2 with a chrominance signal having a peak value C is indicated on horizontal sweep line 3. When these signals are processed by the filter of FIG. 1, the sum signal S ab provides a luminance signal that is the average of Y 2 +Y 1 with a chrominance ripple thereon having an amplitude C/2, while the difference signal D ab provides a chrominance signal with an amplitude C/2 riding on a luminance level that is equal to 1/2(Y 2 -Y 1 ).
Hanging dots created by combining lines 2 and 3 to separate the luminance and chrominance signals for line 3 may be eliminated by combining line 3 with line 4, that is combining line 3 with the line below rather than the line above. In this situation the resultant chrominance signal for line 3 is provided by the difference signal D be having a chrominance signal of peak value C with a zero luminance signal thereon and a luminance signal provided by S be having a value Y 2 and no chrominance ripple thereon. Thus, the hanging dot problem may be eliminated by providing an adaptive filter which selects the line above or the line below for combining with the line of interest in accordance with the color transitions about the line of interest. To accomplish this, two sets of sum and difference signals are formed and compared to determine which set is selected to provide the chrominance and luminance signals for the given line. These sum and difference sets may be represented as follows:
S.sub.ab (n)=[x(n)+x(n-1)]/2
D.sub.ab (n)=[x(n)-x(n-1)]/2
S.sub.be (n)=[x(n)+x(n+1)]/2
D.sub.be (n)=[x(n)-x(n+1)]/2
Such sum and difference sets may be provided by the adaptive filter 20 shown in FIG. 3. The first horizontal line x(n-1) that is utilized in the processing by the filter 20 is delayed, in delay circuit 20a, by a time interval equal to two times a horizontal sweep time by a first delay element 21 and a second delay element 22, while the second line in the processing x(n), the line for which the luminance and chrominance signals are to be separated, is delayed for a time interval to one horizontal sweep time by the delay element 21 and the third horizontal line entering into the process x(n+1), the line below the present line of interest, is not delayed at all.
A sum and difference set for line above processing is provided by summing x(n) with x(n-1) in summation network 23 and subtracting x(n-1) from x(n) in summation network 24 of summing circuit 20b to respectively provide S ab ,D ab . Similarly a sum and difference set for line below processing is provided by summing x(n) with x(n+1) in summation network 25 to obtain S be and subtracting x(n+1) from x(n) in summation network 26 to obtain D be . These sum and difference sets are coupled to selection logic circuitry 27 wherefrom the luminance and chrominance signals appear at the output terminals 28 and 29, respectively.
Selection logic unit 27 chooses a sum and difference set on a pixel-by-pixel basis using the D ab and D be signals. This selection may be made in accordance with an algorithm, the flow chart of which is shown in FIG. 4. First the absolute value of the difference between D ab and D be is investigated. If this value is substantially equal to zero the video signal is correlated vertically and both line above and line below processing may be employed. In this situation the conventional line above processing is chosen. Should the absolute value of the difference between D ab and D be not be equal to zero, the processing continues with an investigation of D ab . If this signal is substantially equal to zero, substantially equal luminance information on the lines x(n) and x(n-1) with no chrominance information thereon is indicated. In this situation the proper choice is line above processing and the algorithm chooses S ab ,D ab . Processing continues with an investigation of D be should the difference signal for the line above processing not be equal to zero. A value for D be substantially equal to zero indicates substantially identical luminance information on line x(n) and x(n+1) with substantially no chrominance information on these lines. In this situation, processing with the line below is chosen otherwise the processing continues.
When the value of D be is not equal to zero, two additional signals are needed to continue the processing. These are filtered values of D ab and D be . Signals representative of these values are obtained by passing the difference signals resulting from the line above and the line below processing through a low pass filter which rejects the chroma sidebands, removing the chrominance component while passing the vertical detail component, which may be utilized for the processing selection. With these two filtered values D abf and D bef the mode selection process continues by first investigating D abf . If this value is substantially equal to zero, indicating that no vertical transition has occurred from the line above, the signal set S ab and D ab is chosen. Should the filtered difference signal obtained from the line above processing not be equal to zero the processing continues by investigating the filtered difference signal obtained from the line below processing. If this signal is substantially equal to zero, indicating that no vertical transition has occurred to the line below, the line below sum and difference signals S be and D be are chosen. In the event that the filtered difference signal obtained from the line below processing is also not equal to zero then the system is directed to utilize the conventional line above processing.
A block diagram of a circuit capable of performing the logic indicated in the flow chart of FIG. 4 is shown in FIG. 5. The sum and difference signals for the line above and line below processing are coupled to a switch 30 which is normally set to select the sum and difference set obtained with the line above processing and is switched to select the set obtained with the line below processing only when the logic circuitry so indicates. The two difference signals are coupled to summation network 31, where the difference therebetween is obtained. The absolute value of this signal is coupled from the absolute value element 32 to a comparator having a threshold level T 1 . This threshold level is near zero and selected in accordance with a predetermined tolerance limit. If the absolute value coupled from element 32 exceeds the threshold of the comparator 33, an enabling signal is coupled to a comparator 34 wherein the absolute value of D ab from an absolute value element 35 is compared with a second threshold T 2 . The level of this threshold is near zero and chosen in accordance with a predetermined tolerance. If the absolute value of the signal couple from element 35 exceeds the threshold T 2 , an enabling signal is coupled to a comparator 36 wherein the absolute value of the difference signal obtained with the line below processing coupled from an absolute value circuit 37 is compared with the threshold value T 2 . If the absolute value signal coupled from the element 37 does not exceed the threshold T 2 , an activating signal is coupled to the switch 30 via OR gate 38 thereby selecting the sum S be and difference D be set for the line below processing. If the absolute value signal from the element 37 does exceed the threshold T 2 an enabling signal is coupled to another comparator 39.
The difference signal obtained from the line above processing is also coupled to a low pass filter 40 wherein chroma sidebands are rejected, thereby removing the chrominance component and providing a signal representative of the vertical detail component to an absolute value circuit 41. Signals representative of the absolute value of the filtered difference signal from the line above processing D abf are coupled to comparator 39 for comparison to a third threshold T 3 that is near zero and chosen in accordance with a predetermined tolerance. If the signal from the absolute value element 41 exceeds the threshold T 3 , an enabling signal is coupled from comparator 39 to a comparator 42, wherein a signal D bef representative of the absolute value obtained by passing the difference signal resulting from the line below processing through a low pass filter 43, which is identical to the low pass filter 40, and therefrom to an absolute value circuit 44, is compared to the threshold level T 3 . If the absolute value of the filtered difference signal D bef does not exceed the threshold T 3 an activating signal is coupled by an OR gate 33 to the switch 30, thereby selecting the sum and difference pair obtained with the line below processing. If this signal exceeds the threshold T 3 the switch is not activated and remains in a position to select the sum and difference signals for the line above processing.
In addition to the suppression of "hanging dots", the adaptive non-linear comb filter described above may be employed to eliminate cross color components inherent in the combed chroma output D ab of a conventional 1-H comb filter when diagonal luminance transitions are present. Referring to FIG. 6, a composite video signal having a diagonal luminance transition may be represented with luminance level Y 1 to the left of the diagonal and a second luminance level Y 2 to the right. D ab and D be for this situation both exhibit cross color components along the diagonal, the cross color component being represented by 0.5(Y 2 -Y 1 ) for D ab , 0.5(Y 1 -Y 2 ) for D be , and 0.5(Y 1 +Y 2 ) for S ab and S be . By selectively utilizing line-above and line-below processing, as described above, uncorrupted, luminance Y out and chrominance C out signals may be obtained with the mode transitions along the diagonal as shown in FIG. 6. It should be apparent from the composite video representation that either line-above or line-below processing in the region to the right of the line-below processing along the diagonal may be employed to establish the desired luminance and chrominance signals. S ab and D ab are indicated to be consistent with the preferred embodiment previously discussed. Those skilled-in-the-art will recognize that a minor modification to the switching circuitry could maintain line-below processing after the initial transition.
While the invention has been described in its presently preferred embodiments, it is to be understood that the words which have been used are words of description rather than limitation and that changes may be made within the purview of the appended claims without departing from the true scope and spirit of the invention in its broader aspects.
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A comb filter for separating chrominance and luminance signals for each sample of a video signal adaptively selects exactly one line above or one line below for processing with the sample of interest. In the process, luminance and chrominance signals are obtained for both processing modes and coupled to a switch. Selection logic utilizes the chrominance signals established for each mode to sequentially check vertical correlation of the video signal, chrominance variations, and vertical detail to position the switch to choose the proper luminance and chrominance signal pair.
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FIELD OF THE INVENTION
The present invention relates generally to the field of communication systems, and more particularly to methods of searching for the Home Public Land Mobile Network (HPLMN) in a radiotelephone system. Although the invention can be used in a wide range of applications, it is described in connection with a GSM cellular telephone.
BACKGROUND OF THE INVENTION
A GSM cellular telephone or mobile station (MS) operates with a subscriber identity module (SIM) card that specifies the MS's HPLMN. From both a user's and a cellular service provider's (CSP) perspective, it is desirable for the MS to be operating in the HPLMN. The user does not incur additional charges, such as roaming charges, when the MS operates in the HPLMN. The CSP earns more revenue when the MS is operating in the HPLMN.
During times when the MS is not operating in the HPLMN, the GSM ETSI specifications provide a mechanism for the MS to periodically search for the HPLMN. The mechanism utilizes a HPLMN search timer. The timeout value is configurable by the CSP and resides on the SIM card. The timeout value is set to a value in six minute increments and specifies how often the MS should search for the HPLMN. FIG. 7 is a flow chart that illustrates a known method of searching for the HPLMN. At the start of the method, the MS is camped on a non-HPLMN. In block 702 , the MS is in its lowest power state. In block 704 , the HPLMN search timer is set to expire in six minutes. In decision block 706 , the method determines whether the timer has expired. If no, the method continues to check until the timer has expired. When the timer expires, a full search for the HPLMN is performed (block 708 ). A full search includes the steps of measuring the RF carrier level on every frequency supported by the MS, finding carriers of a suitable level, reading broadcast information on the suitable carriers and determining if the carriers are in the HPLMN. Next, the method determines whether the HPLMN is found. If no, the MS returns to its lowest power state. If yes, camping procedures on the HPLMN are initiated (block 710 ) by first searching for the strongest available channel of the HPLMN and then by registering the MS on the HPLMN.
A limitation of the above method is that the timeout value of the HPLMN search timer can be too long. Six minutes may be inadequate, in certain instances, to find the HPLMN soon after it becomes available. For example, if a user moves out of the MS's HPLMN coverage area and quickly returns to the HPLMN coverage area, the user must wait until the HPLMN search timer expires before the MS will attempt to find the HPLMN. Another limitation of the above method is that once the HPLMN search is initiated, it can take up to two minutes to complete. The lengthy completion time can be attributed to the search consisting of taking receive signal level measurements on every channel that the MS is capable of accessing, synchronizing to suitable channels and reading broadcast data on those channels until a channel of the HPLMN is found.
Another method of finding the HPLMN allows the user to manually search for the HPLMN by navigating through a series of menus and then initiating a search for the HPLMN. Like the previously described method, this method also has a lengthy completion time. In addition, the user needs to be aware of when the HPLMN becomes available before initiating the search. If a search is initiated before the HPLMN is available, the search will prove unsuccessful and unnecessarily drain the MS's current.
The limitations of the previously discussed methods of searching for the HPLMN could be overcome by implementing a method that continuously searches for the HPLMN. However, such an activity would cause the battery life of the MS to be significantly reduced. The process of a continuous search takes additional processor cycles and causes the internal components of the MS to be in their receive ready (higher current-drawing) state.
Therefore, there exists a need for a method of searching for the HPLMN that strikes a compromise between a continuous search that drains the resources of the MS and a long-interval search, that is too slow for desirable operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a cellular telephone that can implement the preferred embodiment of the method of the present invention.
FIG. 2 is a block diagram of the MS of FIG. 1 .
FIG. 3 is a flowchart of the preferred embodiment of the HPLMN search method of the present invention.
FIG. 4 is a flowchart of the preferred embodiment of decision block 318 of FIG. 3 .
FIG. 5 is a flowchart of the preferred embodiment of block 322 of FIG. 3 .
FIG. 6 is a pictorial representation of an MS moving between the HPLMN and a non-HPLMN.
FIG. 7 is a flow chart of a known method of searching for an MS's HPLMN.
SUMMARY OF THE PREFERRED EMBODIMENT
The present invention provides an improvement over the long-interval search of the prior art. The HPLMN search method of the present invention utilizes specific times when the internal components of the MS are already in their receive ready (higher current-drawing) state and performs strategic receive signal level measurements to determine whether it is likely that the HPLMN has become available again. If the probability that the HPLMN has become available is high, further data is gathered on the likely available channel to confirm that the HPLMN has in fact become available. Then the MS can begin the camping procedure on the HPLMN.
In a mobile station, the preferred embodiment of the method of searching for a home public land mobile network comprises the steps of reading first broadcast data on a serving cell; measuring a receive power level of a plurality of channels on a first broadcast allocation list to produce a plurality of receive power level measurements; for each of the plurality of channels, until the home public land mobile network is found, determining whether the receive power level measurement is adequate; determining whether the receive power level measurement is strong enough to synchronize to the channel if the receive power level measurement is adequate; reading second broadcast data from the channel if the receive power level measurement is strong enough to synchronize to the channel, wherein the second broadcast data includes a public land mobile network and a second broadcast allocation list; determining whether the public land mobile network identified in the second broadcast data matches the home public land mobile network; and initiating camping on the home public land mobile network using the second broadcast allocation list when the public land mobile network matches the home public land mobile network.
Additional advantages and novel features of the invention will be set forth in part in the description which follows, wherein the preferred embodiment of the invention is shown and described. Reference will now be made in detail to an embodiment configured according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 depicts an MS that can utilize the method of the present invention. The MS 100 has two portions, a body 102 and a cover 104 . FIG. 1 shows cover 104 in an open position such that a user of the MS 100 can listen via earpiece 106 and speak into microphone 108 . The body 102 includes a keypad 110 having a plurality of buttons numbered one through zero, #, and *, in a conventional telephone arrangement. The keypad 110 may also have additional buttons such as power, function, send, and other buttons associated with telephone number recall. The body 102 also has an antenna 202 (FIG. 2) that enables wireless communication between MS 100 and base station (not shown) of the cellular radiotelephone system.
Referring to FIG. 2, a block diagram of the MS 100 of FIG. 1 is shown. The MS 100 includes an antenna 202 , a transceiver 204 , a microprocessor 206 , a power supply IC 208 , a microphone 212 , a speaker 214 , a vibrating alert mechanism 216 , a keypad 110 and a display 220 . The antenna 202 receives signals from and transmits signals to the transceiver 204 . These signals are sent to the microprocessor 206 for processing. The microprocessor 206 also processes inputs from the keypad 110 and outputs to the display 220 . Preferably, the microprocessor 206 is a 32-bit general purpose microprocessor available from many sources. The remainder of the circuitry shown in FIG. 2 can be implemented using commonly available components known in the art. The components should be chosen such that they can be controlled to alternate between their high power and low power standby modes.
The method of the present invention is performed by the microprocessor 206 and is illustrated in FIG. 3 . At the start of the method, the MS is camped onto the HPLMN. In decision block 304 , the MS's microprocessor 206 checks to determine whether it has lost service on the HPLMN. If not, the microprocessor continues to check. If yes, the microprocessor 206 saves the HPLMN's broadcast allocation (BA) list, network color code (NCC) and power level of the channels on the BA list (block 306 ). Next, the microprocessor 206 camps onto a non-HPLMN (block 308 ) and places the MS 100 in its lowest power state or idle mode (block 310 ). When in idle mode, the MS 100 is required to read the broadcast data (or BCCH data) on the serving cell (channel that the MS 100 is currently camped on) every thirty seconds. This requirement is dictated by section 6.6.1 of the Digital cellular telecommunications system: Radio subsystem link control—GSM 5.08 specification. The broadcast data consists of a plurality of frames and includes data about a specific frequency (channel). The data can include, for example, reselection information, location area information (consisting of PLMN and location area), paging information, the BA list, the frequency correction burst (FCB), the synchronization channel (SCH) and the base station identity code (BSIC) which includes the NCC.
The reselection information includes cell reselection parameters. The parameters control the rate at which an MS is allowed to perform a reselection operation. A reselection operation occurs when the MS changes camp status from a first cell in a PLMN to a second cell in the same PLMN. The paging information includes parameters that instruct the MS when to listen to pages addressed to itself. The BA list for a particular channel includes the channel and channels of surrounding cells. The FCB is a specific tone broadcast so that the MS can obtain rough timing and accurate frequency information about a given cell. The SCH is used for fine timing adjustments, frame timing and simplified channel identification, i.e., BSIC.
Referring back to FIG. 3, in block 312 , the microprocessor 206 sets a timer to expire in thirty seconds. In decision block 314 , the microprocessor 206 determines whether the timer has expired. If the timer has expired, the microprocessor 206 reads the broadcast data on the serving cell (block 316 ). Preferably, when the microprocessor 206 reads the broadcast data on the serving cell, it also simultaneously measures the power level of a plurality of channels C i (where i=1 to n) included in the BA list saved in block 306 . In block 317 , the microprocessor 206 initializes “i” to 1. In decision block 318 , the microprocessor 206 determines whether the power level of channel C i (the first channel in the BA list) is adequate. Preferably, as shown in FIG. 4, this determination consists of checking whether the power level of C i is above the noise floor (decision block 410 ), and if so, checking whether the power level of C i is significantly higher than the channel's most recent measurement (decision block 412 ). In the preferred embodiment, the noise floor is −110 dBm and the receive level is significantly higher than the saved measurement if it is 5 dB higher. Referring to FIG. 3, if the power level of channel C i is adequate, the microprocessor 206 determines if the receive signal is strong enough to synchronize to channel C i (block 322 ). If the receive signal is strong enough to synchronize to channel C i , the microprocessor 206 proceeds to block 324 .
FIG. 5 illustrates the preferred embodiment of decision block 322 previously described. In block 510 , the microprocessor 206 searches for the FCB. If the FCB is found (decision block 512 ), the microprocessor 206 , in block 514 , searches for the SCH. If the SCH is found (decision block 516 ), preferably the microprocessor 206 determines whether the channel's NCC matches the HPLMN's NCC saved in block 306 (decision block 518 ). If no, the microprocessor 206 proceeds to block 328 (FIG. 3 ). If yes, the microprocessor 206 proceeds to block 324 (FIG. 3) and reads broadcast data (including the PLMN and BA list) from channel C i . In decision block 326 , the microprocessor 206 determines whether the PLMN just read matches the HPLMN. If so, the microprocessor 206 initiates camping on the HPLMN using the BA list from channel C i .
During the procedure described above, if the answer to any of decision blocks 318 , 322 , 326 , 410 , 412 , 512 , 516 or 518 is no, the microprocessor 206 saves the measured power level of channel C i and the channel identification for future comparisons (block 328 ). Next, in block 329 , the microprocessor 206 increments “i” and determines whether there are any remaining channels for which power measurements were taken in step 316 (decision block 331 ). If so, the microprocessor 206 continues the process starting with step 318 for each of the remaining n channels until the HPLMN is found. If not, the microprocessor 206 returns the MS 100 to its lowest power state.
FIG. 6 depicts an HPLMN (H) and a non-HPLMN (NH) coverage area for a given MS. In the present example, the HPLMN coverage area includes cells 10 , 20 and 30 . The non-HPLMN coverage area includes cells 61 , 62 and 63 . As long as the MS 100 remains in one of cells 10 , 20 and 30 , the MS 100 is able to make and receive calls using the HPLMN. When the MS 100 leaves the HPLMN coverage area and camps onto a non-HPLMN, the method of the present invention can be used to determine when the HPLMN has again become available so that camping procedures can be initiated.
In the example shown in FIG. 6, the MS starts out at point A in cell 10 of the HPLMN. When the MS is moved to point B in cell 61 of a non-HPLMN, the MS will detect that it has lost service on the HPLMN (FIG. 3, decision block 304 ), will save the HPLMN's BA list, NCC and power level of channels on the BA list (block 306 ), and camp on the non-HPLMN (block 308 ). After the MS is camped on the non-HPLMN, the microprocessor 206 returns the MS 100 to its lowest power state (block 310 ). Next, the microprocessor 206 will set the thirty second timer (block 312 ) to begin the process of reading broadcast data on the serving cell and looking for the HPLMN. When the timer expires, the microprocessor 206 will read the broadcast data on the serving cell (block 316 ). In the current example, the serving cell is cell 61 . Preferably, while reading the broadcast data on cell 61 , the microprocessor 206 will simultaneously look for the HPLMN by taking power level measurements on the plurality of channels C i included in the BA list saved in block 306 . In the present example, the BA list saved in block 306 is the list for channel 10 which includes channel 10 and surrounding channels 20 and 30 . In block 317 , the microprocessor 206 initializes “i” to 1. Next, the microprocessor 206 determines whether the power level of channel C 1 (channel 10 ) is adequate. Preferably, if the power level of C 1 is above the noise floor and if C 1 has a power level measurement significantly higher than the most recent measurement (measurement saved in block 306 ), the microprocessor 206 proceeds with determining whether the received signal is strong enough to synchronize to channel C 1 (decision block 322 ). However, since the MS 100 has moved from the HPLMN in cell 10 to a non HPLMN in cell 61 , the power measurement on channel 10 is not likely to be higher than the power level of the channel's most recent measurement. Thus, the microprocessor 206 will save the power level of channel C 1 and the channel ID for future comparisons (block 328 ) and increment “i” (block 329 ). Next, the microprocessor 206 will determine that there are remaining channels C 2 (channel 20 ) and C 3 (channel 30 ) and will repeat the process staring with block 318 . Since the MS 100 is still in cell 61 of the non-HPLMN, the power measurements on C 2 and C 3 are not likely to be significantly higher than these channel's most recent measurements. The microprocessor 206 will save the power levels of channels C 2 and C 3 and the channel identifiers for future comparisons (block 328 ). Next, in block 310 , the MS 100 will return to its lowest power state (since there are no remaining channels in the BA list for channel 10 ) and wait for the thirty second timer to expire to repeat the process starting from decision block 316 .
In the present example, the MS 100 moves from cell 61 to point C and performs a reselection to cell 62 of the non-HPLMN. (As stated previously, a reselection occurs when the MS 100 moves from one channel to a different channel within the same PLMN.) Now, the MS 100 is camped on channel 62 of the non-HPLMN but is also within the HPLMN coverage area. When the thirty second timer expires, the microprocessor 206 reads the broadcast data on the serving cell, now cell 62 , while simultaneously taking power level measurements on the plurality of channels C i included in the BA list saved in block 306 (block 316 ). Next, the microprocessor 206 initializes “i” to 1 (block 317 ). In block 318 , the microprocessor 206 determines whether the power level measurement on channel C 1 (channel 10 ) is adequate. Since the MS 100 has moved to cell 30 (not 10 ) in the HPLMN, the power level measurement on channel 10 is not likely to be adequate (i.e., power measurement not likely to be significantly higher than the measurement saved in block 328 above). Thus, the microprocessor will save the measured power level of channel C 1 and the channel identifier for future comparisons (block 328 ). Next, the microprocessor will increment “i” (block 329 ), determine whether there are remaining channels to analyze (decision block 331 ) and repeat the process starting in block 318 for channel C 2 . Again, the power level measurement on channel 20 is not likely to be adequate (i.e., power measurement not likely to be significantly higher than the measurement saved in block 328 above. Thus, the microprocessor will save the measured power level of channel C 2 and the channel identifier for future comparisons (block 328 ). Next, the microprocessor will increment “i” (block 329 ), determine whether there are remaining channels to analyze (decision block 331 ) and repeat the process starting in block 318 for channel C 3 .
In block 318 , the microprocessor 206 determines whether the power level is adequate. This time the power level of C 3 is likely to be significantly higher than the measurement saved in block 328 above since the MS 100 has moved to cell 30 in the HPLMN. Thus, the microprocessor 206 determines whether the receive signal is strong enough to synchronize to the channel (decision block 322 ). In the present example, the determination of whether the receive signal is strong enough to synchronize to the channel preferably includes searching for the FCB and the SCH of channel 30 . If the receive signal is strong enough to synchronize to the channel, the microprocessor 206 reads broadcast data from channel C 3 which includes at least the PLMN and the BA list for the channel (block 324 ). If the receive signal is not strong enough to synchronize to the channel, the microprocessor 206 saves the power level measurement for channel C 3 and the channel identification for further comparisons and returns the MS 100 to its lowest power state (decision block 326 ). After reading the PLMN and BA list components of the broadcast data, the microprocessor 206 determines whether the PLMN just read matches the HPLMN. If there is a match, the microprocessor 206 initiates the camping procedure on the HPLMN using the BA list from channel 30 (block 330 ).
The method of the present invention provides advantages over known methods of searching for a MS's HPLMN. First, the method of the present invention searches for the HPLMN while the MS 100 is performing the required attempt to decode the broadcast data on the serving cell. Second, the method performs strategic signal level measurements on strong channels instead of every channel that the MS 100 is capable of accessing. Thus, the method of the present invention saves on current drain and efficiently utilizes the MS's resources. Third, since the method searches for the HPLMN in thirty second intervals instead of six minute intervals, for example, the HPLMN can be found much more quickly when it becomes available.
Those skilled in the art will recognize that various modifications and variations can be made in the apparatus of the present invention and in construction of this apparatus without departing from the scope or spirit of this invention.
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In a mobile station (MS) of a cellular radiotelephone system, a method of searching for the MS's home public land mobile network (HPLMN) when the MS is camped on a non-HPLMN. The method is performed in thirty second intervals while the MS is already in its receive ready (higher current-drawing) state. The method performs strategic measurements of the receive signal level in order to determine if it is likely that the HPLMN has become available again. If the probability is high that the HPLMN has become available, further data is gathered on the likely available channel. Once the channel is identified, the MS begins the camping procedure to register on the HPLMN.
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This is a Divisional of application Ser. No. 08/226,627 filed Apr. 12, 1994, now abandoned.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a waste disposing apparatus. Diapers and menstrual paper or the like for cleaning the woman's body when waste matter has been passed from it are often thrown away in garbage boxes. Such waste matters when thrown away like ordinary rubbish are likely to cause unpleasant smells and sanitary troubles particularly in schools, hospitals, hotels, restaurants, department stores and other public buildings. Such situation requires improvement for sanitary reasons particularly from the recent tendency of increasing social concerns in AIDS.
Use of paper bags to put waste matters in has been proposed, but there are some problems in handling and sealing such paper bags by hand. Therefore, paper bags have not been popularly used for the purpose. Machines for automatically sealing such paper bags when designed, were found to be complicated and too large to be installed in toilet booths.
Assume that a waste disposing apparatus which is small enough to be installed in a toilet booth is designed and actually made, and that such disposers are installed in a plurality of toilet booths as for instance in a school. Collection of insanitary waste matters from all toilet booths, however, is very inconvenient.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a disposable container for waste matters which is very convenient, and can improve the public sanitary condition.
The other object of the present invention is to provide a waste disposing apparatus which is simple in structure and small in size, facilitating the placement of waste matters in containers and the sealing of such waste-filled containers, and to provide a disposing apparatus having at least one of the waste disposing apparatus.
To attain this and other objects according to the present invention, a disposable container for treating waste matters comprising an inverted conical frustum, cup-like container body of paper or synthetic resin with its brim having an adhesive applied thereto.
The container body is a waterproof container body. The container body size is determined as appropriate for waste amount to be disposed, and the top, largest diameter of the container is selected to be within the range from 1.1 to 1.4 times of the bottom, smallest diameter of the container. The container body has a top edge curled to form a thick circumference.
A waste disposing apparatus according to the present invention uses the container, and comprises a container supplying means for holding a stack of containers by one sliding over another and releasing, in response to a request, one after another from the stack of containers, permitting the falling of a sequential container when descending down to the bottom of the stack for its turn; a standby means for holding the container with its opening side up, thereby permitting the throwing of waste into the container on standby; a sealing means for pressing the top circumference of the container which is filled with waste to seal the container; and a carrier means for transporting containers from the container supplying means to the standby means, and from the standby means to the sealing means.
The waste disposing apparatus further comprises detecting means for detecting that the container on standby has been filled with waste; and a control responsive to a signal from the detecting means for: making the carrier means to transport the waste-filled container from the standby station to the sealing means for pressing the top circumference of the waste-filled container, and throwing the sealed container away; moving the carrier to a predetermined position under the container supplying means, and stopping there; permitting the falling of a sequential container on the carrier from the stack of containers at request; and finally making the carrier means to transport the empty container to the standby station.
A waste disposing system according to the present invention comprises: at least one waste disposing apparatus using inverted conical frustum, cup-like containers of paper or synthetic resin with their brims having an adhesive applied thereto, said waste disposing apparatus comprising: a container supplying means for holding a stack of containers by one sliding over another and releasing, in response to a request, one after another from the stack of containers, permitting the falling of a sequential container when descending down to the bottom of the stack for its turn; a standby means for holding the container with its opening side up, thereby permitting the throwing of waste into the container on standby; a sealing means for pressing the top circumference of the container which is filled with waste to seal the container; and a carrier means for transporting containers from the container supplying means to the standby means, and from the standby means to the sealing means; and a vacuum transport means connected to said waste disposing apparatus for drawing up and transporting the sealed containers in air from said sealing means to a remote waste collection site.
The vacuum transport means may be connected to a plurality of waste disposing apparatuses to collect and transport all sealed containers from the waste disposing apparatuses to a common waste collection site.
The waste disposing apparatus may comprise detecting means for detecting that the container on standby has been filled with waste; and a control responsive to a signal from the detecting means for: making the carrier means to transport the waste-filled container from the standby station to the sealing means for pressing the top circumference of the waste-filled container, and throwing the sealed container away; moving the carrier to a predetermined position under the container supplying means, and stopping there; permitting the falling of a sequential container on the carrier from the stack of containers at request; and finally making the carrier means to transport the empty container to the standby station.
The control may be responsive to a signal from the detecting means for starting the vacuum transport means.
The containers may be waterproof containers. The container size may be determined as appropriate for waste amount to be disposed, and the top, largest diameter of the container is selected to be within the range from 1.1 to 1.4 times of the bottom, smallest diameter of the container.
Each container may have a top edge curled to form a thick circumference.
With this arrangement used dispers and menstrual paper or articles are thrown away in containers, and then such containers are sealed automatically without using the hands, thus assuring the sanitary condition guaranteed free of leakage of insanitary liquid and unpleasing smell. Also, the sealed containers are drawn up in air and transported to a waste collection site.
Other objects and advantages of the present invention will be understood from the following description of a waste disposing apparatus according to one embodiment of the present invention, which is shown in accompanying drawings:
FIG. 1 is a perspective view of a disposable container to be used in the waste disposing apparatus;
FIG. 2 is a perspective view of the disposable container after being sealed;
FIG. 3 is a perspective view of a waste disposing apparatus according to the present invention; and
FIG. 4 is a perspective view of a waste disposing system comprising a plurality of waste disposers each installed in a toilet booth and connected to a vacuum transport means according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, a disposable container 1 to be used in the waste disposing apparatus has an inverted conical frustum, cup-like shape, and is made of paper or synthetic resin. Paper includes natural paper made of natural filaments, and synthetic paper. The container comprises a circumferential wall and a bottom, opening at its top. As described later, the top edge of the container 1 is collapsed to be sealed, and therefore, it may be made of any materials other than described, provided that the material facilitates the collapsing of the top edge of the container without causing tears. Preferably each container may have a top edge 3 curled to form a thick circumference.
The container size is determined as appropriate for the amount of waste matter to be disposed, specifically the size of a disper or a menstrual paper or article. Preferably the top, largest diameter A of the container may be selected to be within the range from 1.1 to 1.4 times of the bottom, smallest diameter B of the container. When the container whose top diameter A is larger than the upper limit of the prescribed range is collapsed, the collapsed top edge will be so large as to be inconvenient in throwing away in a garbage can. Also, the collapsed container has an unpleasing shape. Containers whose top diameter A is smaller than the lower limit of the prescribed range are difficult to be stacked by one sliding over another, thus requiring a relatively large storing space.
Containers are used for containing wet waste matter, and therefore, waterproof, waxed paper containers are preferably used.
As seen from FIG. 1, the container has an adhesive 2 applied to its brim. Preferably such an adhesive 2 is a coldseal adhesive, the layer of which adhesive can stick to a same adhesive layer, but cannot stick to anything other than the same adhesive layer. One example of such adhesive is BOND CR600 (trade name) produced by Konishi K.K. Heat-sensitive adhesive or a resin of relatively low melting point may be equally used. These adhesives when applied to the brims of containers assure good sealing of containers, still permitting containers to be stacked by one sliding over another for storage.
Referring to FIG. 3, the waste disposing apparatus 10 comprises, in its housing 11, a container supplying means 20, a standby means 30, a sealing means 40 and a carrier means 50.
The container supplying means 20 comprises a container supplying unit 21 which is equipped with an actuator 22, and is designed to hold a stack of containers by one sliding over another and release one after another from the stack of containers when the actuator 22 is actuated, permitting the falling of a sequential container when descending down to the bottom of the stack for its turn. The container supplying unit 21 and associated actuator 22 are the same ones as used in a paper-cup dispenser, and need not be described in detail. Disposable containers are stored in the housing 11 although not shown in FIG. 3.
The standby means 30 holds the container 1 with its opening side up, allowing it to appear partly from the circular opening 12 of the housing 11, thus permitting the throwing of waste into the container on standby, as seen from FIG. 3. The circular opening 12 is, therefore, somewhat larger in diameter than the upper opening of the container.
The sealing means 40 for pressing and sealing the top circumference of the waste-filled container comprises a sealing unit 41 having a pair of parallel board strips 42 and 43, which can be moved along opposite guide rods 44 and 44 toward and apart from each other by associated actuator 46 and drive unit 45. When containers have a heat-sensitive adhesive applied to their brims, the parallel board strips 42 and 43 have heating coils inside, thereby permitting them to function as heating-and-pressing means.
In operation a waste-filled container 1 is brought to the sealing unit 41, staying there with its top edge remaining in the space defined by the parallel board strips 42 and 43, which are laid apart from each other. Then, the drive unit 45 is energized to put the actuator 46 in motion, thereby causing the parallel board strips 42 and 43 to move toward each other to press the top edge of the waste-filled container 1. After sealing the waste-filled container 1, the parallel board strips 42 and 43 move apart from each other to release the sealed container 1, allowing it to fall down in a garbage can.
The standby means 30 and the sealing means 40 are placed on the opposite sides of the container supplying means 20.
The carrier means 50 is designed to transport containers from the container supplying means 20 to the standby means 30, and from the standby means 30 to the sealing means 40. The carrier means 50 comprises elongated guide rods 51 extending under and between the standby means 30 and the sealing means 40, and a selfdriven container carrier 52 movable along the elongated guide rods 51. The self-driven container carrier 52 is equipped with a drive means 53 and a lift means 54, which has divergent fingers 55 for receiving the container falling from the container supplying means 20.
As shown in FIG. 4, a plurality of waste disposers 10 may be installed in the corresponding plurality of toilet booths, for instance in a school, and are connected to a remote waste collection site 80 via a vacuum transport means 70. The waste collection site 80 may be located in the building or apart from the building.
The vacuum transport means 70 comprises a vacuum unit 72 and a transport passage 71 comprising a plurality of branch tubes 71a each connected to a selected toilet booth 60 and a collection tube 71b connected to these branch tubes 71a and the vacuum unit 72. Each branch tube 71a has a divergent end to receive sealed containers 1 when released from the sealing means 40 of the waste disposing apparatus 10, and the sealed containers are drawn up in air to be transported to the waste collection site 80 via the transport passage 71.
All actuators and drives in the waste disposing apparatus may use electric motors, or hydraulic or pneumatic cylinders, and may be automatically controlled by a controller 60 using a microcomputer.
The controller 60 in the waste disposing apparatus performs the controlling of a container 1 in response to different signals from a sensor 61 for detecting the presence of the container 1 at the standby stage, a sensor 62 for detecting that the container 1 on standby has been filled with waste, a sensor 63 for detecting the presence of the self-driven container carrier 52 under the container supplying means 20, a sensor 64 for detecting the presence of the selfdriven container carrier 52 under the standby means 30, a sensor 65 for detecting the presence of the self-driven container carrier 52 under the sealing means 40, a sensor 66 for detecting the appearance of the top edge 41 of the container 1 between the opposite board strips 42 and 43 and other sensors although not shown in the drawing. These sensors may be optical sensors or weight-sensitive sensors, and may be replaced by limit switches or position detectors for detecting arrival of an object at its limit.
The operation of the waste disposing apparatus 10 under the control of the controller 60 is described below.
Assume that a container 1 is put in the standby position 30 where the container 1 is held by the divergent fingers 55, which are raised by the lift means 54. When waste matter is thrown in the container, the sensor 62 detects that the container is filled with the waste, sending a signal to the controller 60. In response to the signal the controller 60 permits the lowering of the divergent fingers 55 and hence, the waste-filled container, and subsequently the energizing of the drive means 53 to move the self-driven container carrier 52 leftward along the guide rods 51. When the selfdriven container carrier 52 comes under the sealing position 40, the detector 65 detects the presence of the waste-filled container at the sealing position to send a signal to the controller 60. Then, the controller 60 stops the energizing of the drive means 53 to stop the self-driven container carrier 52, and at the same time, the controller 60 permits the energizing of the lift means 54 to raise the waste-filled container 1. When the top edge of the waste-filled container 1 enters between the opposite board strips 42 and 43, the sensor 66 sends a signal to the controller 60. In response to the signal the controller 60 permits the energizing of the drive unit 45 for putting the actuator 46 in motion, thereby causing the parallel board strips 42 and 43 to move toward each other to press the top edge of the waste-filled container 1. On the other hand the drive means 53 is energized to move the self-driven container carrier 52 rightward along the guide rods 51. After sealing the top edge of the waste-filled container it is released from the sealing means 40, thereby allowing it to fall down.
When the self-driven container carrier 52 moves rightward to come under the container supplying means 20, the sensor 63 detects the arrival of the carrier at the container supplying spot to send a signal to the controller 60, which stops the drive means 53 to allow the carrier 52 to stay there. At the same time the controller 60 puts the actuator 22 in motion, thereby permitting the container supplying unit 21 to release one container from the stack of containers, thus allowing it to fall down.
The container 1 falls on the carrier 52 to be caught by the divergent fingers 55. The drive means 53 is energized to move the self-driven container carrier 52 rightward along the guide rods 51 to come under the standby means 30, the sensor 64 detects the arrival of the carrier at the standby spot to send a signal to the controller 60, which stops the drive means 53 to allow the carrier 52 to stay there. Then, the lift 54 rises until the container 1 is put in the standby position. When the sensor 61 detects the container 1 on standby, the whole apparatus remains standstill. When the sensor 61 detects no container 1 on standby, the self-driven container carrier 52 is allowed to return to the container supplying means 20 to receive one container 1.
The controller 60 is operatively connected to the vacuum transport means 70. The controller 60 may be responsive to a signal from the sensor 62 representing the filling of waste matter in a container at the standby station for starting the vacuum transport means 70, or may be responsive to a signal from a sensor detecting the releasing of a sealed container 1 from the sealing station 40 or to a signal from a sensor detecting receipt of a sealed container by the divergent end of the branch tube 71a for starting the vacuum transport means 70. Preferably the vacuum transport means 70 may be made to stop automatically in a predetermined time long enough for sealed containers to pass through the transport passage 71 to the waste collection site 80. Alternatively the vacuum transport means 70 may be made to stop automatically when no containers are detected in the transport passage 71.
As is apparent from the above, the waste disposing apparatus according to the present invention can seal waste-filled containers without fail, thereby permitting the disposing of waste in sanitary condition. Also, the waste-filled containers can be automatically collected from a plurality of toilet booths to be transported to a waste collection site apart from the building. Installation of waste disposing apparatuses in toilet booths for public use, therefore, will improve the public sanitary condition.
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A waste disposing system and apparatus are described which use inverted conical frustum cup-like containers of paper or synthetic resin with brims having an adhesive applied thereto, said apparatus comprising: a container supplying means for holding a stack of containers having a top and a bottom, and formed by one sliding over another, and releasing, in response to a request, one after another, from the stack of containers, permitting the falling of a sequential container that has descended down to the bottom of the stack for its turn; a standby means for holding the container with the open side thereof up, thereby permitting the filling of waste into container on standby; a sealing means for pressing the top circumference of the container which is filled with waste to seal the container; and a carrier means for transporting containers from the container supplying means to the standby means, and from the standby means to the sealing means. The waste disposing system and apparatus facilitate automatization of perfect sealing of waste-filled containers and provides for efficient disposal of unsanitary waste matter.
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RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application Ser. No. 10/652,837, filed Aug. 29, 2003 entitled “IMPLANTABLE BIOSENSOR DEVICES FOR MONITORING CARDIAC MARKER MOLECULES”, herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to sensors for detecting, measuring and/or monitoring levels of physiological analytes in a patient, and particularly, to biosensors suitable for implantation to provide in vivo detection and/or monitoring of one or more cardiac markers.
BACKGROUND OF THE INVENTION
[0003] Heart disease, including myocardial infarction, is a leading cause of death and impaired activity in human beings, particularly in the western world. Ischemic heart disease is the major form of heart failure. A common symptom of cardiac ischemia is chest pain that may lead to heart attack (acute myocardial infarction or AMI) and sudden death.
[0004] Myocardial ischemic disorders occur when blood flow in the heart is restricted (ischemia) and/or when the oxygen supply to heart muscle is compromised hypoxia) and the heart's demand for oxygen is not met. Ischemia and hypoxia can be transient and reversible, but can also lead to a heart attack. During such an attack, cardiac tissue is damaged and the heart cells become permeabilized, releasing a portion of their contents to the surrounding environment, including cardiac enzymes and other biochemical markers. These cellular markers, such as creatine kinase (CK), lactic acid dehydrogenase (LDH) and creatine kinase-MB (CKMB) and troponin (I and T) and myoglobin mass levels become detectable in the blood of the patient. The use of these markers and new forms of treatment has increased the survival rate of patients having a heart attack. This factor combined with the increased life expectancy has led to an increase in the prevalence of congestive heart failure (CHF).
[0005] CHF causes significant morbidity and mortality, and the health care expenditure for this disease is substantial. The need exists for better diagnostic and prognostic methods for this disease. Recently, assays for B-type natriuretic peptide (BNP) which is secreted by the ventricles in response to ventricular expansion and pressure overload resulting in an elevation of the plasma concentration of BNP have been used in the diagnosis of CHF. BNP levels have been found to increase in proportion to the degree of left ventricular dysfunction and the severity of CHF symptoms and monitoring the levels of circulating BNP has been used to monitor the effectiveness of therapy. Significant decreases in BNP levels correlate with a longer interval between admissions. Thus, BNP monitoring allows therapy to be tailored to maximize the desired effects in an individual patient. Levels of BNP precursor molecules such as the N-terminal proBNP (NT-proBNP), which is released when BNP is cleaved from its precursor, a 108 amino acid molecule, referred to as “pre pro BNP) have also been measured in assays to diagnose CHF, particularly when the patient's therapy includes being treated which a synthetic BNP molecule.
[0006] The inability to determine when a patient's CHF is worsening (before a patient gains several pounds in weight and/or edema is greatly increased) until the patient has a doctor's appointment or requires hospitalization will result in a delay of treatment. While in vitro diagnostic assays measuring BNP levels are now in use, these assessments are point-in-time assessments that do not provide the clinician a complete profile of a patient's changing status. Moreover, required changes to the patient's therapy will be delayed.
[0007] A recent development in in vitro assays is the use of biosensors as a substrate for the assay. Biosensors are electronic devices that produce electronic signals as the result of biological interactions. Biosensors are commonly divided into two groups. Catalytic sensors that use enzymes, microorganisms, or whole cells to catalyze a biological interaction with a target substance. Affinity systems use antibodies, receptors, nucleic acids, or other members of a binding pair to bind with a target substance, which is typically the other member of the binding pair. Biosensors may be used with a blood sample to determine the presence of an analyte of interest without the need for sample preparation and/or separation steps typically required for the automated immunoassay systems.
[0008] Implantable electrochemical biosensors have recently become an important tool for analyzing and quantifying the chemical composition of a patient's blood. For example, glucose sensors are generally employed to measure blood glucose levels in patients having diabetes. Such biosensors are described in U.S. Published Application No. 2002/0120186, the teachings of which are incorporated herein by reference.
[0009] It would be desirable to have implantable biosensors for use in in vivo detection and monitoring of biologically relevant markers in the diagnosis and treatment of cardiovascular diseases, including heart failure and myocardial infarction.
SUMMARY OF THE INVENTION
[0010] The present invention provides an implantable sensor system for detecting and/or monitoring the presence and concentration of a desired analyte in a patient. In one embodiment of the invention, the system includes a biochemical sensor to detect levels of a desired cardiac marker or markers such as BNP in the intra-cardiac circulatory system or cardiac tissue, a controller and processor to measure the levels of the cardiac marker and optionally to store the data, and an external user-interface system to display the data. In one embodiment, the system further includes circuitry to trigger a patient alert if the level of the measured cardiac marker exceeds a predetermined critical level.
[0011] The sensor system of the invention may be deployed on an intra-cardiac lead or other delivery device as a stand-alone system or incorporated into an implantable medical device such as a pacemaker, defibrillator or cardiac resynchronization therapy (CRT) system. When incorporated into an implantable medical device, the sensor may also be used in cooperation with the device in the therapeutic treatment provided by the device. In some embodiments, the sensor system is deployed on an intra-cardiac lead placed in the coronary sinus orifice of the right atrium of the heart.
[0012] In one embodiment of the invention, the sensor is a nanoscale device. The sensor system includes a biological recognition element attached to a nanowire and a detector able to determine a property associated with the nanowire. The biological recognition element is one member of a binding pair where the cardiac marker or analyte being measured is the other member of the binding pair. Preferably, the nanowire sensor includes a semiconductor nanowire with an exterior surface formed thereon to form a gate electrode and a first end in electrical contact with a conductor to form a source electrode and a second end in contact with a conductor to form a drain electrode. In one aspect of the invention the sensor is a field effect transistor comprising a substrate formed of an insulating material, a source electrode, a drain electrode and a semiconductor nanowire disposed there between with a biological recognition element attached on a surface of the nanowire. When a binding event occurs between the biological recognition element and its specific binding partner a detectable change is caused in a current-voltage characteristic of the field effect transistor.
[0013] In one embodiment the sensor system includes an array of sensors. One or more of the sensors in the array is associated with a protective member that prevents the associated sensor from interacting with the surrounding environment. At a selected time, the protective member may be disabled, thereby allowing the sensor to begin operating to interact with the surrounding fluid or tissue so that the biological recognition element can interact with the other member of its binding pair if that pair member is present.
[0014] In another aspect of the invention, the protective member is formed of a conductive material that can oxidize, is biocompatible, bio-absorbable, and that may be dissolved in solution such as blood upon application of an electric potential. For example, a sensor may be formed within a well of a substrate that is capped by a conductive material such as a biocompatible metal or an electrically-erodible polymer. In another embodiment, the protective member is formed using a material that dissolves over a predetermined period of time.
[0015] At a given time, one or more activated sensors from the sensor array may be utilized to determine levels of desired analytes by detecting a detectable signal generated when a substance binds to a biological recognition element of the sensor. The data is then processed and compared to stored data to provide a more accurate indication of a biological or other condition. Another processing scheme may be utilized to obtain a measurement that may then be used to monitor a patient's condition, or modify therapy delivery.
[0016] In one embodiment, the sensor system includes a therapy delivery system for providing therapy based on the levels of one or more of the cardiac markers being measured. The therapy delivery system may include a drug pump, a circuit to provide electrical stimulation to tissue, or any other type of therapy delivery means known in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a diagram illustrating one embodiment of a sensor according to the current invention.
[0018] FIG. 2 is a flow chart illustrating one method of attaching a biological recognition element to a sensor such as that shown in FIG. 1 .
[0019] FIG. 3 is a diagram illustrating one embodiment of a sensor system according to the current invention.
[0020] FIG. 4 is a diagram illustrating one embodiment of a sensor system according to the current invention including a therapy delivery system.
[0021] FIG. 5 is a system block diagram of one embodiment of a controller that may be used with the sensor system of the invention.
[0022] FIG. 6 is a diagram illustrating an embodiment of a sensor of the invention.
[0023] FIG. 7 is a diagram illustrating one embodiment of a sensor of the invention having a protective member and a plurality of individual nanowire sensor elements.
[0024] FIG. 8 is a flow chart illustrating one embodiment of a method as may be practiced with the current invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present invention relates to an implantable affinity biosensor system for continuous in vivo monitoring of levels of analytes, such as cardiac markers, as a stand-alone system or as part of an implanted or implantable medical device (“IMD”), such as a pacemaker, defibrillator, CRT system and the like. Preferably, the biosensor includes a nanowire field effect transistor substrate having a biological recognition element attached thereto capable of binding to a cardiac marker of interest.
[0026] A “nanowire” as used herein refers to an elongated nanoscale semiconductor that, at any point along its length, has at least on cross-sectional dimension and, in some embodiments, two orthogonal cross-sectional dimensions less than 1,000 nanometers. In some embodiments the nanowire has at least one cross-sectional dimension ranging from about 0.5 nanometers to about 200 nanometers. In one embodiment, the nanowire refers to an overlayer row resulting from the deposition of a metal on a silicon surface. Such a nanowire desirably has a width of about 1 to 4 nm and a length of 10 nm or longer.
[0027] Nanowires useful in the sensor system of the invention includes any nanowires, including carbon nanowires, organic and inorganic conductive and semiconducting polymers. Other conductive or semiconducting elements of various nanoscopic-scale dimensions can be used in some instances. U.S. Published Application No. 2002/0117659, the teachings of which are herein incorporated by reference, describes nanowires and nanotubes that may be used with the invention.
[0028] A primary criteria for selection of nanowires and other conductors or semiconductors for use in the invention is whether the nanowire itself is able to non-specifically bind a substance in the area where the sensor system will be implanted and whether the appropriate biological recognition element, i.e. specific binding pair member, can be attached to the surface of the nanowire. The nanowire used in the sensor system is desirably an individual nanowire. As used herein, “individual nanowires” means a nanowire free of contact with another nanowire (but not excluding contact of a type that may be desired between individual nanowires in a crossbar array). Generally, each sensor element of the invention will include an individual nanowires. When multiple sensor elements are located or arranged together in one housing, for example in an array, a row or column of individual nanowire sensor elements may be associated together that each specifically bind the same analyte so that they provide a nanowire sensor element set. In one embodiment, each individual nanowire sensor element within a sensor element set will be activated simultaneously and the detectable signal produced by each individual sensor will be detected simultaneously. Methods of making individual nanowires is known.
[0029] The biological recognition element refers to any agent that is capable of binding to a cardiac marker of interest. Preferably, the element is a binding pair member that binds to a desired analyte with specificity, i.e., has a higher binding affinity and/or specificity to the analyte than to any other moiety. Such binding pairs are well known and include the following: antigen-antibody, growth factor-receptor, nucleic acid-nucleic acid binding protein, complementary pairs of nucleic acids and the like. Preferably, the biological recognition element is an antibody or an effective portion thereof retaining specific binding activity for the analyte. Effective portions include, for example Fv, scFv, Fab, Fab 2 and heavy chain variable regions or a chimeric molecule or recombinant molecule or an engineered protein comprising any of the portions. The biological recognition element is attached to the nanowire. As used herein, “attached to,” encompasses all mechanisms for binding antibodies and proteins, directly or indirectly to surfaces so that when the sensor is implanted and the biological recognition element interacts with its surrounding environment the element remains associated with the surface. Such mechanisms chemical or biochemical linkage via covalent attachment, attachment via specific biological binding (e.g., biotin/streptavidin), coordinative bonding such as chelate/metal binding, or the like.
[0030] Illustrative embodiments of the invention are shown in the Figures. As will be readily apparent to those skilled in the art upon a complete reading of the present application, the present methods and systems are applicable to a variety of systems other than the embodiments illustrated herein.
[0031] FIG. 1 shows one example of an implantable affinity nanosensor of the invention. The sensor system 10 includes a single nanowire 20 positioned above upper surface 32 of the substrate 30 . A housing 40 that may be a hermetic sensor integrated circuit package. The sensor system also includes electrodes 35 and 37 , respectively, that are connected with electrical connections, which in this embodiment are located in the housing. The sensor system is deployed on a lead 50 that may be connected to a user interface and/or to an IMD.
[0032] The substrate 30 is typically made of a polymer, silicon, quartz or glass. The electronic circuitry may be powered by one or more batteries, or alternatively, may receive power via implanted medical electrical leads coupled to another implantable medical device (IMD) as will be described below. Any electronic circuitry adapted to provide long-term continuous monitoring may be used in conjunction with the device of the present invention. In some embodiments, the electronic circuitry may be powered by external means.
[0033] The housing of the sensor systems of the present invention may use a packaging technique that protects the components of the system in aqueous media. For example, the top and bottom portions of the housing may be manufactured from a thermoformed high-density polyethylene. The area inside the housing surrounding the electronic circuitry and other components may be filled with a material that cushions the system while not interfering with circuit operation. The filling material may be a mixture of petroleum wax and low melting temperature resins, for instance.
[0034] FIG. 2 is a schematic illustrating the steps for attaching the biological recognition element to the surface of a nanowire sensor 10 such as that shown in FIG. 1 . The surface of the nanowire is chemically activated as shown and a biomolecular linker chosen to bind the antibody of interest is added and allowed to react with the chemically activated surface to facilitate binding of antibody or other biological recognition element to the surface.
[0035] The method of attaching the biological recognition element will differ depending on the material of nanosensor surface and the binding pair used. When the element is an antibody or protein may be performed by covalently bonding the protein to the surface with bi-functional molecules such as glutaraldehyde, carbodiimides, biotin-avidin, and other molecules with one or more functional groups on each of at least two ends as are well known to those skilled in the art. Additionally, bi-functional spacer molecules such as N-hydroxysuccinimide derivatized polyethylene glycols may be used to bind the protein.
[0036] FIG. 3 is a block diagram showing an example of a nanosensor system of the invention. The affinity nanowire sensor 300 such as that shown is FIG. 1 is carried on a medical lead for implantation in a patient. Desirably, the sensor is located in cardiac tissue or in the intra-cardiac circulatory system of the patient or elsewhere in the blood stream where levels of certain cardiac markers associated with cardiovascular diseases may be measured. In one aspect of the invention, the cardiac markers being detected include without limitation, BNP, pre proBNP, NT pro BNP, C-type reactive protein, Troponin I and T, respectively, Myoglobin, D-Dimer, cytokines, such as tissue necrosis factor alpha, and other cardiac markers known in the art. Sensor 300 is connected to a detector 310 that will measure the detectable signal generated by the sensor when one or more molecules of the cardiac marker or markers being measure binds to the biological recognition element attached to the nanowire, where the amount of signal generated can be used to determine the level of the cardiac marker present in the patient. The detector may be associated with a user interface display 320 that may be accessed by the patient and/or the patient's health care provider either as a continuous display or stored in a processor (shown as 520 in FIG. 5 ). In one embodiment, the detector 310 can be connected to a telemeter 330 that will transmit the sensed information to receiver 340 that may be associated with a server 350 . The server 350 may include a patient database with other patient information that may be relevant to monitoring the patient's status. In the system of FIG. 3 , the server 350 is optionally accessible through an internet access management system 320 so that the health care provider can access information obtained from the continuous monitoring of the levels of one or more of the patient's cardiac markers.
[0037] FIG. 4 shows a block diagram of a nanosensor system of the invention associated with an implanted medical device (IMD) and optionally with an electrical stimulation system of the IMD. In this embodiment, a nanosensor 400 such as that described in FIG. 1 is connected with a detector 410 , which may also include an electrical stimulator, and to electrical stimulation leads 420 associated with an IMD, including without limitation, a CRT, pacemaker, or defibrillator. Detectable signal produced by the nanosensor 400 , the amount of which is related, directly or indirectly, to the levels of one or more cardiac markers in the patient are received by the detector and/stimulator and the levels of desired cardiac markers determined. The information may be processed by a controller (shown as 500 in FIG. 5 ) within the detector to vary parameters of the IMD in response to changes in the levels of the measure cardiac marker in the blood or tissue of the patient. A telemeter 440 may be included that is associated with the detector 410 to transmit information received by detector to a receiver 430 . The receiver 430 is in one embodiment connected to a server 450 that provides for internet access to patient information through a user interface 460 by the health care provider or patient.
[0038] FIG. 5 is a system block diagram of one embodiment of a controller of a nanosensor system of the invention. The controller 500 may be provided within any IMD known in the art, or may be part of the detector or processor elements of the nanosensor systems, such as the systems shown in FIGS. 3 and 4 . The controller 500 may include circuitry for delivering electrical stimulation for pacing, cardioversion, and/or defibrillation purposes on electrical stimulation outputs.
[0039] The controller 500 may include a communicator 510 , such as a telemetry system described in commonly-assigned U.S. Pat. No. 6,169,925, incorporated herein by reference in its entirety. The use of this telemetry system would provide a system capable of long-range communication with personal patient communication devices. Such patient communication devices may have an alarm function to alert the patient of sensor readings outside a range considered acceptable. The alarm may also be included to inform the user of actions that should be taken by the user in response to an original alert. The level of urgency of the alarm could also be encoded into the signal changes. The alarm may be of any type of patient alert known in the art, including without limitation, an audible alarm, a visual alarm, or an alarm that alerts the patient through vibration. Additionally, the patient could be informed of information through muscle or nerve stimulation from additional electrodes on the device. In another embodiment, a telemetry signal may be provided to an external device to deliver an automatic alert in the event an emergency situation is detected. For example, if levels of cardiac markers indicated that a patient was suffering a heart attack, emergency workers may be automatically contacted via an uplink to a communications system. Patient data may automatically be provided to emergency health-care workers using information stored with the data storage element 520 . The controller 500 may also include a data acquisition element 530 and a data processor 540 .
[0040] In one embodiment of the invention, the nanosensor of the invention may include a protective member located adjacent the sensor to shield the sensor from a surrounding environment for a selectable time period. The controller 500 may include a protection activator element 560 that would generate a signal that would result in the protective member or a predetermined portion of the protective member(s) to be oxidized, dissolved or otherwise removed so that the nanosensor is allowed to become operational. When a plurality of sensor elements are used, one or more protective members can be associated with one or more sensor elements, where the selectable time period differs. In one embodiment, one or more protective members may be associated with one set of nanowire sensor elements so such protective members may be disabled simultaneously to simultaneously activate the individual nanowire sensor elements within the set. In another embodiment, one or more protective members may be associated with a first set of nanowire sensor elements, wherein one or more first protective member(s) will shield the set of sensor elements for a first selectable time period and a second one or more protective members will shield a second set of nanowire sensor elements for a second selectable time period. The first set of sensor elements may be activated to measure levels of an analyte at the first time, and the second set of sensor elements may be activated at a second time and levels of analyte measured. In yet another embodiment, first and second sets of nanowire sensor elements may include first and second biological recognition elements that specifically bind different substances. In this embodiment, one protective member may be associated with both sets of nanowire sensor elements and when that protective member is disabled both sets of sensor elements are activated so that that the level of more than one analyte may be determined simultaneously. Alternatively, one or more protective members may be associated with each set of sensor elements and the protective members disabled sequentially. A person of ordinary skill in the art will know how to optimize the activation of individual nanowire sensor elements in desired numbers in a set to obtain a desired sensitivity and specificity of analyte being measured. In one of the preferred embodiments, the number of individual nanowire sensor elements in a set will be chosen to provide nanogram to picogram sensitivity.
[0041] The processor may be a microprocessor or other processing circuit as is known in the art. Storage device may comprise Random Access Memory (RAM), Read-Only Memory, registers, a combination thereof, or any other type of memory storage device suitable for use in implantable medical devises. The controller 500 may also include a sensor address 570 .
[0042] The controller 500 may additionally include a protection activator that will cause a protective member that may be formed over the sensor in one embodiment to prevent the sensor from being exposed to bodily fluids prior to a selected time to dissolve.
[0043] Protective members are described for use with sensors in commonly assigned U.S. Published Patent Application No. 2002/0120186, the teachings of which are herein incorporated by reference. In one embodiment, the protective member consists of a thin film of conductive material. Any conductive material that can oxidize, is biocompatible, bio-absorbable, and that may be dissolved in solution such as blood upon application of an electric potential can be used for the fabrication of a protective member. Examples of such materials include copper, gold, silver, and zinc, and some polymers.
[0044] Protective members may be formed by injection or spin coating. In one embodiment, the nanosensor is positioned with a well formed in the substrate. The protective member may be sized to cover the well or may extend beyond the edge of the well to partially cover the substrate. In one embodiment the well can be capped with the protective member by capillary action, by drawing the material partially into the well with a vacuum or other pressure gradient, by melting the material in to the well, by centrifugation and related processes, by inserting solids into the well, or by any combination of these or similar methods.
[0045] In one aspect, the protective member is electrically and mechanically coupled to a respective conductor referred to as the anode. An additional “cathode” conductor is desirably located adjacent to, but electrically and mechanically isolated from, a respective reservoir. A voltage difference applied across the anode and cathode when the protective member is placed in a conductive solution causes electrons to pass from the anode conductor to the cathode conductor through the conductive solution. This, in turn, causes the protective member, which may be considered the anode of the circuit, to oxidize and dissolve into the surrounding fluids, exposing the sensor to surrounding body fluids so that the sensor becomes operational and the biological recognition element may interact with the surrounding environment.
[0046] Although the foregoing examples described protective members that dissolve or erode through the use of a current, any bio-absorbable material that will dissolve within a patient's body in a predictable time period may be used. For example, in an embodiment of the invention where more than one sensor element is included in the system, one or more of the sensor elements may be left unprotected, while one or more additional sensor elements may be associated with a respective protective member that substantially absorbs over a first time period. Yet another set of sensor elements may each be associated with protective members formed of another material known to substantially dissolve over a second time period which is longer than the first time period, and so on. Use of protective members with a plurality of sensor elements to provide for sequential activation of one or more sensor elements can increase the functional life of the sensor by reducing the time period the biological recognition period is exposed to the surrounding environment and reducing the likelihood of non-specific binding of proteins and other materials present in the body to the sensor element in a way that will interfere with the specific binding of analyte or a substance related to the level of analyte present in the patient. In some embodiments, protective members may be used with a plurality of sensor elements to provide for activation of a desired number of sensor elements necessary to control the gain or signal to noise of the sensor elements. For example, in order to obtain a meaningful measurement of levels of an analyte of interest in a patient, it may be necessary to activate more than one sensor element to increase the level of detectable signal being produced.
[0047] FIG. 6 is a diagram illustrating an example of an implantable nanosensor array 600 for monitoring of multiple analytes. A plurality of nanowire field effect transistors 610 are positioned on substrate 620 . Substrate 620 is positioned over a hermetic sensor integrated circuit package 630 , which includes electronic circuitry of the sensor. The sensor is arranged on or connected to lead 640 . Although six nanosensors are shown, any other number of nanosensors as may be supported by substrate 620 is possible.
[0048] FIG. 7 is a diagram illustrating an example of an implantable nanosensor array 700 for monitoring of multiple analytes or for monitoring of a single analyte over a selected period of time or a combination thereof. The array shown in FIG. 7 includes a plurality of individual nanosensors 720 , each positioned within a well 740 formed in the substrate 750 and covered with protective member 730 . In one embodiment, each nanosensor includes a biological recognition element for the same cardiac marker. In use, the array may be implanted within a patient and a predetermined number of nanosensors rendered operational by dissolving the corresponding protective member. The number of nanosensors rendered operational will be determined by the specificity and sensitivity of the binding between the biological recognition element and the cardiac marker of interest and how the detectable signal data is processed. If, under certain conditions, the levels of cardiac marker of interest increase significantly, the specific binding of cardiac marker to the biological recognition element in one nanosensor may not be sufficient to accurately measure the change.
[0049] In another embodiment, each nanosensor must be activated prior to use by applying signals on associated control and address lines to remove a protective member adjacent to the nanosensor in a manner discussed above. Prior to activation, a nanosensor is not exposed to the surrounding environment, so degradation does not occur. After the protective member is removed, sensing may be performed with the sensor until such a time as the sensor performance is determined to be degrading and outside a pre-defined range of accuracy. Thereafter, the nanosensor may be left unused and a different nanosensor activated in its place. In this manner, the implanted sensor system may be used for long periods without requiring replacement.
[0050] FIG. 8 is a flowchart illustrating an example of a closed-loop nanosensor system that works in conjunction with therapy delivered by and IMD. The type of therapy may involve pacing, defibrillation, drug delivery, monitoring and/or patient management therapies. In the embodiment exemplified in FIG. 8 , the therapy is provided by an IMD such as a pacemaker, defibrillator or the like. Computer implemented software logic system in the nanosensor system and/or in the implantable device activates one or more nanosensors in implanted in a patient and begins to measure the levels of a desired cardiac marker in the patient. When the nanosensor determines that the levels of the cardiac marker or markers being measured have increased or decreased to a level that indicates that the patient's status is worsening, the therapy parameters of the IMD may be adjusted accordingly. The nanosensor continues to measure the levels of cardiac marker of interest and appropriate adjustments made in the therapy.
[0051] When the IMD is a CRT system, an increase in levels of a cardiac marker such as BNP may be used to optimize AV and VV timing, to assess the impact of a therapeutic regime on reverse remodeling of the heart or to assess the impact of concomitant drug therapy. Operating under software and/or hardware control, a processing circuit processes the received signal(s) to determine a course of action. Alternatively, the processor may average one or more nanosensor readings, or may use a voting scheme to discard out-of-range signals or may correlate the levels of more than cardiac marker prior to determining the course of action.
[0052] The nanosensor system of the invention is particularly useful in monitoring levels of cardiac markers in patients with cardiovascular diseases and particularly in monitoring levels of BNP in such patients. Methods for determining the prognosis of a patient diagnosed with heart failure or other cardiovascular diseases are described in U.S. Published Patent Application No. 2003/0022235. Briefly, the method includes identifying a BNP level, or the level of a marker related to BNP and associated with an increase in symptoms associated with the patient's cardiovascular disease. Once that level has been determined, a nanosensor system of the invention having a biological recognition element that is a binding pair member of BNP or related marker attached to a nanowire field effect transistor is be implanted in the patient's intra-cardiac circulatory system, either as a stand-alone device or as part of an implantable medical device already implanted in the patient or to be implanted in the patient. The nanosensor controller will measure the patient's BNP levels at predetermined intervals, store the measurements and compare them to the prognostic level of BNP previously determined for the patient. If the BNP level indicates that the patient's condition is worsening, then a patient alert will be triggered so that the patient knows to contact his or her health care provider. Optionally, if the BNP level indicates that the patient's condition is worsening the parameters of the therapy may be automatically be adjusted to a more optimal setting.
[0053] Preferably the biological recognition element is an antibody or a fragment thereof that specifically binds to peptide epitopes within the BNP molecule. In one embodiment the antibody is a monoclonal antibody. Antibodies and other elements that will specifically bind to BNP or markers related to BNP are known. For example, U.S. Pat. No. 6,124,430 describes antibodies that bind to epitopes within the hBNP molecule, the teachings of which are incorporated herein by reference.
[0054] In another embodiment of the invention, a nanosensor system of the invention that includes an array of individual nanosensors adapted to measure the levels of more than one cardiac marker may be used in a method for diagnosing organ failure. Preferably, the cardiac markers of interest include markers that indicated a pressure, volume change and stress to the heart (e.g. BNP and pro-BNP) and markers that are indicative of tissue damage (e.g. cardiac Troponin I). Methods of correlating the measurements of such marker levels obtained using in vitro diagnostic assays to the diagnosis of heart failure are described in U.S. Pat. No. 6,461,828, the teachings of which are herein incorporated by reference.
[0055] All patents and publications referenced herein are hereby incorporated by reference in their entireties. It will be understood that certain of the above-described structures, functions and operations of the above-described preferred embodiments are not necessary to practice the present invention and are included in the description simply for completeness of an exemplary embodiment or embodiments. In addition, it will be understood that specifically structures, functions and operations set forth in the above-referenced patents can be practiced in conjunction with the present invention, but they are not essential to its practice. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described without actually departing from the spirit and scope of the present invention.
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An implantable biosensor system is disclosed for determining levels of cardiac markers in a patient to aid in the diagnosis, determination of the severity and management of cardiovascular diseases. The sensor includes nanowire sensor elements having a biological recognition element attached to a nanowire transducer that specifically binds to the cardiac marker being measured. Each of the sensor elements is associated with a protective member that prevents the sensor element from interacting with the surrounding environment. At a selected time, the protective member may be disabled, thereby allowing the sensor element to begin sensing signals within a living body.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a reciprocating piston compressor such as a swash plate type compressor. More specifically, the present invention relates to a compressor which can constantly perform appropriate discharging actions irrespective of the compression ratio.
2. Description of the Related Art
Reciprocating piston compressors are generally used for air-conditioning passenger compartments in vehicles. In the typical reciprocating piston compressor, a swash plate is supported on a drive shaft, and the wobbling motion of the swash plate caused by rotation of the drive shaft is converted to reciprocating motion of the pistons. With the reciprocating motion of the pistons, gas is sucked from a suction chamber to each cylinder bore, is compressed, and is discharged to a discharge chamber.
Japanese Unexamined Patent Publication No. Hei 5-79456 discloses such a compressor in which a front housing 100 is fixed to the front end of a cylinder block 101 as shown in FIG. 6. A rear housing 106 is fixed to the rear end of the cylinder block 101 with a valve plate 105 interposed therebetween. A drive shaft 103 is rotatably supported in a supporting hole 102 of the cylinder block 101. A swash plate 99, which is fitted on the drive shaft 103, wobbles when the drive shaft 103 is rotated. The cylinder block 101 contains a plurality of cylinder bores 104 formed around the drive shaft 103. A piston 108 is located in each cylinder bore 104 and connected via a piston rod 98 to the swash plate 99.
A suction chamber 107 and a discharge chamber 109 are formed in the rear housing 106. Discharge ports 110, which are formed in the valve plate 105, allow the cylinder bores 104 to communicate with the discharge chamber 109. A flapper type discharge valve 111 and a retainer 112 are applied to the valve plate 105 on the discharge chamber (109) side in association with the corresponding discharge port 110. The discharge valve 111 opens or closes the associated discharge port 110 depending on the difference between the pressure in the cylinder bore 104 and the pressure in the discharge chamber 109 (hereinafter referred to as the discharge pressure). The retainer 112 regulates the aperture of the discharge valve 111.
A communication passage 113 is formed between the supporting hole 102 and each cylinder bore 104. A rotary valve 114, which is contained in the supporting hole 102, is connected to the rear end of the drive shaft 103 to be rotatable integrally therewith. The rotary valve 114 contains a suction passage 115 and a discharge passage 116.
Wobbling of the swash plate 99 caused by the rotation of the drive shaft 103 is transmitted to pistons 108 via the piston rods 98 to allow the pistons 108 to reciprocate in the cylinder bores 104. Suction of a refrigerant gas into the cylinder bores 104, compression of the refrigerant gas in the cylinder bores 104 and discharge of the compressed gas are achieved by the reciprocating motion of the pistons 108.
More specifically, with the rotation of the rotary valve 114 in synchronization with the drive shaft 103, communication is established between the communication passages 113 of the respective cylinder bores 104 in which the piston 108 is in the suction stroke and the suction chamber 107 via the suction passage 115 of the rotary valve 114 for a predetermined time. Thus, the refrigerant gas in the suction chamber 107 is sucked into the cylinder bores 104 sequentially. Further, after the refrigerant gas is compressed by the pistons 108, communication is established for a predetermined time, via the discharge passage 116 of the rotary valve 114, between the discharge chamber 109 and the communicating passage 113 of the cylinder bore 104 in which the piston 108 is in a predetermined discharge stroke at a certain time. It should be noted here that the certain time is when the pressure in the cylinder bore 104 reaches a predetermined value. This value corresponds to the pressure required in the cylinder bore 104 when the compressor is driven at a high compression ratio, i.e., the discharge pressure when the compressor is driven at a high compression ratio.
For example, when the discharge pressure is high and the compressor is driven at a high compression ratio, the communication between the cylinder bore 104 and the discharge chamber 109 is established after the pressure in the cylinder bore 104 is substantially equilibrated with the high discharge pressure, and thus the refrigerant gas in the cylinder bore 104 can securely be discharged to the discharge chamber 109. Therefore, in this compressor, the cylinder bore 104 does not communicate with the discharge chamber 109 before the pressure in the cylinder bore 104 is sufficiently increased so that the refrigerant gas does not flow back from the discharge chamber 109 into the cylinder bore 104.
When the discharge pressure is low and the compressor is driven at a low compression ratio, the discharge valve 111 opens when the pressure in the cylinder bore 104 becomes slightly higher than the discharge pressure, and the refrigerant gas in the cylinder bore 104 is discharged through the discharge port 110 to the discharge chamber 109. In other words, in the situation where the pressure in the cylinder bore 104 greatly exceeds the discharge pressure before communication is established between the communication passage 113 and the discharge chamber 109 via the discharge passage 116, the discharge valve 111 opens to prevent the pressure in the cylinder bore 104 from increasing unnecessarily. Accordingly, the compressor does not perform useless compressing actions to cause pressure loss.
As described above, when the above compressor is driven at a high compression ratio, the refrigerant gas is discharged through the discharge passage 116 of the rotary valve 114 which is rotated integrally with the drive shaft 103. Accordingly, the rotary valve is free from the problems of noise and fatigue, typical in flapper type valves, caused by the opening and closing of the valve. Further, when the compressor is driven at a low compression ratio, the refrigerant gas is discharged through the flapper type discharge valve 111, which opens depending on the difference between the pressure in the cylinder bore 104 and the discharge pressure. Accordingly, pressure loss, which is caused when the refrigerant gas is discharged using the rotary valve 114 only, does not occur.
However, in the above-described compressor, one discharge valve 111 is required for each cylinder bore 14. In addition, the valve plate 105 must be placed between the cylinder block 101 and the rear housing 106 so as to position the discharge valves 111. Also, a retainer 112 must be employed for each discharge valve 111. Accordingly, a number of extra parts in addition to the rotary valve 114 are required, which not only adds to the cost but complicates the structure. Consequently, not only are production costs elevated, but assembly becomes laborious and the compressor is enlarged.
SUMMARY OF THE INVENTION
It is a primary objective of the invention to provide a compressor which can constantly perform discharging actions properly irrespective of the level of compression ratio.
It is another objective of the invention to provide a compressor which requires reduced number of parts and can achieve simplification of the structure and downsizing.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention that are believed to be novel are set forth with particularity in the appended claims. The invention, together with the objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments taken in conjunction with the accompanying drawings in which:
FIG. 1 shows in vertical cross section an entire view of a double-headed piston type swash plate compressor according to a preferred embodiment of the invention;
FIG. 2 is a cross section taken along the line 2--2 of FIG. 1;
FIG. 3 is a cross section taken along the line 3--3 of FIG. 1;
FIG. 4 shows an enlarged perspective view of a rotary valve;
FIG. 5 is a graph showing change in the pressure of a refrigerant gas in the compression chamber; and
FIG. 6 is a vertical cross-sectional view of a prior art swash plate compressor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A double-headed piston type swash plate compressor according to the preferred embodiment will be described referring to FIGS. 1 to 5.
As shown in FIG. 1, a cylinder block 1 is structured by combining two blocks 2 and 3. A front housing 4 is fixed to the front end of the cylinder block 1 and positioned by a pin 5 with respect to the cylinder block 1. A rear housing 6 is fixed to the rear end of the cylinder block 1 and positioned by a pin 7 with respect to the cylinder block 1. A plurality of bolts 8 are screwed from the front surface of the front housing 4 into threaded holes 9 defined on the rear housing 6 to secure the front housing 4, cylinder block 1 and rear housing 6 to one another. The cylinder block 1, front housing 4 and rear housing 6 constitute a housing 10.
A drive shaft 11 is rotatably supported between the end portions of the cylinder block 1 with a pair of bearings 12 having conical rollers. Holding protrusions 4a, 6a are formed on the inner wall surfaces of the front housing 4 and rear housing 6, respectively. The holding protrusion 6a on the rear housing 6 is abutted against the outer ring of the rear bearing 12. A conical disc spring 20 is located between the holding protrusion 4a of the front housing 4 and the outer ring of the front bearing 12 and is compressed therebetween. The conical disc spring 20 applies an axial pre-load to the drive shaft 11.
As shown in FIGS. 1 to 3, pairs of cylinder bores each consisting of a front bore 13 and a rear bore 14 are defined in the cylinder block 1 at equal intervals about the axis of the drive shaft 11. A double-headed piston 15 is disposed in each pair of cylinder bores 13, 14.
A crank chamber 16 is formed in the cylinder block 1 between the front cylinder bores 13 and the rear cylinder bores 14. To this crank chamber 16 is introduced a refrigerant gas through an inlet 17 from an external refrigerant circuit (not shown). A swash plate 18 serving as a driving plate is fixed to the drive shaft 11 in the crank chamber 16 and is connected to the middle portion of each piston 15 with a pair of hemispherical shoes 19. Accordingly, wobbling of the swash plate 18 to be caused by the rotation of the drive shaft 11 is transmitted via the shoes 19 to each piston 15 to cause each piston 15 to reciprocate.
A pair of retaining chambers consisting of a front chamber 21 and a rear chamber 22 are formed in the cylinder block 1 at the centers of the blocks 2,3, respectively. Each chamber 21,22 is concentric with the axis of the drive shaft 11. The retaining chambers 21,22 communicate with the crank chamber 16. A plurality of ports 23,24 are formed between the retaining chambers 21,22 and the cylinder bores 13,14, respectively. These ports 23,24 allow compression chambers 25,26, which are defined in the cylinder bores 13,14 by the piston 15, to communicate with the retaining chambers 21,22, respectively.
A pair of rotary valves 27,28 having a substantially cylindrical form are retained in the retaining chambers 21,22 respectively, and are connected to the drive shaft 11 by keys 29. The outer circumferences of the rotary valves 27,28 contact the inner circumferences of the retaining chambers 21,22, respectively. Annular walls 30,31 are formed on the inner circumferences of the rotary valves 27,28, respectively. Seal rings 32 are located between the outer circumference of the drive shaft 11 and the inner circumference of the walls 30,31. The walls 30,31 define, between the inner circumferences of the rotary valves 27,28 and the outer circumference of the drive shaft 11, first chambers 33,34 communicating with the crank chamber 16 and second chambers 35,36 adjacent to the bearings 12. The seal rings 32 provide a seal between the first chambers 33,34 and the second chambers 35,36, respectively.
As shown in FIGS. 1 to 4, suction passages 37,38 are formed in the circumferential walls of the rotary valves 27,28, respectively. Inlets of the suction passages 37,38 open to the first chambers 33,34, respectively, while outlets of the suction passages 37,38 open to the outer circumferences of the rotary valves 27,28, respectively. First grooves 37a,38a are formed on the outer circumferences of the rotary valves 27,28 to extend in the axial directions thereof and to communicate with the outlets of the suction passages 37,38, respectively. Second grooves 37b,38b are formed on the outer circumferences of the rotary valves 27,28 to extend in the circumferential directions thereof and to communicate with the first grooves 37a,38a, respectively. These second grooves 37b,38b are located to communicate with the ports 23,24, respectively.
First discharge passages 39,40 and second discharge passages 41,42 are formed on the circumferential walls of the rotary valves 27,28, respectively. Inlets of the discharge passages 39,41 and 40,42 open to the outer circumferences of the rotary valves 27,28 locations permitting communication with the ports 23,24 respectively. Outlets of the discharge passages 39,41 and 40,42 open to the second chambers 35,36, respectively. The first discharge passages 39,40 are formed to be narrower in the circumferential direction than the second discharge passages 41,42.
Flapper valve type discharge valves 43,44 are disposed on the inner circumferences of the rotary valves 27,28 to extend in the circumferential directions thereof in association with the first discharge passages 39,40, respectively. These discharge valves 43,44 each have crooked fixed ends which are fitted in fitting grooves 27a,28a formed on the inner circumference of the rotary valves 27,28 and are held tightly between the inner circumferences of the rotary valves 27,28 and the outer circumference of the drive shaft 11, respectively. Thus, the discharge valves 43,44 are secure. The free ends of the discharge valves 43,44 are designed to abut against the outer circumference of the drive shaft 11 so that the aperture of the valves 43,44 may be regulated. The discharge valves 43,44 are disposed in such a way that free ends thereof trail with respect to the rotational directions of the rotary valves 27,28.
A discharge chamber 45 is defined between the front housing 4 and the cylinder block 1. The refrigerant gas is led out of the discharge chamber 45 via an outlet 46 to the external refrigerant circuit (not shown). A discharge passage 47 is formed at the center of the drive shaft 11. The front extremity of the passage 47 communicates with the discharge chamber 45. The drive shaft 11 contains discharge ports 48,49 communicating the second chambers 35,36 with the discharge passage 47.
In the suction stroke where the pistons 15 are moved from the top dead points to the bottom dead points, the suction passages 37,38 are allowed to communicate with the ports 23,24 via the first grooves 37a,38a and second grooves 37b,38b with the rotation of the rotary valves 27,28. This communication allows the refrigerant gas in the crank chamber 16 to be sucked into the compression chambers 25,26 in the cylinder bores 13,14 via the first chambers 33,34, suction passages 37,38 and ports 23,24. Further, in this suction stroke, the first discharge passages 39,40 and the second discharge passages 41,42 are dissociated from the ports 23,24 to isolate the compression chambers 25,26 from these discharge passages 39,41 and 40,42, respectively.
Meanwhile, in the compression and discharge stroke, where the pistons 15 are moved from the bottom dead points to the top dead points, the second grooves 37b,38b dissociate from the ports 23,24 with the rotation of the rotary valves 27,28, to isolate the compression chambers 25,26 from the suction passages 37,38. The refrigerant gas in the compression chambers 25,26 is compressed by the isolation thus achieved. Then, the discharge stroke follows. In the discharge stroke, the first discharge passages 39,40 are first allowed to communicate with the ports 23,24 with the rotation of the rotary valves 27,28. During this time, the discharge valves 43,44 open or close the first discharge passages 39,40 based on the difference between the pressure of the compressed refrigerant gas in the compression chambers 25,26 and the pressure in the external refrigerant circuit or the pressure in the discharge chamber 45 (hereinafter referred to as the discharge pressure).
More specifically, when the pressure in the compression chambers 25,26 is lower than the discharge pressure, the discharge valves 43,44 are not opened. When the pressure in the compression chambers 25,26 is slightly higher than the discharge pressure, the compressed refrigerant gas in the compression chambers 25,26 pushes the discharge valves 43,44 aside to be exhausted into the second chambers 35,36 through the ports 23,24 and first discharge passages 39,40. Then, the refrigerant gas in the second chambers 35,36 flows through the discharge ports 48,49 and discharge passage 47 into the discharge chamber 45.
Further, in this discharge stroke, the second discharge passages 41,42 are then allowed to communicate to the ports 23,24 after the first discharge passages 39,40. This communication allows the compressed refrigerant gas in the compression chambers 25,26 to flow through the ports 23,24, second discharge passages 41,42, second chambers 35,36, discharge ports 48,49 and discharge passage 47 into the discharge chamber 45. The time that the second discharge passages 41,42 communicates with the ports 23,24 is designed to be the same time point S where the pressure in the compression chambers 25,26 reaches a predetermined value P1, as shown by the solid line in FIG. 5. The valve P1 corresponds to the pressure required in the compression chambers 25,26 when the compressor is driven at a high compression ratio. In other words, it corresponds to the discharge pressure when the compressor is driven at a high compression ratio.
Next, the operation of the compressor will be described.
When the compressor is actuated, in the suction stroke, the refrigerant gas in the crank chamber 16 is sucked through the first chambers 33,34, suction passages 37,38, and ports 23,24 into the compression chambers 25,26 of the cylinder bores 13,14. In the compression and discharge stroke, the refrigerant gas in the compression chambers 25,26 of the cylinder bores 13,14 is compressed by the pistons 15 and then discharged into the discharge chamber 45.
When the refrigerant gas in the external refrigerant circuit is not cooled sufficiently due, for example, to slow driving of the vehicle, the discharge pressure becomes high, and the compressor is driven at a high compression ratio. In this case, as shown by the solid line in FIG. 5, the discharge valves 43,44 do not open until the pressure in the compression chambers 25,26 exceeds the discharge pressure (corresponding to P1 in FIG. 5), even if communication is established between the first discharge passages 39,40 and the ports 23,24. Accordingly, the refrigerant gas in the compression chambers 25,26 does not escape through the first discharge passages 39,40 but is compressed fully until its pressure substantially equilibrates with the high discharge pressure.
At the time point S where the pressure in the compression chambers 25,26 substantially equilibrates with the higher discharge pressure, the second discharge passages 41,42 communicate with the ports 23,24. Thus, the compressed refrigerant gas in the compression chambers 25,26 is discharged through the ports 23,24, and second discharge passages 41,42 into the discharge chamber 45 preventing the gas from flowing back from the discharge chamber 45 into the compression chambers 25,26.
In the situation where the gas in the external refrigerant circuit is overcooled due, for example, to fast driving of the vehicle, the discharge pressure becomes low, and the compressor is driven at a low compression ratio. In this case, the discharge valves 43,44 are opened when the pressure in the compression chambers 25,26 become slightly higher than the discharge pressure (corresponding to P2 in FIG. 5) after communication is first established between the first discharge passages 39,40 and the ports 23,24. Thus, the compressed gas in the compression chambers 25,26 is discharged through the ports 23,24, and first discharge passages 39,40 into the discharge chamber 45. Accordingly, in the case where the pressure in the compression chambers 25,26 greatly exceeds the discharge pressure before communication is established between the second discharge passages 41,42 and the ports 23,24, such opening of the discharge valves 43,44 prevents the pressure in the compression chambers 25,26 from increasing unnecessarily.
Subsequently, at the time point S, the second discharge passages 41,42 communicate with the ports 23,24. Thus, the compressed refrigerant gas in the compression chambers 25,26 is discharged through the ports 23,24, and the second discharge passages 41,42 into the discharge chamber 45 with the pressure of the gas being substantially equilibrated with the discharge pressure. Accordingly, the compressor does not perform useless compressing actions to cause pressure loss.
While the operation of the compressor has been described with respect to the cases where the compressor is driven at a predetermined high compression ratio and at a predetermined low compression ratio, the compressor constantly performs appropriate discharging actions even if the compression ratio is varied from these levels. That is, discharging actions are appropriately performed irrespective of the level of the discharge pressure, i.e., the level of the compression ratio. Further, the two rotary valves 27,28 each contain one discharge valve 43,44 associated with the first discharge passages 39,40 of the rotary valves 27,28, respectively. Accordingly, unlike the prior art, discharge valves do not need to be employed for each cylinder bore. Thus, the number of discharge valves 43,44 is minimized. In addition, there is no need for valve plates between the cylinder blocks and the housings. Thus, the number of parts is reduced, and the structure of the compressor is simplified leading to a reduction in the production cost. In addition, the assembly of the compressor is simpler, and the compressor is smaller in size.
Further, the first chambers 33,34, which communicate with the crank chamber 16 via the walls 30,31 of the rotary valves 27,28, are located adjacent to the second chambers 35,36, respectively, which communicate with the discharge chamber 45. Accordingly, the suction passages 37,38 communicating with these chambers 33,35 and 34,36 and the discharge passages 39,41 and 40,42 can easily be formed in the rotary valves 27,28. In addition, the discharge valves 43,44 are located on the inner circumferential sides of the rotary valves 27,28, respectively. Consequently, the mechanisms for sucking and discharging the refrigerant gas can be made compact by locating them around the rotary valves 27,28.
Further, the discharge valves 43,44 are secured in such a way that the fixed ends thereof are fitted in the fitting grooves 27a,28a formed on the inner circumferences of the rotary valves 27,28, and they are held tightly between the inner circumferences of the rotary valves 27,28 and the outer circumference of the drive shaft 11. Accordingly, the discharge valves 43,44 can easily be fitted to the rotary valves 27,28 without using any special fasteners such as screws. Also, the motion of the free ends of the valve flaps is limited by the outer circumference of the drive shaft 11. Thus, there is no need to provide retainers for regulating the aperture of the discharge valves 43,44, and thus the number of parts is reduced and the structure of the valves 43,44 is simplified. In addition, the discharge valves 43,44 are disposed such that the free ends thereof trail with respect to the rotational directions of the rotary valves 27,28 so that the opening and closing of the discharge valves 43,44 are not interfered with by the flow of refrigerant gas.
Further, no discharge valve is needed for the second discharge passages 41,42, which merely consist of holes. Accordingly, the valves are not vibrated by the flow of gas when the gas is discharged via the second discharge passages 41,42. This allows the gas to be discharged smoothly and quietly. In addition, since the discharge valves 33,34 associated with the first discharge passages 39,40 are not opened or closed constantly in the discharge stroke, fatigue and noise are reduced as much as possible.
It should be understood that the present invention is not limited to the above embodiment but may be modified and embodied as follows:
(1) the present invention may be employed in a single-headed piston type compressor;
(2) the present invention may be employed in a variable displacement compressor, in which discharge displacement can be varied according to the inclined angle of a swash plate;
(3) the present invention may be employed in a wave cam type compressor, in which a wave cam having wavy cam surfaces is used instead of a swash plate to drive pistons; or
(4) Each of the rotary valves 27,28 may contain only one discharge passage, and the discharge valves 43,44 may be associated with the discharge passages, respectively. In this case, the discharge valves 43,44 are opened when the pressure in the compression chambers 25,26 is slightly higher than the discharge pressure to discharge the compressed gas in the compression chambers 25,26 into the discharge chamber 45. Accordingly, back flow of refrigerant gas from the discharge chamber 45 into the compression chambers 25,26 is prevented. For the same reason, pressure loss is also avoided. Consequently, the compressor can constantly perform appropriate discharging actions irrespective of the level of the discharge pressure, i.e., the compression ratio.
Therefore, the present embodiment is to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope of the appended claims.
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A rotary valve is supported on a rotary shaft for an integral rotation. The rotary valve has a suction passage and a discharge passage. The suction passage connects a cylinder bore with a suction chamber according to the rotation of the rotary valve when a piston is in the suction stroke. The discharge passage connects the cylinder bore with a discharge chamber according to the rotation of the rotary valve when the piston is in the discharge stroke. The discharge passage includes a first passage and a second passage. The second passage communicates with the cylinder bore after the first passage has communicated with the cylinder bore after the first passage has communicated with the cylinder bore according to the rotation of the rotary valve. A discharge valve is mounted on the rotary valve. The discharge valve selectively opens and closes the first passage according to the difference between the pressures in the cylinder bore and in the discharge chamber.
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BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates generally to control apparatus for use in conjunction with conditioned air distribution systems which are employed for heating, cooling and ventilating of buildings and more particularly to an improved variable volume air controller for use in conjunction with such systems.
In heating and cooling of various types of buildings it is common practice to provide one or sometimes more central heating and/or cooling units which operate to deliver a supply of conditioned (either heated or cooled) air to various locations via a duct work system. In one type of system, the heating/cooling unit is operative to continuously provide a supply of air at a substantially constant temperature. In order to control the temperature of the various locations within the building the duct work system is provided with one or more individually controlled variable volume air controllers which operate to vary the volume of the conditioned air which is being delivered therethrough to the various locations. Typically, actuation of the volume air controllers will be controlled by thermostats located within the spaces to which the controller is delivering the conditioned air.
Basically, these variable volume air controllers comprise a housing having an inlet and an outlet connected respectively to supply and delivery portions of a duct work system and a motor driven damper within the housing. The motor drive system will be controlled by a thermostat or other suitable means and operates to position the damper at substantially any setting between and including fully open or fully closed positions so as to modulate the flow of air therethrough.
In order to facilitate modulation of the air flow, the cross sectional area of the volume control housing is typically significantly greater than that of the inlet opening provided therein. Hence, it is desirable to provide means to improve the distribution or diffusion of the air flow entering the housing over the entire cross sectional area so as to enable the damper to more effectively and efficiently modulate the air flow. Further, because the delivery duct work system opens directly into the spaces to be heated or cooled any noise produced as a result of operation of the air controller will most likely be very noticeable and possibly annoying to occupants of those spaces. Accordingly, it is very desirable to design the air controller in such a manner that it will offer substantially noise-free operation both in terms of wind noise which may result from modulation of the air flow as well as vibration of the various components forming a part of the air controller. Additionally, because the duct work system is often located in spaces within the building which are substantially closed off or sealed from the spaces to which the conditioned air is to be supplied, it is desirable that the air controller be substantially sealed so as to prevent leakage of the conditioned air therefrom. Conflicting with this objective, however, is the need to attach various support devices such as hangers and the like to the housing in order to support the air controller which may require puncturing the outer shell thereof.
The present invention, however, provides a substantially improved variable volume air controller which is designed to overcome these problems and provide an extremely quiet and efficient air controller capable of providing substantially noise-free modulation of air flow over substantially the entire range of operation. The variable volume air controller of the present invention comprises an outer shell having a liner fitted therein the sidewalls of which are spaced from the sidewalls of the outer liner so as to prevent penetration of any fastening devices into the interior of the controller and thus reduce resulting air leakage therethrough. Improved air diffusion means is also provided within the controller which operates to distribute the incoming air flow in such a manner as to provide a velocity profile which facilitates efficient relatively noise-free modulation of the air flow over substantially the entire range of operation of the damper. Additionally, stop means are also provided within the air controller which is engageable with the damper so as to prevent movement thereof beyond a full open position. This stop means thus prevents possible misadjustment of drive linkage which could result in the damper being driven beyond a full open position and thus reduce maximum air flow when in fact the control means is signalling for delivery of maximum conditioned air to the spaces. The stop means also includes an air flow deflector which is designed to deflect air flow which would otherwise impinge on the leading edge of the damper when in a full open position thus creating the possibility of noise producing flutter or vibration of the damper. The present invention is also designed to enable inlet plates having different size inlet openings to be easily and conveniently attached to an otherwise completely assembled air controller. Thus, it is possible for a distributor to stock a standard size air controller and to fit an inlet plate thereto having an inlet opening particularly suited for the specific job as opposed to requiring stocking of a variety of different size air controllers. Thus, the present invention provides a variable volume air controller which offers significant advantages over presently available units.
Additional advantages and features of the present invention will become apparent from the subsequent description and the appended claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a variable volume air controller in accordance with the present invention, portions thereof being broken away;
FIG. 2 is a sectioned view of the air controller of FIG. 1, the section being taken along line 2--2 thereof;
FIG. 3 is another sectioned view of the air controller of FIG. 1, the section being taken along line 3--3 thereof; and
FIG. 4 is a fragmentary sectioned view of a portion of the air controller of FIG. 1 showing the stop member provided therein with the damper in engaging relationship therewith.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and in particular to FIGS. 1 and 2, there is shown a variable volume air controller 10 in accordance with the present invention which comprises a housing 12 including an outer shell 14 and a liner 16, an inlet 18 at one end thereof and an outlet 20 at the other end. Diffusion means 22 and air flow control means 24 are also provided being disposed within housing 12.
Outer shell 14 is preferably fabricated from a single sheet of a suitable sheet metal such as a galvanized steel for example which is formed to define a chamber having a generally rectangular cross sectional shape open at both ends including substantially parallel spaced upper and lower wall portions 26 and 28 and substantially parallel spaced interconnecting sidewall portions 30 and 32. A peripheral flange portion 34 is also formed around one end of outer shell 14 projecting inwardly at generally right angels to the respective wall portions. Sidewalls 30 and 32 may be provided with a generally parallel extending outwardly spaced flange 35 at the opposite end from peripheral flange 34 to facilitate attachment of outlet 20 to the delivery duct system if desired.
Liner 16 is similarly preferably formed from a single piece of a suitable sheet metal and has a substantially identical shape although of slightly smaller dimensions so as to enable it to be fitted within shell 14 and includes upper and lower walls 36 and 38 and interconnecting sidewalls 40 and 42. As shown in FIG. 2, the height and width of liner 16 will be approximately equal to the opening defined by peripheral flange portion 34 and thus respective wall portions 36, 38, 40, and 42 are spaced from wall portion 26, 28, 32, and 30. A layer of a suitable insulation material 44 is disposed with the space between the respective wall portions of liner 16 and outer shell 14 so as to inhibit heat transfer into or out of the chamber defined thereby.
As best seen with reference to FIG. 2, peripheral flange portion 34 is operative to support one end 46 of liner 16 which projects outwardly therefrom while the other end 48 of liner 16 is provided with a generally L-shaped outwardly projecting peripheral flange portion 50 including legs 52 and 54 which are so dimensioned as to place leg portion 54 in supporting engagement with wall portions 26, 28, 30, and 32 of outer shell 14. Suitable fasteners such as pop rivets 56 may be used to secure leg portion 54 to respective sidewall portions 26, 28, 30, and 32 so as to secure liner 16 in assembled relationship with shell 14. Preferably, liner 16 will have a depth less than that of outer shell 14 so as to avoid interfering with the attachment of air controller 10 to a delivery duct work system and additional suitable insulating material 58 may be applied to the inner surface of the outer shell wall portions extending beyond liner 16.
Thus, as seen in FIGS. 2 and 3, air flow through the air controller will be substantially fully contained within liner 16 and because of the spacing between the sidewalls of liner 16 and shell 14, fasteners used to attach hangers or other supporting devices to the air controller will only penetrate the walls of the outer shell 14 thus eliminating the possibility of air leakage resulting therefrom.
An inlet plate 60 is adapted to be secured to outwardly projecting end portion 46 of liner 16 by means of a generally U-shaped peripheral flange portion 62 provided thereon which is adapted to receive end portion 46 of liner 16. Preferably a suitable sealant or caulking material will be applied to this joint to prevent air leakage therefrom and suitable fasteners installed to securely attach inlet plate 16 to liner 46. Inlet plate 60 has an opening 64 provided therein within which a relatively short connector section of duct pipe 66 is fitted. As shown in FIG. 3, connector section 66 is provided with an annular outwardly projecting bead 67 adapted to abut the outer surface of inlet plate 60 and has the inner end thereof folded over the inner surface of inlet plate 60 so as to form a secure attachment therebetween. Again, a suitable sealant may be applied at this joint to prevent possible air leakage therefrom. Connector section 66 may be of any suitable size and shape required to enable air controller 10 to be connected to supply duct work of a conditioned air system. Thus, because inlet plate 60 is in the form of a separately attachable member which is designed so as to be secured to liner 16 relatively easily, it is possible for a distributor to stock only a single standard or universal size air controller without inlet plate 60 attached thereto and to then cut the desired size and shape opening therein necessary to fit the intended application. This feature offers significant economic advantages to the distributor in terms of reducing the required capital investment in inventory as well as reducing the required warehouse space while still enabling air controllers to be provided suitable for a full range of supply duct system sizes.
As previously mentioned. diffusion means 22 is provided within liner 16 and preferably comprises a sheet metal member having a relatively large number of closely spaced relatively small openings 68 therein. Diffusion member 22 is generally rectangular in shape and extends between and is secured to upper and lower wall portions of liner 16. The height of diffusion member 22 is substantially greater than distance between upper and lower wall portions 36 and 38 of liner 16 and will thus be formed to a generally arcuate contour when installed in overlying spaced relationship to opening 18 so as to present a generally concave surface to the air flowing through inlet opening 18. Diffusion member 22 also has a width less than the width of liner 16 but substantially wider than inlet opening 18 so as to position opposite lateral edge portions 70 and 72 in spaced relationship to sidewalls 40 and 42. Thus, a pair of substantially unrestricted passages 74 and 76 are provided around the opposite lateral edges of diffusion member adjacent opposite sidewalls so as to distribute air flow more evenly across substantially the entire transverse width of air controller 10. Additionally, because of the concave contour presented to the air flow entering through inlet 18 diffusion member 22 will also tend to produce a maximum velocity air flow rate approximately midway between upper and lower sidewalls 36 and 38 because the plane of the openings provided in the diffusion member will be oriented at substantially right angles to the direction of air flow through inlet openings along this transverse midline thus presenting a greater effective open area than the openings adjacent either the upper or lower sidewalls 36 and 38 which lie in a plane angularly related to the direction of air flow through inlet 18.
As best seen with reference to FIGS. 2 and 3, air flow control means 24 provided within air controller 10 comprises a damper 78 supportingly non-rotatably secured to a rotatable actuating shaft 80. Damper 78 is generally rectanguar in shape and of a size so as to substantially close off air flow through controller 10 when in a fully closed position as shown in FIG. 2.
Actuating shaft 80 has one end 82 rotatably supported in a suitable bearing 84 fitted within an opening 86 in sidewall 42 of liner 16 while the other end 88 extends outwardly through openings 90 and 92 in sidewalls 40 and 32 of liner 16 and outer shell 14 respectively and is rotatably supported therein by another suitable bearing 94.
A drive motor 96 which may be either pneumatically or electrically operated is secured to sidewall 32 of outer shell by means of a support bracket 98 and has an output shaft 100 connected by suitable adjustable linkage means 102 to a crank arm 104 secured to end 88 of actuating shaft 80. Thus, drive motor 96 may operate to rotatably drive actuating shaft 80 so as to continuously vary the position of the damper secured thereto between a fully closed position and a fully open position in accordance with the demand for delivery of condition air to the spaces being supplied thereby. Preferably, drive motor 96 will include internal biasing means operative to maintain the damper in a fully closed position when it is not energized although suitable external biasing means may be provided if desired.
In order to limit movement of damper 78 beyond the fully closed position as shown, a pair of generally "L"-shaped flange members 106 and 108 are secured to upper and lower sidewalls 36 and 38. Similarly, two pairs of "L"-shaped flange members 110 and 112 are provided, one pair being secured to sidewall 40 above and below actuating rod 80 generally as shown in FIG. 2 and the other being similarly secured to sidewall 42. These flange members are positioned so as to prevent movement of damper beyond a plane lying generally perpendicular to sidewalls 36 and 38.
A generally L-shaped stop member 114 is also provided extending transversely between and being supportingly secured to opposite sidewalls 40 and 42. Stop member 114 includes a first leg portion 116 positioned in a plane lying generally parallel to upper and lower sidewalls 36 and 38 and passing through the rotational axis of damper 78 which is engageable with the leading edge 120 of damper 78 when damper 78 is moved to a fully open position such as is shown in FIG. 4 so as to prevent overtravel thereof. A second relatively short leg portion 118 projects upwardly in the direction of approach of damper 78 from leg portion 116 at substantially a right angle thereto and has a width somewhat greater than the thickness of damper 78. Leg portion 116 operates to deflect air flow away from the leading edge 120 of the damper 78 so as to prevent possible flutter or vibration thereof which could result in annoying noise production thereby.
As previously mentioned, air flow entering air controller 10 via inlet opening 18 will have a maximum velocity approximately midway between upper and lower walls 36 and 38 and will be more uniformly distributed transversely across the full width of the air controller due to the interaction with diffusion member 22. This distribution offers several advantages in facilitating effective modulation of the air flow. For example because of the centralizing of the maximum velocity air flow, the greatest forces acting on damper 78 will be located immediately adjacent the rotational axis thereof which because of the reinforcing effect of the actuating rod 80 will be the strongest portion thereof. Further, because of the proximity of these forces to the location of the rotational axis, only relatively small moment arms result therefrom. Additionally, the low volume modulation of air flow is greatly facilitated because of the lower velocity air flow adjacent the upper and lower walls 36 and 38. Thus, the percentage increase in air flow volume will be more evenly distributed over the full range of damper operation thus allowing more accurate modulation even at very low flow rates. This also aids in reduction of wind noise even at very small damper opening positions.
Thus, as is apparent, the present invention provides a substantially improved variable volume air controller which provides for improved modulation over the entire operational range with lower attendant noise levels than previously available units.
While it will be apparent that the preferred embodiment of the invention disclosed is well calculated to provide the advantages and features above stated, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims.
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An improved variable volume air controller for use in conjunction with a conditioned air distribution system is disclosed which comprises an insulated lined housing having an inlet, an outlet, and a control assembly operative to vary the volume of air flowing therethrough. An air flow diffuser is also provided being positioned in overlying relationship to the inlet opening which operates to substantially improve air flow distribution over the cross sectional area of the housing whereby the control assembly may operate to provide improved relatively noise-free modulation of air flow. Additionally, a stop assembly is provided which cooperates with a portion of the control assembly to limit movement thereof beyond a true full open position as well as to inhibit air flow induced vibration thereof when the control assembly is in a full open position.
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TECHNICAL FIELD
This invention relates to new and useful benzothiazine dioxide derivatives. More particularly, it is concerned with certain novel oxyethyl derivatives of 4-hydroxy-2-methyl-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide and several other closely-related oxicams, which are of especial value as prodrugs in view of their chemotherapeutic properties.
BACKGROUND ART
In the past, various attempts have been made to obtain new and better anti-inflammatory agents. For the most part, these efforts have involved the synthesis and testing of various steroidal compounds such as the corticosteroids or non-steroidal substances of an acidic nature such as phenylbutazone, indomethacin and the like, including piroxicam. The latter substance is a member of a class of anti-inflammatory/analgesic N-heteroaryl-4-hydroxy-2-methyl-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxides (known as oxicams) described and claimed in U.S. Pat. No. 3,591,584 and is specifically, 4-hydroxy-2-methyl-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide. Other agents of this type are disclosed in U.S. Pat. Nos. 3,787,324, 3,822,258, 4,180,662 and 4,376,768, as well as in German Offenlegungsschrift No. 2,756,113 and Published European Patent Application No. 138,223. In U.S. Pat. No. 4,434,164, there are specifically described and claimed the ethylenediamine, monoethanolamine and diethanolamine salts of 4-hydroxy-2-methyl-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide, which are particularly valuable in pharmaceutical dosage forms as non-steroidal therapeutic agents for the treatment of painful inflammatory conditions, such as those caused by rheumatoid arthritis, since they are all crystalline, non-hygroscopic, rapidly-dissolving solids with high water solubility. In U.S. Pat. No. 4,309,427, there are disclosed certain novel acyl derivatives (i.e., enol esters) of 4-hydroxy-2-methyl-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide and 4-hydroxy-2-methyl-N-(6-methyl-2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide, which are useful as non-steroidal therapeutic agents for alleviating various inflammatory conditions, including those of the skin, especially when given by the topical route of administration. However, in the continuing search for still more improved anti-inflammatory/analgesic agents, there is a need for anti-arthritic agents that are orally administrable.
In this connection, it is to be noted that while the prior described enolic oxicam lower alkyl ethers of U.S. Pat. No. 3,892,740 do not possess anti-inflammatory activity to any substantial degree, the more recently described anti-inflammatory oxyalkyl ethers of the enolic oxicams of U.S. Pat. No. 4,551,452 all require that the oxyalkyl moiety be restricted to --CH 2 --O--, --CH(CH 3 )--O-- or --CH(C 6 H 5 )--O--. As a result, there is little or no information available about the effect of other oxyalkyl ethers in this area and particularly, about compounds like the corresponding enolic oxicam lower oxyalkyl ethers wherein the alkyl moiety is exclusively arranged in a straight chain.
DISCLOSURE OF THE INVENTION
In accordance with the present invention, it has now been found that certain novel oxyethyl derivatives of 4-hydroxy-2-methyl-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide and several other closely-related known oxicams are useful in therapy as prodrug forms of the known anti-inflammatory and analgesic oxicams. Consequently, the compounds of this invention are useful in therapy as non-steroidal therapeutic agents for alleviating painful inflammatory conditions such as those caused by rheumatoid arthritis, for example. The novel compounds of this invention are of the formula: ##STR2## wherein R 1 is hydrogen, methyl, fluorine or chlorine, and R 2 is hydrogen or --COOR 3 wherein R 3 is alkyl having from one to eight carbon atoms.
The compounds of this invention are useful in therapy as prodrug forms of the known anti-inflammatory and analgesic oxicams from which they are derived. The term "prodrug", when used in this connection, refers to compounds which are drug precursors, which following administration and absorption in the body release the drug in vivo by some metabolic pathway or process such as hydrolysis. Accordingly, these novel compounds are particularly valuable as non-steroidal therapeutic agents for the treatment of painful inflammatory conditions, especially those caused by rheumatoid arthritis, and are particularly adapted for use in various pharmaceutical dosage forms, including those designed for oral, topical or parenteral administration. Moreover, the prodrugs of this invention are unusual in that they exhibit anti-inflammatory activity to a high degree in contrast to the enolic oxicam lower alkyl ethers of the aforesaid prior art (U.S. Pat. No. 3,892,740). They also exhibit good oral absorption, as compared to the parent acidic oxicams from which they are derived. Accordingly, the preferred method of administration for the presently-claimed compounds is oral, although parenteral and topical formulations are also readily made available with these compounds and such formulations are found to be useful.
Of especial interest in this connection are the preferred compounds of the invention where R 1 in the structural formula is hydrogen (i.e., derivatives of piroxicam), and R 2 is hydrogen or --COOR 3 wherein R 3 is alkyl having from one to eight carbon atoms. Typical and preferred member compounds of the invention include 4-(2-hydroxyethyloxy)-2-methyl-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide, 4-(2-hydroxyethyloxy)-2-methyl-N-(6-methyl-2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide and N-[1-(2-hydroxyethyl)-2-pyridinium]-2-methyl-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide 4-enolate. These particular compounds are especially effective in treating many painful inflammatory conditions by the oral route of administration.
DETAILED DESCRIPTION
In the process for preparing the novel compounds of the invention, the parent oxicam compound of the formula: ##STR3## wherein R 1 is defined as aforesaid, is treated with at least an equivalent amount in moles of an oxyethyl halide of the formula:
XCH.sub.2 CH.sub.2 OR.sub.2
wherein R 2 is as previously defined and X is either chlorine, bromine or iodine. This reaction is normally carried out in a reaction-inert organic solvent, preferably under substantially anhydrous conditions, in the presence of at least an equivalent amount of an appropriate standard base (e.g., triethanolamine or potassium carbonate). A particularly convenient reaction system employs acetone as the solvent and potassium carbonate as the base, with up to three or more equivalents of sodium iodide added, if desired, when the oxyethyl halide employed is other than an iodide, in order to enhance the rate of the reaction. It should be noted that the amount of standard base employed must be such that it is present in sufficient amount to neutralize the liberated hydrogen halide formed in the reaction. Excess of the reagent R 2 OCH 2 CH 2 X is not critical to the reaction, but such excess will generally be used in order to shift the reaction to completion in a shorter period of time. The rate of reaction will also depend greatly on the nature of X (e.g., I>Br>Cl) and to some extent on the nature of the R 2 OCH 2 CH 2 -- group (where R 2 is hydrogen or an organic radical as previously defined). In general, the reaction is conducted at a temperature of from about 50° C. up to about 100° C. for a period of at least about 24 hours and preferably for a period of about five to about seven days. When acetone is employed as the solvent and potassium carbonate as the base, the reflux temperature of acetone is a particularly convenient reaction temperature for these purposes. The reaction is most conveniently followed by high pressure liquid chromatography, thereby determining reaction times sufficient to provide complete reaction and at the same time, avoiding any unnecessary heating and excessive reaction times which can increase the level of byproduct formation and reduce yields. Upon completion of the reaction, the desired oxyethyl derivatives are readily recovered in a conventional manner and preferably by using known chromatographic techniques.
The starting materials required for preparing the novel oxyethyl derivatives of this invention are all known compounds. For instance, 4-hydroxy-2-methyl-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide (piroxicam) and 4-hydroxy-2-methyl-N-(6-methyl-2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide are both fully described in U.S. Pat. No. 3,591,584 to J. G. Lombardino, as well as in the paper by J. G. Lombardino et al., appearing in the Journal of Medicinal Chemistry, Vol. 16, p. 493 (1973), including their synthesis from readily available organic compounds. The other closely-related oxicams required as starting materials in the process of this invention are readily available by methods well known to those skilled in the art, e.g., see the patent references to the other oxicams cited in the background section of the instant specification.
The oxicam prodrugs of the present invention are all readily adapted to therapeutic use as anti-inflammatory agents. For instance, 4-(2-hydroxyethyloxy-2-methyl-4-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide, a typical and preferred agent of the present invention, exhibits anti-inflammatory activity in the standard carrageenin-induced rat foot edema test [described by C. A. Winter et al., Proc. Soc. Exp. Biol. Med., Vol. 111, p. 544 (1962)], where it was found to cause a 48% inhibition in swelling at the 32 mg./kg. dose level when given by the oral route. The herein described derivatives exhibit additional advantages. For instance, they all exhbit good oral absorption as compared to the parent oxicam from which they are derived. In this connection, it is to be noted that the aforesaid preferred agent of the present invention exhibits a rather surprisingly high oral absorption potential (e.g., a value of 1.81) when tested orally at 22.7 mg. according to the standard test procedure described by J. B. Dressman et al., as set forth in the Journal of Pharmaceutical Sciences, Vol. 74, No. 5, p. 588 (1985).
The herein described oxicam prodrugs of this invention can be administered via either the oral, parenteral or topical routes. In general, these compounds are most desirably administered in doses ranging from about 5.0 mg. up to about 1000 mg. per day, although variations will necessarily occur depending upon the weight and condition of the subject being treated and the particular route of administration chosen. However, a dosage level that is in the range of from about 0.08 mg. to about 16 mg. per kg. of body weight per day is most desirably employed. Nevertheless, variations may still occur depending upon the individual response to said medicament, as well as on the type of pharmaceutical formulation chosen and the time period and interval at which such administration is carried out. In some instances, dosage levels below the lower limit of the aforesaid range may be more than adequate, while in other cases still larger doses may be employed without causing harmful side effects provided that such higher dose levels are first divided into several small doses for administration throughout the day.
The oxicam prodrugs of this invention may be administered alone or in combination with pharmaceutically acceptable carriers by either of the three routes previously indicated. More particularly, the novel therapeutic agents of the invention can be administered in a wide variety of different dosage forms, i.e., they may be combined with various pharmaceutically acceptable inert carriers in the form of tablets, capsules, lozenges, troches, hard candies, powders, sprays, creams, salves, suppositories, jellies, pastes, lotions, ointments, aqueous suspensions, injectable solutions, elixirs, syrups, and the like. Such carriers include solid diluents or fillers, sterile aqueous media and various non-toxic organic solvents, etc. Moreover, oral pharmaceutical compositions can be suitably sweetened and/or flavored. In general, the therapeutically-effective compounds of this invention are present in such dosage forms at concentration levels ranging from about 0.5% to about 90% by weight.
For oral administration, tablets containing various excipients such as microcrystalline cellulose, sodium citrate, calcium carbonate, dicalcium phosphate and glycine may be employed along with various disintegrants such as starch and preferably corn, potato or tapioca starch, alginic acid and certain complex silicates, together with granulation binders like polyvinylpyrrolidone, sucrose, gelatin and acacia. Additionally, lubricating agents such as magnesium stearate, sodium lauryl sulfate and talc are often very useful for tabletting purposes. Solid compositions of a similar type may also be employed as fillers in gelatin capsules; preferred materials also include lactose or milk sugar as well as high molecular weight polyethylene glycols. When aqueous suspensions and/or elixirs are desired for oral administration, the active ingredient may be combined with various sweetening or flavoring agents, coloring matter or dyes, and, if so desired, emulsifying and/or suspending agents as well, together with such diluents as water, ethanol, propylene glycol, glycerin and various like combinations thereof.
For parenteral administration, solutions of these oxicam prodrugs in either sesame or peanut oil or in aqueous propylene glycol may be employed. The aqueous solutions should be suitably buffered (pH>8) if necessary and the liquid diluent first rendered isotonic. These aqueous solutions are suitable for intravenous injection purposes. The oily solutions are suitable for intra-articular, intramuscular and subcutaneous injection purposes. Additionally, it is also possible to administer the aforesaid oxicam oxyethyl derivatives topically when treating inflammatory conditions of the skin or eye and this may be preferably done by way of creams, jellies, pastes, ointments, solutions and the like, in accordance with standard pharmaceutical practice.
The anti-inflammatory activity of the compounds of the present invention is demonstrated in the previously mentioned standard carrageenin-induced rat foot edema test. In this test, anti-inflammatory activity is determined as the percent inhibition of edema formation in the hind paw of male albino rats (weighing 150-190 g.) in response to a sub-plantar injection of carrageenin. The carrageenin is injected as a 1% aqueous suspension (0.05 ml.) one hour after oral administration of the drug, which is normally given in the form of an aqueous solution. Edema formation is then assessed by measuring the volume of the injected paw initially as well as three hours after the carrageenin injection. The increase in volume three hours after carrageenin injection constitutes the individual response. Compounds are considered active if the difference in response between the drug-treated animals (six rats/group) and a control group receiving the vehicle alone is significant on comparison with the results afforded by a standard compound like phenylbutazone at 33 mg./kg., via the oral route of administration.
PREPARATION A
To a well-stirred solution consisting of 17.89 g. (0.104 mole) 2-iodoethanol dissolved in 25 ml. of benzene, there is added in a dropwise manner a solution consisting of 8 ml. (0.104 mole) of methyl chloroformate in 25 ml. of benzene. The reaction mixture is then cooled to 0° C. with the aid of an ice/water bath, at which point a solution consisting of 8.3 ml. (0.104 mole) of pyridine dissolved in 25 ml. of benzene is slowly added thereto. The resulting reaction mixture is then stirred for one hour at 0° C. and for four hours at room temperature (˜20° C.) while under a nitrogen atmosphere. At the end of this time, 100 ml. of diethyl ether is added to the mixture and the precipitated pyridine hydriodide which forms is then removed from the system by means of suction filtration. The filtrate is then washed twice with 3N hydrochloric and once with brine, followed by drying over anhydrous sodium sulfate. After removal of the drying agent by means of filtration and the solvent by means of evaporation under reduced pressure, there is obtained 2-iodoethyl methyl carbonate as the residual material.
PREPARATION B
To a well-stirred solution consisting of 34.40 g. (0.20 mole) of 2-iodoethanol dissolved in 25 ml. of benzene precooled to 0° C. with the aid of an ice/water bath, there is added in a dropwise manner a solution consisting of 19.1 ml. (0.20 mole) of ethyl chloroformate dissolved in 25 ml. of benzene. Upon completion of this step, the reaction mixture is treated with 19.1 ml. (0.20 mole) of pyridine which is also added in a dropwise manner. The resulting suspension is then stirred for a period of one hour at 0° C. (while under a nitrogen atmosphere) and for six hours at room temperature (˜20° C.). At the end of this time, the pyridine hydriodide is removed by filtration and the organic filtrate is washed twice with 50 ml. of 3N hydrochloric acid and once with 50 ml. of brine, followed by drying over anhydrous magnesium sulfate. After removal of the drying agent by means of filtration and the solvent by means of evaporation under reduced pressure, there is obtained 2-iodoethyl ethyl carbonate as the residual material.
PREPARATION C
To a well-stirred solution consisting of 17.89 g. (0.104 mole) of 2-iodoethanol dissolved in 25 ml. of benzene precooled to 0° C. with the aid of an ice/water bath, there is added in a dropwise manner a solution consisting of 20 g. (0.104 mole) n-octyl chloroformate dissolved in 25 ml of benzene. Upon completion of this step, the reaction mixture is treated with 8.3 ml (0.104 ml.) of pyridine which is also added in a dropwise manner. The resulting suspension is then stirred for 30 minutes at 0° C. and thereafter for a period of five hours at room temperature while under a nitrogen atmosphere. At the end of this time, 100 ml. of diethyl ether is added to the mixture and the precipitated pyridine hydriodide is then removed by filtration. The organic filtrate is thereafter washed twice with 3N hydrochloric acid and once with brine, followed by drying over anhydrous magnesium sulfate. After removal of the drying agent by means of filtration and the solvent by means of evaporation under reduced pressure, there is obtained 2-iodoethyl n-octyl carbonate as the residual material.
EXAMPLE 1
A. In a 1000 ml. four-necked, round-bottomed reaction flask equipped with mechanical stirrer and reflux condenser, there was placed a well-stirred mixture consisting of 32.1 g. (0.096 mole) of 4-hydroxy-2-methyl-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide, 100 g. (0.58 mole) of 2-iodoethanol and 26.5 g. (0.192 mole) of anhydrous potassium carbonate in 600 ml. of acetone. The resulting reaction mixture was then refluxed for a period of approximately seven days, cooled to room temperature (˜20° C.) and filtered. The organic filtrate was subsequently concentrated in vacuo to remove the solvent, and the residual material was thereafter triturated with 400 ml. of ethyl acetate and then washed with 300 ml. of water. The yellow crystals (yield, 2.6 g.) which formed on the addition of water to the organics were subsequently collected by means of suction filtration and later added to the crystals (yield, 1.46 g.) which formed on allowing the residue to stand overnight (˜16 hours) at room temperature. The combined yield of N-[1-(2-hydroxyethyl)-2-pyridinium]-2-methyl-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide 4-enolate (m.p. 207°-208° C.) obtained in this manner amounted to 4.06 g. (crop A).
B. The remaining residue, obtained after removal of the crystals as described above, was then chromatographed on a column of silica gel (120 g.), using ethyl acetate as the eluant, and like fractions were subsequently crystallized from diethyl ether to give 8.8 g. of pure 4-(2-hydroxyethyloxy)-2-methyl-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide (m.p. 131°-134° C.) in the form of pale yellow crystals. An additional 1.4 g. of product was obtained from the mother liquor to bring the total yield to 10.2 g. (28%). The pure product was further characterized by means of nuclear magnetic resonance data, mass spectroscopy and high pressure liquid chromatography (HPLC), in addition to elemental analysis.
Anal. Calcd. for C 17 H 17 N 3 O 5 S: C,54.39; H,4.56; N,11.19. Found: C, 54.51; H,4.32; N, 11.08.
C. Later fractions, obtained during the above chromatographic step, gave 700 mg. of pure N-[1-(2-hydroxyethyl)-2-pyridinium]-2-methyl-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide 4-enolate (m.p. 218°-220° C.) in the form of yellow crystals (crop B). This material was combined with the crystalline product obtained before the chromatographic step (viz., 4.06 g. of crop A), so the combined yield of crop A and crop B amounted to 4.76 g. The latter material was then slurried with fresh hexane to ultimately afford 4.72 g. (15%) of pure N-[1-(2-hydroxyethyl)-2-pyridinium]-2-methyl-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide 4-enolate (m.p. 207°-208° C.). The pure product was further characterized by means of nuclear magnetic resonance data and high pressure liquid chromatography (HPLC). A sample for elemental analysis was prepared by recrystallizing the product from dimethylacetamide/methanol.
Anal. Calcd. for C 17 H 17 N 3 O 5 S, corrected for 1.63% inorganics: C,53.50; H,4.48; N,11.01. Found: C, 53.81; H, 4.44; N, 11.05.
EXAMPLE 2
The procedure described in Example 1 is repeated except that 2-iodoethyl methyl carbonate (the product of Preparation A) is the oxyethyl halide reagent of choice employed instead of 2-iodoethanol, using the same molar proportions as before. In this particular case, the corresponding final products obtained are 4-[2-(methoxycarbonyloxy)ethyloxy]-2-methyl-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide and N-{1-[2-(methoxycarbonyloxy)ethyl]-2-pyridinium}-2-methyl-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide 4-enolate, respectively.
EXAMPLE 3
The procedure described in Example 1 is repeated except that 2-iodoethyl ethyl carbonate (the product of Preparation B) is the oxyethyl halide reagent of choice employed instead of 2-iodoethanol, using the same molar proportions as before. In this particular case, the corresponding final products obtained are 4-[2-(ethoxycarbonyloxy)ethyloxy]-2-methyl-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide and N-{1-[2-(ethoxycarbonyloxy)ethyl]-2-pyridinium}-2-methyl-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide 4-enolate, respectively.
EXAMPLE 4
The procedure described in Example 1 is repeated except that 2-iodoethyl n-octyl carbonate (the product of Preparation C) is the oxyethyl halide reagent of choice employed instead of 2-iodoethanol, using the same molar proportions as before. In this particular case, the corresponding final products obtained are 2-methyl-4-[2-(n-octyloxycarbonyloxy)ethyloxy]-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide and N-{1-[2-(n-octyloxycarbonyloxy)ethyl]-2-pyridinium}-2-methyl-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide 4-enolate, respectively.
EXAMPLE 5
The procedure described in Example 1 was essentially followed except that 4-hydroxy-2-methyl-N-(6-methyl-2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide (prepared as described in U.S. Pat. No. 3,591,584) was the starting material employed in place of 4-hydroxy-2-methyl-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide, using the same molar proportions as before. In this particular case, the only corresponding final product actually isolated was 4-(2-hydroxyethyloxy)-2-methyl-N-(6-methyl-2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide (m.p. 180°-182° C.). The yield of pure product amounted to 75% of the theoretical value.
Anal. Calcd. for C 18 H 19 N 3 O 5 S: C,55.52; H,4.56; N,10.79. Found: C,55.31; H,4.82; N,10.68.
EXAMPLE 6
The following oxyethyl oxicam final products of Examples 1B, 1C and 5, respectively, were tested for anti-inflammatory activity in rats, using the standard rat foot edema test, according to the general procedure described by C. A. Winter et al., as first reported in the Proceedings of the Society for Experimental Biology and Medicine, Vol. 111, p. 544 (1962). The compounds were administered orally (by gavage) at 32 mg./kg. and the results obtained are reported below in terms of the percent (%) inhibition of edema formation afforded by each test compound as compared to the control (i.e., vehicle alone with no compound):
______________________________________ % InhibitionCompound at 32 mg./kg.______________________________________Product of Example 1B 48Product of Example 1C 16Product of Example 5 13______________________________________
EXAMPLE 7
4-(2-Hydroxyethyl)-2-methyl-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide, the final product of Example 1B, was tested for oral absorption potential according to the general procedure described by J. B. Dressman et al., as first reported in the Journal of Pharmaceutical Sciences, Vol. 74, No. 5, p. 588 (1985). The oral absorption potential test is used as a first approximation for predicting oral absorption of a given compound. It bears a strong relationship to the percentage of the drug absorbed. Values above 1.0 appear to correspond to virtually complete oral absorption, whereas values below this point indicate either a possible dose proportional absorption (e.g., 0-1.0) or poor oral absorption (e.g., <0).
In this connection, the prodrug final product of Example 1B and several commercial non-steroidal anti-inflammatory agents (NSAI) were first evaluated by high pressure liquid chromatography (RP-HPLC) to assign values for octanol-water partition coefficients and intrinsic water solubility. These values were then used to compute the oral absorption potential for each compound, either at a dose which was the molar equivalent to 20 mg. of piroxicam in the case of the prodrug or at the clinically-recommended (PDR) dose in the case of the commercial NSAI agents. The results obtained in this manner are summarized below in the following table, where the effect (water solubility and absorption potential) of the product of Example 1B is compared with that of other well-known anti-inflammatory agents, such as piroxicam, aspirin, indomethacin, ibuprofen and naproxen, respectively, at the various dose levels indicated:
______________________________________ Oral Water AbsorptionCompound Dose(mg.) Solub.(mg/ml) Potential______________________________________Prod. of Ex. 1B 22.7 470 1.81Piroxicam 20 26.5 1.11Aspirin 325 1963 0.74Indomethacin 25 0.7 0.65Ibuprofen 400 0.3 -0.86Naprofen 250 8.1 -0.06______________________________________
From the data presented in this table, it is clear that the product of Example 1B has the highest oral absorption potential seen in the series of compounds tested, including even piroxicam when tested at an equivalent dose level. Moreover, the product of Example 1B exhibits this effect even though tested at a dose level that ranges well below ten percent of the dose level values of some the other NSAI agents tested.
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A series of novel oxyethyl derivatives of certain selected enolic oxicam compounds are disclosed, including certain novel oxyethyl derivatives of 4-hydroxy-2-methyl-N-(2-pyridinyl)-2H-1,2-benzothiazine-3-carboxamide 1,1-dioxide (piroxicam). These particular compounds are useful in therapy as prodrug forms of the known anti-inflammatory and analgesic oxicams. Said oxyethyl derivatives of enoic oxicam compounds like piroxicam are of the formulae: ##STR1## wherein R 1 is hydrogen, methyl, fluorine or chlorine, and R 2 is hydrogen or --COOR 3 wherein R 3 is alkyl having from one to eight carbon atoms.
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FIELD OF THE INVENTION
This invention relates generally to positioning of apparatus such as subsea well heads at a suitable level below the surface of a sea bed for the purpose of protecting the apparatus from marine danger that would otherwise be prevalent in locations above the sea bed. More particularly, the present invention relates to a method and apparatus for installing marine silos to a desired depth into the seabed in such manner as to minize installation costs and provide for a significant number of installations in a relatively short period.
BACKGROUND OF THE INVENTION
The present invention, for the purpose of simplicity, will be discussed herein particularly in relation to installation of subsea silos intended to enable positioning of subsea well heads at a desired level below the seabed surface or mud line to thereby protect the well head from damage. It is not intended however to limit the present invention solely to subsea silos for well head installation, it being obvious that the present invention is functional in any environment where a protective subsea enclosure may be desired for apparatus of any suitable character. The spirit and scope of the present invention therefore extends to installation of particular enclosures other then subsea well head silos and to methods for installation of the same within the spirit and scope hereof.
It has now become a wide spread practice to drill oil producing wells in shallow offshore sea areas. In sea areas where ice bergs are present, danger to subsea equipment is obvious. Aside from the possibilty of showing the seabed during ice berg movement, they also tumble from time to time as the surface portion melts and the center of gravity changes. During such tumbling ice portions can contact the seabed, developing deep scouring. In the Beaufort Sea for example the water is shallow and there is a serious hazard in the form of floating ice which tends to accumulate. This floating ice may develop into ice ridges which not only accumulate above the water but also develop a substantial submerged section referred to as an ice keel.
The ice ridges and ice keels tend to drift responsive to wind and current and as they are driven relative to shallow areas, they may scour the sea floor. Thus, it has become necessary for all companys operating in the Beaufort Sea where sheet ice is present to provide means for protecting the subsea well head equipment including blowout preventors (BOP), well heads, etc. from the risk of ice damage by the scouring effect of moving ice ridges and ice keels. It has been found desirable therefore to locate subsea well heads and BOP stacks beneath the point of the seafloor of known ice ridge scour. In the past the required depth of well head location was achieved by dredging a large area of the seabed to a depth below known iceberg or ice keel scouring (known as a "glory hole") and setting the well head and BOP stack in this depression on the seabed.
The above method is extremely costly and requires the dredging of large quantities of material with a seagoing dredger of high capacity, or operating the dredge head airlift of a dredging ship. A large "clam shell" dredge may also be employed to dig glory holes, but represent considerable expense. An example of a prior system is described in Canadian Pat. No. 995,583 issued Aug. 24, 1976. That system includes a caisson embedded in the seafloor by methods such as driving, jetting or a combination of the two. The upper region of this caisson includes a plurality of horizontally connected circular segments joined by breakaway joints. In this manner, when an upper portion of the caisson is contacted by an icemass, the entire casing is not damaged or deformed, but only a particular segment may be broken away. With regard to generally related methods and apparatus U.S. Pat. Nos. 4,318,641 and 4,432,671 teach hydrostatic sinking of anchors in waterbottoms.
SUMMARY OF THE INVENTION
It is the principle object of the present invention to provide an improved and less expensive system for sinking a silo or caisson in the seabed and excavating seabed material from within the silo to form a protective chamber extending from the seabed to a level safely below the seabed within which may be located a subsea well head or other marine apparatus. It is also a feature of this invention to provide the novel method and apparatus for transporting a silo to its installation site, lowering the silo to a seabed and sinking the silo into the seabed to a designed depth. The invention also includes maintenance of the silo at a vertical position during its installation.
Briefly, the invention concerns the provision of a buoyancy controlled silo installation template which establishes a secure restraining relationship with a silo and maintains that restraining relationship during towing of the template and silo to the intended installation site. An excuation module is disposed within the silo during movement of the apparatus to its intended site. Through adjustment of its buoyancy control, the template is submerged and lowered to the seabed where it establishes firm contact with the seabed for stabilization of the silo. The template is leveled on the seabed by adjusting its supporting legs. Through manipulation of the silo restraining apparatus of the template, the silo, with the excavation module inside, is lowered relative to the template until its lower extremity contacts the seabed and by virtue of its weight, penetrates the seabed to the extent permitted by seabed composition.
The submergable excavation module rests upon a thrust ring which is provided within the silo. The buoyancy system of the excavation module determines the effective weight which is applied by the excavating module to the silo. The excavation module incorporates a buoyance system, which, together with its position adjustment relative to the template, provides for stability control of the template; silo/excavation module both at the sea surface and during descent to the seabed. This buoyaness system also may be employed to develop an upward force on the silo to retard downward silo movement such as in unconsolidated soil. The excavation module includes suitable apparatus such as a cutter suction dredge head system or a water jet array system for loosening seabed material at the bottom of the silo. The loosened seabed material is then transported from the silo, thus permitting the silo and the excavating module to decend into the seabed by virtue of the hole created by the dredging activity. Simultaneously, the template permits controlled downward movement of the silo relative thereto while at the same time maintaining vertical alignment of the silo until installation of the silo to its desired depth has been completed. The excavation module is then withdrawn from the silo and raised to the surface through activation of its buoyancy control. It may be stationed at the surface or it may be loaded onto a service vessel for transportation to shore or to another silo installation site. The submergable template is then disconnected from the silo and, through its buoyancy control, is raised to the surface for transportation to shore or to another silo installation site. While at the surface or while submerged, the template may receive another silo in assembly therewith, the silo being transferred from a service vessel to a restrained relationship with the submergable template.
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, more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings, which drawings form a part of this specification.
It is to be noted however, that the appended drawings illustrate only typical embodiments of is invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
IN THE DRAWINGS
The present invention both as to its organization and manner of operation, together with further objects and advantages thereof, may best be understood by way of illustration and example of certain embodiments when taken into junction with the accompanying drawings in which:
FIG. 1 is an isometric view illustrating the operative assembly of a subsea silo to be installed in the seabed and a submergible silo installation template for installation of the site together with an excavation module in assembly within the silo.
FIG. 2 is a plan view illustrating a submergable silo supporting template and subsea silo and excavation module which are constructed in accordance with the present invention.
FIG. 3 is an elevational view of the submergable template of FIG. 1 also illustrating a silo and excavation modules in supported assembly therewith.
FIG. 4 is a sectional view of a subsea silo, showing an excavation module of this invention positioned therein with a cutter suction dredge head thereof positioned for excavating contact with material of the seabed.
FIG. 5 is a partial sectional view of a subsea silo with an excavation module shown therein with its cutter suction dredge head system in contact with the material of the seabed.
FIG. 6 is a partial sectional view of a subsea silo representing a modified embodiment of this invention and showing an alternative excavation module positioned operatively therein.
FIG. 7 is also a partial sectional view of a subsea silo representing another embodiment of this invention and showing another type of jet excavation module in operative assembly therein.
FIG. 8 is a pictorial representation of a submergable template shown stationed at the surface with a silo in raised and restrained assembly therewith and further showing the launching and shallow water towing relation of the template silo and excavation module assembly at the surface.
FIG. 9 is a pictorial elevational view similar to that of FIG. 7, illustrating the silo and excavation module being lowered relative to the template for stability during towing in deep water.
FIG. 10 is another pictorial representation showing the template silo and excavation module being controlled by surface vessels and being lowered toward the seabed.
FIG. 11 is a pictorial representation of the template in contact with the seabed and with the lower extremity of the silo at the level of the seabed in readiness for silo installation by the excavation module and template.
FIG. 12 is a sequential pictorial representation showing lowering of the silo relative to the template during excavation by an excavation module located within the silo together with selective weight control and hydrostatically induced drive.
FIG. 13 is a pictorial representation showing the silo of FIG. 12 at its fully inserted position in the seabed.
FIG. 14 is a pictorial representation illustrating removal of the excavation module from the inserted silo following completion of silo installation.
FIG. 15 is a pictorial representation illustrating raising of the submergable template to the surface after installation of the silo has been completed and the excavation modules has been recovered.
FIG. 16 is an illustration showing insertion of an excavation module into a partically inserted silo such as would occur if the excavation module should require repair during silo installation.
FIG. 17 is a view showing the excavation module floating at the surface and buoyed for recovery.
FIG. 18 is a view illustrating loading of the excavating module onto a surface vessel for shipping to port or to another silo installation site or for the purpose of repair.
FIG. 19 is a pictorial representation illustrating an excavating module completely loaded on a surface vessel for transportation or for repair.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Refering now to the drawings and first to FIGS. 1, 2 and 3 a submergable template is illustrated generally at 10 which comprises a structural framework 12 having buoyancy tanks 14 mounted thereon for controlling the buoyancy of the template and a silo in restrained assembly therewith. FIGS. 1-3 show a silo at 16 which is secured by holdback gear 18 including plural drive and holdback units which establish restraining and driving engagement with external gear tracks 19 of the silo 16. The drive and holdback gear is capable of raising and lowering the silo relative to the template such as for maintaining stability of the template and silo during transportation and for lowering the silo during its installation into the seabed. The template is also provided with a plurality of vertical alignment rams 20 having position adjusting engagement with the silo and which are appropriately operative to maintain vertical alignment of the silo during its insertion into the seabed. The template 10 also includes a plurality of seabed engaging elements 22 which establish firm contact with the seabed. The seabed engaging elements, also refered to as spud cans, enter the seabed material sufficiently to maintain stability and orientation of the template at the seabed. Each of the seabed engaging elements is mounted at the lower end of a vertical support element 24 which is operatively received by a position adjustment mechanism 26. The position adjustment mechanism is hydraulically energized or may be energized by any suitable mechanism capable of adjusting the position of the template/silo/excavation module assembly at the seabed. Thus, by operating the adjustment mechanism 26, the seabed contacting elements 22 may be adjusted relative to the template so as to provide for coarse position adjustment of the template and silo. Fine adjustment of the vertical condition of the silo is then accomplished by means of the vertical alignment rams 20.
The silo 16 is generally in the form of an elongated tubular element having a cutting shoe 28 at its lower extremity defining a circular cutting edge 30. As the silo is lowered relative to the seabed the cutting edge 30 slices through the seabed material until the resistence of the material provides support for the silo. As the seabed material is removed from within the silo the cutting edge 30 continues to descend until such time as the upper portion of the silo is properly located with respect to the mud line established by the seabed. Descent of the silo into the seabed formation is controlled by the template and by an excavation module in the manner described below.
With reference now to FIG. 4 the silo structure 16 is illustrated in greater detail. Within the cutting shoe of the silo is located a thrust ring 32 defining a circular, upwardly facing support shoulder 34.
A drilling or excavation module is provided as shown generally at 36 which is in the form of a elongated, compartmented structure defined by a body 38 having a buoyancy chamber 40 secured at the upper portion thereof. Below the buoyancy chamber is provided a transverse bulkhead 42 cooperating with another transverse bulkhead 44 so as to define a machinery compartment 46 within which is located various power equipment for energizing the excavating module and for controlling the buoyancy chamber. At the lower portion of the housing 38 is provided another transverse bulkhead 48 which is of domed configuration and provides structural support for a slew ring 50 having a dredge arm 52 and cutting head 54 rotatably supportive thereby. Positioning of the dredging arm 52 is controlled by a dredge actuator 56 which may be hydraulically energized.
The lower portion of the excavation module defines a support rim 58 which is adapted to seat against the shoulder 34 of the thrust ring 32. At the lower portion of the excavating module the domed transverse bulk head 48 also provides structural support for a pump 60 which is energized by a suitable motor 62. The pump 60 has its suction line 64 extending through the dredge arm 52 to the vacinity of the cutting head 54 so that dredge cutting may be pumped along with water from the vacinity of the cutting head. The cutting head is rotably driven by a motor 65 which may be energized hydraulically or by any other suitable source. A discharge line 66 from the pump 60 extends upwardly to a level above the upper extremity 68 of the silo to a gravel discharge 68. Dredge cuttings, gravel, silt and like are pumped upwardly through the discharge line 66 and are discharged into the surrounding seawater above the level of the silo. For introduction of seawater into the cutting area below the transverse bulkhead 48, a water supply line 72 is provided which extends through the transverse bulkheads 42, 44 and 48 and terminates within the excavation compartment 78 below the transverse bulkhead 48. The upper extremity of the supply line 72 defines a water intake 74 which is so located relative to the discharge 68 that water, free of drill cuttings and other contaminates flow into the excavation compartment replacing contaminated water pumped therefrom.
The excavating module establishes an efficient seal at its supported relationship against the upwardly facing circular shoulder 34 of the thrust ring 32. In the event additional downwardly force is desired to enhance penetration of the cutting edge of the cutting shoe into the seabed formation hydrostatically induced force may be utilized to enhance the forces attributed by the weight of the silo and the weight of the excavation module. Further, the excavation module with its buoyancy system may be controlled to develop an upward force on the silo to retard downward silo movement such is in unconsolidated soil. By controlling introduction of water through water supply line 72 into the excavation chamber below the transverse bulkhead 48 a reduced pressure condition may be developed within the excavation chamber by virtue of pump operation. By controlling water supply in supply line 72 by means of a control valve 80 a differential pressure condition may be developed causing a hydrostatic pressure differential to exist, thereby developing a downwardly directed resultant force on the excavation module, which force is transmitted through the thrust ring to the lower portion of the silo. Thus by simply varying the water supply to the excavation chamber concurrently with activation of the discharge pump, the pressure would then be reduced in the excavation chamber and the pressure differential acting upon the excavating module and silo may be adjusted to provide the magnitude of downwardly directed force that is required for efficient silo installation. Further, through variation of the buoyancy of the buoyancy chamber the effective downwardly directed force of the excavation module may be varied. The hydrostatically induced downwardly directed force may therefore be controlled in its magnitude or it may be varied in cyclical manner to influence penetration of the silo into the seabed. The silo installation may be maintained at zero buoyancy or may be positively or negatively buoyed as appropriate for efficient silo insertion domed bulkhead 48 also provides support for a pump 60 which is driven by motor 62. A pump suction line 64 of the pump 60 is communicated through the dredge arm 52 with the cutting head portion 54. Thus, the pump 60 is capable of removing water, and loosened seabed material from the immediate vacinity of the suction cutting head 54. A discharge line 66 extends upwardly from the pump 60 and terminates at a gravel pump discharge 68 disposed above the upper extremity 70 of the silo. The excavation module also includes a water supply line 72 having a water intake 74 at its upper extremity. The lower end 76 of the water supply line is disposed below the level of the domed transverse bulkhead 48, thus allowing incoming water to flow into the excavation chamber 78 formed cooperatively by the silo and the transverse bulkhead 48. The water supply line 72 may also be provided with a control valve 80 which may be adjusted to control inlet of water into the excavation chamber 78. With the dredged suction pump 60 operating to develop normal suction pressure, the valve 80 may be closed or partially closed as desired to control the magnitude of hydrostatically induced force acting downwardly upon the silo structure. The peripheral portion of the domed bulkhead 48 forms a seal with the upwardly facing shoulder 34 of the thrust ring. By lowering water pressure in the chamber 78 below the bulkhead 48 a pressure differential will exist across the domed bulkhead. Thus, pressure differential determined by the hydrostatic pressure acting upon the upper surface of the bulkhead and the pressure within the chamber 78 will determine the magnitude of the hydrostatically induced force acting downwardly upon the silo. By effectively controlling the valve 80 or by controlling suction of the pump 60 the hydrostatically induced downward drive may be varied between zero and the maximum hydrostatic drive available at water depth. For example with a silo of 20 meters in height and a diameter of 5 meters and with a water depth of 100 meters the maximum hydrostatic drive will be in the order of 1250 tons. Obviously, with water of different depths, the maximum hydrostatic drive will be of different magnitude. It will also be determined that soil condition influence hydrostatic drive. With loose soil conditions, such is typically formed as at or near the surface of the seabed, the available hydrostatic drive will be less than with more compact soil conditions several feet below the surface of the seabed. Also, as the silo and excavation module desend, available hydrostatic force will increase due to increasing water depth above the level of the domed bulkhead 48.
As indicated in FIG. 1 the silo structure will be provided with a plurality, preferably three of elongated ladder, rask or gear like members 19 enabling a like number of holdback units 18 of the template to engage and provide restraing support for the silo. The holdback units 18 are capable of providing a supporting or restraining function as desired to support the silo in substantially immobile relation with respect to the template and also provide a driving function to raise or lower the silo relative to the template, such as for stability of the template and silo assembly at the surface and for controlling insertion of the silo into the seabed.
FIG. 5 of the drawings discloses a cutter suction dredge head system in combination with an excavation module the structure being similar to that disclosed in FIG. 4. The slew ring 50 may be rotated by a hydraulic motor 82 and the motor 62 driving the dredge pump 60 may also be a hydraulic motor if desired. The dredge head actuator 56 may be hydraulically energized for imparting controlling movement to the cutter suction dredge head as it is rotated by the slew ring causing the cutter element 54 thereof to sweep all of the surface area of the seabed located within the confines of the cutting shoe 28. During sweeping of the cutter head 54 the cutter head will be rotated against the seabed soil thereby loosening the soil. This loosened soil, combined with water, will be removed from the silo by the suction line 64 of the pump 60 and will be ejected from the silo via the discharge line 66 of the pump. For rotation of the cutter portion of the dredge head the hydraulic motor 82 is energized, thereby driving a gear system incorporating drive and driven gears 84 and 86 to achieve rotation of the slew ring 50. Thus, by virtue of the rotating slew ring and the pivotal articulating movement of the dredge head the seabed material exposed within the silo will be effectively loosened and removed.
Refering now to FIG. 6 it is evident that the excavation module may be provided with a water jet array system wherein soil loosening and removal may be accomplished by jetting activity without the use of a rotary dredge head. Further, ejection of seabed material from the excavation chamber near the cutting shoe of the silo is achieved at the lower extremity of the silo rather then at the upper extremity as discussed above in connection with FIGS. 1-5. The silo 16 includes a cutting shoe 88 having a lower cutting edge 90 which enables the silo to slice through the formation as it extends into the seabed. The cutting shoe 88 defines an internal thrust ring 92 which provides for seating of the lower sealing and seating peripheral portion 94 of an excavation module 96. The excavation module includes transverse bulkheads 98 and 100 with bulkhead 98 providing support for a pair of jet pumps 102 and 104. The discharge line 106 of pump 102 extends through bulkheads 98 and 100 and terminates within the excavation chamber 108. The discharge line 110 of pump 104 is in communication with a jet head 112 having disposed thereon a plurality of water jets 114 which are oriented to cause loosening of the seabed material. The head 112 is rotatably mounted on a support plate and bearing system 116 and is rotated by means of a rotary drive mechanism 118 energized by a hydraulic drive motor 120. Thus, the water jet head 112 is rotatable within the excavation chamber 108, causing revolving of the jet members 114 to cause loosening of the formation by water jetting activity. Outflow of water and loosened soil from the excavation chamber 108 occurs by virtue of a plurality of outlet openings 122 formed in the cutting shoe 88. These outlet openings define upwardly directed passages which direct the outflow from the chamber 108 upwardly along the outer wall surface of the silo 16. Thus, loosened soil from the excavation chamber is carried along with the outflow of water upwardly to the surface of the seabed where it spreads outwardly or is carried away from the site by water current. The water outflow also maintains the silo substantially clear of soil which might otherwise retard downward movement of the silo into the seabed. It should be noted that the embodiment of FIG. 6 is not capable of employing hydrostatic drive to enhance silo insertion.
Refering now to FIG. 7, another embodiment of the present invention is disclosed wherein a silo 16 is provided having a cutting shoe 124 defining a lower cutting edge 126 and an inwardly directed thrust ring 128. An excavation module 130 is provided having a lower support ring 132 establishing force transmitting sealed relationship with respect to the thrust ring of the silo. The excavation module 130 defines transverse bulkheads 134 and 136 defining a machinery compartment 138. A jet pump 140 is provided which is supported by bulkhead 134 and is positioned with its discharge line 142 in communication with a rotary jet nozzle array 144 having plural jets 146 for loosening and dispersing seabed material in the excavation chamber 148. The jet nozzle array is supported by a bearing plate 150 which is rotatably mounted on bulkhead 136. The jet nozzle array is rotatably driven by a rotary drive mechanism 152 powered by a hydraulic drive motor 154.
For discharge of water and soil from the excavation chamber 148 a dredge pump is provided as shown at 156 which is energized by a hydraulic motor 158. The discharge 160 of pump 156 is in communication with a soil ejection pipe 162 which functions to transport soil and water upwardly to a level above the upper extremity of the silo for discharge into the surrounding water in the manner shown in FIG. 4.
Downwardly directed hydrostatic drive may be achieved in the systems shown in FIGS. 5 and 7 such as by varying the pumping velocity or controllably varying the supply of water into the excavation chamber. In each case, the excavation module forms a seal with the thrust ring portion of the cutting shoe. By varying inflow and outflow of water from the excavation chamber of the embodiments shown in FIGS. 5 and 7 and controlling pressure differential across the sealed bulkhead, this pressure differential may be efficiently controlled to develop a downwardly directed hydrostatic pressure induced force varying from zero to many tons. Moreover, the hydrostatically directed force may be induced cyclically in order to assist in downward movement of the silo into the soil depending upon the soil conditions encountered or silo insertion movement may be retarded by the buoyancy control of the excavation module.
Refering now to FIG. 8 the template system 10 is shown in its floating condition with buoyancy being provided by the flotation tanks 14. The silo 16 is shown in its raised position such as during launching or for towing in shallow water conditions. The template and silo assembly may be towed such as by a towing vessel 170 to a suitable location for a silo installation. It should be born in mind that the system is fairly unstable in the condition of FIG. 8.
As shown in FIG. 9 the silo installation system is shown with the silo 16 and its excavation module lowered relative to the template 10 such as for stability while being towed in deep water conditions or water conditions involving heavy seas. Refering to FIG. 10, the template 10 is shown tethered by service vessels 172 and 174 while the buoyancy of the template/silo/excavation module system is reduced by appropriate control of the flotation tanks 14. With the silo 16 in its raised position relative to the template, the system is lowered into contact with the sea floor as shown in FIG. 11. The spud cans 22 become partially embedded into the sea floor to establish appropriate stabilized support for the silo and template. Coarse vertical alignment or leveling of the template is then achieved by controllably adjusting the spud cans relative to the template so as to achieve nearly vertical positioning of the silo 16. At this point silo installation can begin through controlled energization and buoyancy control of the template and excavation module.
In FIG. 12, which is a sequential illustration during silo insertion, the silo installation template is shown with the silo 16 partially inserted into the seabed. Both the template and the excavation module are provided with appropriate control umbilicles 176 and 178 permitting adjustment or leveling of the template relative to the seabed and permitting adjustment the silo relative to the template so as to render it vertical. The control umbilicles 176 and 178 of the template and excavation module permits their control from a surface vessel. As shown in FIG. 12 the silo 16 has penetrated the seabed formation substantially half its length being maintained vertically by means of the position adjustment rams of the template. As shown in FIG. 13 the silo 16 is fully installed into the seabed formation and the excavation module is ready for removal from the silo.
In the sequential view of FIG. 14 the silo installation template 10 is shown grounded to the seabed with the silo 16 being fully inserted into the seabed formation. The excavation module 36 is shown after extraction from the silo and during its ascent to the surface by control of its flotation vessel 40. It is raised and lowered by controlling the buoyancy thereof. The installation cables merely serve as guides to insure its positioning relative to the silo and its controlled guidance to the surface after extration from the silo. After the excavation module has been recovered, the template 10 is ready for its ascent to the surface. With its flotation tanks appropriately adjusted, the assend to the surface where it floats until further activities are desired. Another silo may be transferred from a surface vessel and brought into assembly with the template, thus restoring it to the condition as shown in FIG. 8 or FIG. 9 except for the presence of the excavation modules. As an alternative, mating of the silo and excavation modules to the template may be accomplished underwater if desired. It is envisioned that a silo may be installed in one days time with actual injection of the silo into the seafloor being accomplished in only a few hours time. The expense of installation is significantly reduced in comparision with "glory hole" location of well heads relative to the mud line at the seabed.
Referring to FIG. 16 the template is shown grounded to the seabed with the silo partially inserted. In the event repair of the excavation module 36 is required it may be withdrawn from the silo and recovered such as through a guidance of service vessels 172 and 174 and guide cables 173 and 175. The module 36 is caused to ascend to the surface by its buoyancy control system and, after repair is caused to descend to silo level by its buoyancy control, being guided into the silo by the guide cables.
FIGS. 17, 18 and 19 illustrate recovery of the excavation module 36 such as for repair or transport. As shown in FIG. 17 the excavation module is buoyed at the surface of the sea in readiness for its further activities. It may be towed to a nearby site or, if the site is at a significantly remote location or it is intended that the excavation module be transported to port, it may be loaded in the manner shown in FIG. 18 onto a service vessel in the manner shown in FIG. 19.
We have provided a novel method and apparatus for installation of subsea silos which permits rapid, low cost installation of protective chambers for equipment intended for location near the mudline of the ocean floor. Through the use of silos, expensive equipment such as wellheads may be safely located out of danger such as by collision by various marine objects or ice which might otherwise cause severe damage thereto. This invention is therefore well adapted to attain all of the objects and features set forth hereinabove together with other objects and features that are inherent in the description of the silo installation apparatus itself. It will be understood that certain combinations and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is in the scope of the present invention.
As many possible embodiments may be made at this invention without departing from the spirit or scope thereof, it is to be understood that all matters hereinabove set forth or shown in the accompanying drawings are to be interperted as illustrative and not in any limiting sense.
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A method and apparatus for installing marine silos to a desired depth into the seabed such that the interior of the silos is void of seabed material to a desired depth. A submergable silo positioning template operatively supports a silo and excavation modules during surface transportation to the intended site and is capable while floating and submerged of raising and lowering the silo relative to the template and maintaining vertical alignment of the silo. The submergable excavating module incorporates apparatus for loosening and removing sea bed material within the silo thus permitting the silo and excavating module to descend to a desired depth in the seabed. The template and the excavating module are separated from the silo after silo installation and are reused for other silo installations. During silo installation the influence of hydrostatically stimulated force may be employed to assist forcible insertion of the silo into the soil of the seabed.
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CROSS REFERENCE TO RELATED APPLICATIONS
This Application claims priority of Taiwan Patent Application No. 103124494, filed on Jul. 17, 2014, the entirety of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a liquid-crystal display, and in particular to a liquid-crystal display having at least one contact hole.
2. Description of the Related Art
In a liquid-crystal display, a contact hole is utilized to conduct a pixel electrode and a source electrode. However, with reference to FIG. 1 , the liquid-crystal molecules 2 are arranged along a profile of the contact hole 1 . The contact hole 1 is like a funnel structure, and light leakage happens due to the liquid-crystal molecules 2 arranged along the profile of the contact hole 1 , and the contrast of the liquid-crystal display is decreased.
With reference to FIG. 1 , conventionally, an area of the source electrode 3 at the bottom the contact hole 1 is increased to cover the light-leaking liquid-crystal molecules 2 , and to improve the contrast of the liquid-crystal display. However, this method decreases the aperture ratio and the illumination of the liquid-crystal display, and an improved solution is required.
BRIEF SUMMARY OF THE INVENTION
In one embodiment of the invention, an element substrate is provided, which includes a substrate, a metal layer and a planarization layer. The metal layer is disposed on the substrate, wherein the metal layer has a first width along a first direction. The planarization layer is located on the metal layer, wherein the planarization layer comprises a contact hole, the contact hole has a contiguous wall and a bottom, the bottom exposes the metal layer, and the bottom of the contact hole has a second width along the first direction, wherein the first width and the second width satisfy the following equation:
2
⋆
{
L
2
2
+
(
1
-
p
)
h
ln
(
p
)
·
tan
(
1.5
θ
)
·
ln
[
-
0.176
⋆
(
1
-
p
)
ln
(
p
)
·
tan
(
1.5
θ
)
]
}
-
1.8
≤
L
1
≤
2
⋆
{
L
2
2
+
(
1
-
p
)
h
ln
(
p
)
·
tan
(
1.5
θ
)
·
ln
[
-
0.176
⋆
(
1
-
p
)
ln
(
p
)
·
tan
(
1.5
θ
)
]
}
+
1.8
wherein L 1 is the first width along the first direction, and L 2 is the second width along the first direction, h is a thickness of the planarization layer, and θ is an included angle between a straight line and a extension surface of the bottom, and the straight line connects a reference point and a base point, and the reference point and the base point are located on the contiguous wall, wherein the vertical distance from the reference point to the substrate is 0.95 h. The base point is located at the point where the contiguous wall is connected to the bottom, p is an adjustable parameter, and (1−p)h is the height of the reference point in a vertical direction, and 0<p≦0.1.
Utilizing the embodiment of the invention, the aperture ratio and the light transmittance (the contrast in dark state) of the liquid-crystal display are optimized, and the light leakage and the low-contrast problem are prevented.
A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
FIG. 1 shows an element substrate of a conventional liquid-crystal display;
FIG. 2 shows an element substrate of an embodiment of the invention;
FIG. 3A shows the element substrate of the embodiment of the invention utilized in a liquid-crystal display;
FIG. 3B shows the structure of portion 3 B of FIG. 3A in detail;
FIG. 4 shows an element substrate of a modified embodiment of the invention;
FIG. 5 shows a liquid-crystal display of an embodiment of the invention; and
FIG. 6 shows the designed width and the actual width of the metal layer.
DETAILED DESCRIPTION OF THE INVENTION
The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
FIG. 2 shows an element substrate 100 of an embodiment of the invention, which comprises a substrate 110 , a metal layer 120 and a planarization layer 130 . The metal layer 120 is disposed on the substrate 110 , wherein the metal layer 120 has a first width L 1 along a first direction X. The planarization layer 130 is located on the metal layer 120 , wherein the planarization layer 130 comprises a contact hole 131 , the contact hole 131 has a contiguous wall 132 and a bottom 133 , the bottom 133 exposes the metal layer 120 , and the bottom 133 of the contact hole 131 has a second width L 2 along the first direction X.
The applicant has discovered that the liquid-crystal molecules are arranged along the contiguous wall 132 , and the light transmittance (the contrast in dark state) is changed with the slope of the contiguous wall 132 . At the location where the tangent slope of the contiguous wall 132 is about tan 10°, light leakage is acceptable, and the contrast of the liquid-crystal display is qualified. When the edge of the metal layer 120 extends to the critical point 136 (where the tangent slope of the contiguous wall 132 is about tan 10°), the aperture ratio and the light transmittance (the contrast in dark state) are optimized.
With reference to FIG. 2 , the applicant has discovered from deriving curve equations that when the first width and the second width satisfy the following equation, the aperture ratio and the light transmittance (the contrast in dark state) are optimized:
2
⋆
{
L
2
2
+
0.95
h
ln
(
0.05
)
·
tan
(
1.5
θ
)
·
ln
[
-
0.1672
ln
(
0.05
)
·
tan
(
1.5
θ
)
]
}
-
1.8
≤
L
1
≤
2
⋆
{
L
2
2
+
0.95
h
ln
(
0.05
)
·
tan
(
1.5
θ
)
·
ln
[
-
0.1672
ln
(
0.05
)
·
tan
(
1.5
θ
)
]
}
+
1.8
wherein L 1 is the first width of the metal layer 120 along the first direction X, and L 2 is the second width of the bottom 133 of the contact hole 131 along the first direction X, h is the thickness of the planarization layer 130 , θ is an included angle between a straight line L and a extension surface of the bottom 133 . The straight line L connects a reference point 134 and a base point 135 , the reference point 134 and the base point 135 are located on the contiguous wall 132 , wherein the vertical distance from the reference point 134 to the substrate is 0.95 h. The base point 135 is located at the point where the contiguous wall 132 is connected to the bottom 133 , and ±1.8 is the tolerance. By modifying the parameters above, the curvature and the shape of the contiguous wall 132 can be modified.
With reference to FIG. 2 , the derivative of the curve equation is presented in the following description.
First, curve fitting (assuming), assuming a curve equation of the contiguous wall of the contact hole is:
y=f ( x )=− A ′exp(− x ) (1)
In equation (1), only asymptotes of the contiguous wall are defined, and the equation (1) must be regulated relative to X axis and Y axis.
Next, the curve fitting (relative to reference point 134 , base point 135 and included angle θ), assuming that a distance between the reference point 134 and the top of the planarization layer 130 is p times of the thickness h of the planarization layer 130 , and satisfies equation f(R′), and the horizontal distance between the reference point 134 and the base point 135 is R′, then:
f
(
R
′
)
=
-
ph
=
-
h
exp
(
-
R
′
α
)
⇒
α
=
-
R
′
ln
(
p
)
;
(
1
)
p
>
0
,
h
>
0
,
R
′
>
0
(
2
)
Correction parameter α is achieved.
Next, a straight line L connects the reference point 134 and the base point 135 , and an included angle between a straight line and the horizontal line is θ, then:
tan
θ
=
(
1
-
p
)
h
R
′
⇒
R
′
=
(
1
-
p
)
h
tan
θ
(
3
)
Material property θ is brought in.
Next, the vertical distance between the reference point and the substrate is 0.95 h. By combining equations of equation (2) and equation (3), we get:
α
=
-
R
′
ln
(
0.05
)
=
-
0.95
h
ln
(
0.05
)
·
tan
θ
(
4
)
Correction parameter α is achieved.
Next, the included angle β between a cut line L′ at base point 135 and the horizontal line defines the angle of the curve of the planarization layer 130 , and included angle β substantially equals 1.5θ. Therefore, by revising the curve equation (angle revising) further, we get:
f
(
R
′
)
=
-
h
·
exp
{
-
R
′
/
α
}
=
-
h
·
exp
{
R
′
·
ln
(
0.05
)
·
tan
β
0.95
h
}
=
-
h
·
exp
{
R
′
·
ln
(
0.05
)
·
tan
(
1.5
θ
)
0.95
h
}
(
5
)
Curve equation of the contact hole is achieved.
Next, R=R 0 +R′, by bringing this equation into the above equation, we get:
∵
R
′
=
R
-
R
0
…
(
shiftting
)
⇒
f
(
R
′
)
=
-
h
·
exp
{
-
(
R
-
R
0
)
/
α
}
=
-
h
·
exp
{
(
R
-
R
0
)
·
ln
(
0.05
)
·
tan
(
1.5
θ
)
0.95
h
}
(
6
)
Actual curve equation of the contact hole is achieved.
Next, as mentioned above, at the location where the tangent slope of the contiguous wall 132 is about tan 10°, the light leakage is acceptable, and the contrast of the liquid-crystal display is qualified. When the edge of the metal layer 120 extends to the critical point 136 (where the tangent slope of the contiguous wall 132 is about tan 10°), and the aperture ratio and the light transmittance (dark state contrast) are optimized. The equation of half of the second width of the metal layer along the first direction is:
∂
f
(
R
′
)
∂
R
′
=
tan
10
°
=
0.176
=
∂
∂
R
′
{
-
h
·
exp
[
R
′
·
ln
(
0.05
)
·
tan
(
1.5
θ
)
0.95
h
]
}
⇒
-
h
·
exp
[
R
′
·
ln
(
0.05
)
·
tan
(
1.5
θ
)
0.95
h
]
·
∂
∂
R
′
[
R
′
·
ln
(
0.05
)
·
tan
(
1.5
θ
)
0.95
h
]
=
0.176
⇒
exp
[
R
′
·
ln
(
0.05
)
·
tan
(
1.5
θ
)
0.95
h
]
=
-
0.176
·
0.95
ln
(
0.05
)
·
tan
(
1.5
θ
)
⇒
R
′
·
ln
(
0.05
)
·
tan
(
1.5
θ
)
0.95
h
=
ln
[
-
0.1672
ln
(
0.05
)
·
tan
(
1.5
θ
)
]
⇒
R
′
=
0.95
h
ln
(
0.05
)
·
tan
(
1.5
θ
)
·
ln
[
-
0.1672
ln
(
0.05
)
·
tan
(
1.5
θ
)
]
⇒
R
=
R
0
+
0.95
h
ln
(
0.05
)
·
tan
(
1.5
θ
)
·
ln
[
-
0.1672
ln
(
0.05
)
·
tan
(
1.5
θ
)
]
(
7
)
Considering that ±1.8 is acceptable manufacturing tolerance, when the first width and the second width satisfy the following equation, the aperture ratio and the light transmittance (dark state contrast) are optimized:
2
⋆
{
L
2
2
+
0.95
h
ln
(
0.05
)
·
tan
(
1.5
θ
)
·
ln
[
-
0.1672
ln
(
0.05
)
·
tan
(
1.5
θ
)
]
}
-
1.8
≤
L
1
≤
2
⋆
{
L
2
2
+
0.95
h
ln
(
0.05
)
·
tan
(
1.5
θ
)
·
ln
[
-
0.1672
ln
(
0.05
)
·
tan
(
1.5
θ
)
]
}
+
1.8
In one embodiment, the included angle θ is between 20˜40 degrees, such as between 25˜35 degrees.
With reference to FIG. 2 , the element substrate 100 further comprises a conductive layer 140 disposed on the planarization layer 130 , wherein the conductive layer 140 is electrically connected to the metal layer 120 via the contact hole 131 . The conductive layer 140 is a made of transparent material or metal.
In one embodiment, the metal layer is a source electrode or a drain electrode of a driving element. In one embodiment, the element substrate 100 further comprises a semiconductor layer 137 located between the metal layer 120 and the substrate 110 . The semiconductor layer 137 can be made of polycrystalline silicon, noncrystalline silicon or metal oxide.
FIG. 3A shows the element substrate of the embodiment of the invention utilized in a liquid-crystal display 200 , which comprises a active area (pixel area) A and an non-active area (B). FIG. 3B shows detailed structures of portion 3 B is FIG. 3A , wherein the liquid-crystal display 200 further comprises scan lines 201 , data lines 202 , a semiconductor layer 203 , source electrodes 240 , a contact hole 231 , a bottom 233 of the contact hole, drain electrodes 204 , common electrodes 205 and pixel electrodes 210 , which are located in the active area A. In an embodiment of the invention, the metal layer 120 comprises the source electrodes 240 , the drain electrodes 204 , the scan lines 201 and the signal lines 202 .
With reference to FIG. 2 , in another embodiment, the metal 120 comprises a first edge 121 along the first direction X, the first edge 121 vertically corresponds to a critical point 136 which is on the contiguous wall 132 , and the tangent slope of the contiguous wall 132 at the critical point 136 is less than tan 10° (0.176). The base point 135 is located at the point where the contiguous wall 132 is connected to the bottom 133 . The straight line L connects a reference point 134 and a base point 135 . An included angle θ is between a straight line L and a horizontal line, and the included angle θ is between 20˜40 degrees, such as 25˜35 degrees. The metal layer 120 has a first width L 1 along the first direction X, and the bottom 133 of the contact hole 131 has a second width L 2 along the first direction X, wherein the first width and the second width satisfy the following equation:
2 ⋆ { L 2 2 + ( 1 - p ) h ln ( p ) · tan ( 1.5 θ ) · ln [ - 0.176 ⋆ ( 1 - p ) ln ( p ) · tan ( 1.5 θ ) ] } = L 1
L 1 is the first width of the metal layer 120 along the first direction X, and L 2 is the second width of the bottom 133 of the contact hole 131 along the first direction X, and p is an adjustable parameter, and (1−p)h is a height of the reference point in a vertical direction, and 0<p≦0.1, such as 0<p≦0.05. By modifying the parameters above, the curvature and the shape of the contiguous wall 132 can be modified.
In the embodiments above, the contact hole is in the active area (pixel area) A. However, the invention is not limited thereby. The contact hole structure of the embodiment of the invention can also be located in non-active area B. With reference to FIG. 4 , in one embodiment, the conductive layer 140 in the contact hole 131 ′ is connected to the data line 202 , and the relationship between the profile of the contact hole 131 ′ and the width of the data line 202 can satisfy the above equations. The contact hole 131 ′ is connected to the scan line 201 via the contact hole 131 ″ on the planarization layer 130 and the gate insulation layer 222 . The relationship between the profile of the contact hole 131 ″ and the width of the scan line 201 can satisfy the above equations. In this embodiment, the gate insulation layer 222 is formed between the data line 202 and the scan line 201 .
FIG. 5 shows a liquid-crystal display 200 of an embodiment of the invention, which comprises an opposite substrate 260 , a liquid-crystal layer 250 and the element substrate 100 .
With reference to Table 1 and FIG. 6 , in the embodiment of the invention, the width of the metal layer (M 2 ) 120 has tolerance of ±1.8.
TABLE 1
Sample 1
Sample 2
Sample 3
Sample 4
Sample 5
Designed
14.54
6.42
8.69
8.12
12.07
width of the
metal layer
(M2)
Actual width
15.37
7.66
7.41
7.79
11.52
of the metal
layer (M2)
120
tolerance
0.83
1.24
−1.28
−0.33
−0.55
Utilizing the embodiment of the invention, the aperture ratio and the light transmittance (dark state contrast) of the liquid-crystal display are optimized, and the light leakage and the low-contrast problem are prevented.
Use of ordinal terms such as “first”, “second”, “third”, etc., in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having the same name (but for use of the ordinal term).
While the invention has been described by way of example and in terms of the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. On 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.
|
An element substrate is provided, including a substrate, a metal layer and a planarization layer. The metal layer is located on the substrate. The metal layer has a first edge in a first direction. The planarization layer is located on the metal layer. The planarization layer includes a contact hole. The contact hole has a contiguous wall and a bottom side. The metal layer is exposed in the bottom side. A contour line of the contiguous wall on a vertical plane is a curved line. The first edge corresponds vertically with a critical point on the contour line. The slope of a tangent line on the critical point of the contour line is smaller than 0.176.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of our copending application Ser. No. 521,487, filed Aug. 8, 1983, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to smoking articles such as cigarettes and to wrappers for such smoking articles which reduce ignition proclivity, i.e., the tendency to cause ignition of surfaces which come in contact with the lit cigarette. Reports have been made of fires attributed to burning cigarettes coming in contact with combustible materials. Such reports have generated interest in reducing the tendency of cigarettes to ignite surfaces and materials forming furniture, bedding, and the like upon contact. One obviously desirable attribute of cigarettes in this regard would be that they extinguish themselves if accidentally or carelessly dropped upon such combustible materials or surfaces. Since it is recognized by those skilled in the art that the wrapper strongly influences the behavior of a cigarette during smolder, modification of the wrapper construction to achieve these desired results would be highly beneficial. In particular, such a wrapper construction that does so without serious detrimental effects on desired smoking properties and characteristics would be especially advantageous. The present invention is directed to such wrapper constructions and improved smoking articles.
2. Description of the Prior Art
The subject of reducing the tendency of cigarettes to ignite upholstery, bedding, and the like has received much attention. Considerable effort has been directed to modification of cigarette papers to reduce to reduce fire hazards, including the development of non-burning wrappers for example as disclosed in U.S. Pat. No. 2,998,012 to Lamm dated Aug. 29, 1961, and design of wrappers having patterned rings or areas of non-burning materials for example as disclosed in U.S. Pat. No. 4,044,778 to Cohn dated Aug. 30, 1977.
It is also known, as in U.S. Pat. No. 4,321,377 to Cline, for example, to treat conventional wrappers with chemical adjuvants such as alkali metal citrates to control burn properties.
It is, moreover, known as described in copending and coassigned U.S. patent application Ser. No. 334,120 filed Dec. 24, 1981, now U.S. Pat. No. 4,461,311 dated July 24, 1984 to Mathews, DeLucia, and Mattina that the addition of extraordinary amounts of burn promotion additives to cigarette paper leads to a reduced emission of sidestream smoke. Cigarettes made with such papers normally would not have reduced ignition proclivity, however.
Additionally, copending and coassigned U.S. patent application Ser. No. 521,306 filed Aug. 8, 1983 refiled as Ser. No. 627,711 on July 11, 1984, describes wrappers for self-extinguishing cigarettes where the wrappers are treated in zones with elevated levels of burn promotion additives. Cigarettes made with these wrappers will not provide continuous free burn since they burn normally for a designed period of time and then reliably self-extinguish in air.
In summary, in spite of this extensive activity, it remains desired to produce a wrapper for cigarettes and the like that would result in the cigarette self-extinguishing when in contact with a substrate, including many composed of combustible materials, but which would otherwise perform as a conventional cigarette in terms of smoke delivery, puff count, free burn rate, and the like.
SUMMARY OF THE INVENTION
The present invention is directed to commercially practical wrapper constructions for smoking articles such as cigarettes, that reduce the ignition proclivity of cigarettes without substantial impairment of desirable cigarette properties, and to the resulting smoking articles. The wrappers of the present invention enable smoking articles to burn continuously at a desirable rate in air and yet self-extinguish quickly when dropped onto a substrate, including many common, combustible materials. Further, the smoking articles with wrappers of the present invention result in such benefits without a significant elevation in smoke delivery, thus satisfying the desires of smokers for lower tar delivery. In accordance with the invention, the wrappers and smoking articles may be white, opaque, and attractive in appearance, machine well on high speed cigarette making machines, require no new or unproven ingredients, and do not necessitate costly alterations in the manufacturing process or the composition of the wrapper construction.
In accordance with the invention, the wrappers have a structure defined by a Burn Mode Index ("BMI"), which is defined below and is a direct measure of the wrapper's ability to reduce the proclivity of cigarettes to ignite substrates. Additionally, the wrappers contain a finite amount of a burn promotion additive in order to allow smoking articles with that wrapper to free burn continuously in air. The required level of a burn promotion additive depends on the BMI of the wrapper.
In the single-wrap configuration the BMI of the wrapper can be between 1.5 cm -1 and 5.0 cm -1 . In an alternative embodiment, a double-wrap configuration is employed, where the inner-wrapper is a paper with a BMI in the range of about 0.1 cm -1 to 4.0 cm -1 and the outer-wrapper can be a conventional cigarette paper. In either the single wrap or the double wrap configuration cigarettes will burn rapidly and to completion when suspended in air, for example, in an ash tray or during smoking. However, such cigarettes are very sensitive to environmental conditions, and, if dropped or otherwise put in contact with a surface, including those of many combustible materials, they will self-extinguish or, if they burn to completion, will result in minimal charring of the surface of the substrate material.
In summary, the unique and surprising feature of this invention for reduction of fire hazard is the use of burn promoters in specially designed papers whose structures are defined by the BMI. The result is a reduced fire hazard in contrast to conventional wisdom which would indicate that the use of burn promoters is antithetical to the goal of decreasing the fire hazard of cigarettes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts the apparatus for the determination of the Burn Mode Index.
FIG. 2 illustrates in perspective view a single-wrapped cigarette formed in accordance with the present invention partially broken away to illustrate burn characteristics.
FIG. 3 is a view like that of FIG. 2 except illustrating a double-wrapped configuration.
FIG. 4 illustrates in graph form the decreasing amounts of alkali- metal salt (as potassium citrate) required to obtain complete free burn in a single-wrap embodiment as a function of increases in the BMI as defined below. It also shows the range of paper structures and chemical levels for wrappers of cigarettes which will self-extinguish in the simulated upholstered furniture test, which is similar to the test used by the Upholstered Furniture Association Committee (UFAC). The preferred BMI range for wrappers in use with single-wrapped cigarettes is also shown.
FIG. 5 is a graph, similar to that of FIG. 4, illustrating results obtained with the double-wrap embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the description which follows, certain tests have been employed which will be described.
The BMI test is based on the discovery that the wrapper's resistance to the flow of an electric current, when the paper is immersed in a non-aqueous solution of electrolyte and is placed between two electrodes, correlates very well with the fire ignition proclivity of a cigarette made with that wrapper. The ratio of the intrinsic resistivity of the electrolyte solution (ohm-cm) to the product of the electrical resistance of the paper (ohm) and the area of paper in mutual contact with both electrodes (cm 2 ) is defined as the "Burn Mode Index" (BMI), a direct measure of a wrapper's ability to suppress ignition proclivity. This electrical resistance was measured as a series resistance with an impedance bridge, Model 1658 manufactured by GenRad Corporation. An alternating voltage at a 1 kiloherz frequency was applied across the electrodes. The test cell is shown in FIG. 1. As illustrated, glass vessel 50 contains electrolyte 52, for example, an 0.5 molar solution of tetraethylammonium chloride in butyrolactone. Bottom electrode 54, having a diameter of about 7.6 cm, for example, supports paper sample 56 upon which is placed a top electrode 57 having a diameter of about 1.4 cm, for example, and surrounded by a nonconductive support 59 of, for example, Teflon (polytetrafluoroethylene). The electrodes are connected by wire 58 through impedance bridge 60 providing an alternating current of 1 Khz frequency. The electrodes may be, for example, gold-plated brass cylinders. The BMI is determined by dividing the intrinsic resistivity of the solution by the product of the measured resistance and the area of paper in contact with both electrodes (in the case described, area=1.6 cm 2 ).
The ignition proclivity results were obtained by lighting a cigarette, allowing it to smolder in air until the coal was fully developed, and then placing it on top of the crease made by two cushions at right angles to each other. The cushions were designed to simulate the seat and backing of furniture such as sofas and chairs. This test is similar to that used by UFAC. Each cushion was made by wrapping a piece of standard, Class II cotton flannel (UFAC) having a basis weight of 13.5 oz/yd 2 , over a cushion of unfilled polyurethane foam (without fire retardant treatment), with a density of 1 lb/ft 3 , 2 inches thick, 5 inches in width and 8 inches in length. The time for each cigarette to self-extinguish was noted. When the cigarette continued to burn over its entire length, the extinction time was recorded as infinite. In all such tests a standard cigarette 25 millimeters in circumference and 70 millimeters in length of tobacco column, made from a standard American tobacco blend was tested.
Oxygen concentration limits were determined by suspending lit cigarettes horizontally in a controlled draft chamber. Air admitted to the chamber was slowly diluted with nitrogen and the oxygen concentration at which each cigarette self-extinguished was recorded.
The cooling extinction test results were determined by attaching axially a length of No. 14 copper wire to a cigarette over a distance equal to about half the length of the cigarette. The free end of the wire was immersed in a heat sink and the cigarette was suspended horizontally in air. The end of the cigarette opposite the wire was lit and the time for each cigarette to extinguish after the leading edge of the coal reached the end of the wire was recorded. Where the cigarette continued to burn over its entire length, the extinction time was recorded as infinite.
Puff count was determined in accordance with standard FTC cigarette testing procedures. Carbon monoxide test results were obtained by gas chromatographic analysis of the smoke gas phase sampled during puffs.
The manufacture of paper for wrapping cigarettes is, of course, well-established. Conventional practice employs traditional wet-laid paper manufacturing steps of fiber dispersion, dilution, deposition on a foraminous wire, water extraction, pressing, and drying. The fiber component for cigarette paper is preferably flax, but other cellulose fibers may be used instead of or in combination with flax. Conventional mineral fillers up to about 50% by weight can be used, e.g., precipitated calcium carbonate, ground limestone, calcined kaolinite, titania, diatomaceous earth, sodium silico-aluminate, amorphous silica, calcium silicate, and others for purposes of producing desired opacity. As will be recognized by those familiar with papermaking, minerals of different particle size distribution, shape, and specific gravity may require alteration of fiber types or treatment such as refining or beating in order to obtain desired paper properties.
In accordance with the invention, however, it is necessary that the wrapper material properties of the single-wrapper in that embodiment, and the inner-wrapper in the double-wrap embodiment, be controlled within carefully defined limits.
The BMI of the wrapper for the single-wrap embodiment must be within the range of from about 1.5 cm -1 to about 5.0 cm -1 , and preferably in the range of from about 1.5 cm -1 to about 3.5 cm -1 . For comparison, BMI test values obtained on conventional wrappers are greater than 10 cm -1 and are usually in excess of 15 cm -1 . In addition to satisfying the BMI requirement, it is necessary for the wrapper to contain a finite amount of an alkali-metal burn promoter. The necessary level of burn promoter depends on the BMI of the wrapper. Curve A in FIG. 4 shows the minimum amount of anhydrous potassium citrate per gram of bone-dry paper which is required to enable a cigarette made with that wrapper to free burn continuously in air. However, it is desirable for the wrapper to contain more burn promoter than the minimum level required for free burn in order to obtain normal, or nearly normal, free burn rates and thereby avoid an increase in the puff count. The maximum amount of potassium citrate in the wrapper which will allow a cigarette with that wrapper to self-extinguish in the simulated upholstered furniture test is shown as Curve B in FIG. 4. The range of alkali-metal burn promoter level extends from about 5 mg to about 150 mg of anhydrous potassium citrate per gram of bone-dry base paper, or a stoichiometrically equivalent amount of another alkali-metal salt, for the BMI range of 5.0 cm -1 to 1.5 cm -1 . For the preferred BMI range of 3.5 cm -1 to 1.5 cm -1 , the range of potassium citrate levels extends from about 15 mg to about 150 mg.
The BMI of the inner wrapper for the double-wrap configuration must be within the range of from about 0.1 cm -1 to about 4.0 cm -1 , and preferably in the range of from about 0.1 cm -1 to about 2.0 cm -1 . The outer wrapper preferably has a BMI in the range of from about 6.0 cm -1 to about 25 cm -1 , but the BMI can be as low as about 2.0 cm -1 or as high as about 40 cm -1 . Double-wrapped cigarettes with the inner wrapper in the 0.1 cm -1 to 4.0 cm -1 range cannot sustain free-burn without the aid of burn promoters. However, in the double-wrap configuration, the inner wrapper need not contain a burn promoter. Preferably, the outer wrapper contains the promoter, potassium citrate or a stoichiometrically equivalent amount of another alkali-metal salt, in excess of the minimum amount required for free burn, but less than the amount which would prevent a cigarette with this wrapper from self-extinguishing in the simulated upholstered furniture test. The range of alkali-metal burn promoter levels, as potassium citrate, extends from about 5 mg to about 150 mg in the outer wrapper when the inner wrapper BMI range of 0.1 to 4.0 cm -1 . For the preferred, inner wrapper BMI range of 0.1 cm -1 to 2.0 cm -1 , the range of potassium citrate extends from about 15 mg to about 150 mg.
The range of BMI and potassium citrate levels for the double-wrap configuration is shown in FIG. 5. Curve A shows the minimum amount of potassium citrate in the outer wrapper required for a continuous free burn when the inner wrapper contains no burn promotion additive and its BMI is 4.0 cm -1 , the upper limit of the allowable BMI range. Curve B shows the amount of potassium citrate in the outer wrapper which will allow cigarettes to self-extinguish in the simulated upholstered furniture test when they are made with that wrapper, and an inner wrapper without burn promotion additives and with a BMI of 0.1 cm -1 , the lower limit of the allowable BMI range. Therefore, the region enclosed by curves A and B comprises the possible combinations of BMI of the inner and outer wrapper and potassium citrate levels in the outer wrapper, which will result in cigarettes that both free burn continuously in air and self-extinguish in the simulated upholstered furniture test. The preferred region is shaded.
Single-wrapped or double-wrapped cigarettes with wrappers having BMIs and burn promoter levels lying in the previously described ranges exhibit a desirable rate and continuity of free burn in air but self-extinguish quickly and reliably if contacted with a substrate, including many combustible materials such as are used in upholstered furniture. This unique combination of properties demonstrates the highly improved and unexpected results obtained in accordance with the invention. While it is not desired to be limited by any particular theory, it is believed that, although cigarettes wrapped in accordance with the invention burn continuously, reliably, and rapidly in air, they are very sensitive to minor reductions in oxygen supply or coal temperature. This sensitivity provides for the cigarette becoming self-extinguishing when in contact with a substrate, which, at least locally, reduces available oxygen even though that substrate may be made of a combustible material.
Treatment with elevated amounts of the alkali metal burn promoter is an essential feature of the invention when the wrapper has a BMI range less than about 3.5 cm -1 . In the case of the double-wrap configuration, when the inner wrapper has a BMI of less than 2.0 cm -1 , the outer wrapper must be treated with elevated amounts of an alkali-metal burn promoter. In general, the ability of the wrapper of the invention to promote vigorous burn of the cigarette in an ash tray, but at the same time cause it to quickly self-extinguish when in contact with a substrate, including many combustible materials, is best achieved when the BMI is in this low range. The alkali-metal salt used can be selected from a wide variety of compositions including the salts of carbonic acid, formic acid, acetic acid, propionic acid, oxalic acid, malonic acid, succinic acid, glutaric acid, malic acid, lactic acid, citric acid, glycolic acid, tartaric acid, and nitric acid. Mixtures of these salts or stoichiometrically equivalent amounts of other carboxylic acid salts of alkali metals can also be used. In the preferred BMI range, potassium salts rather than sodium salts should be used because they more effectively promote free-burn. Levels of potassium citrate above about 150 mg of anhydrous potassium citrate per gram of bone-dry paper are not useful because above this level potassium citrate begins to act as a burn retarder rather than a burn promoter.
Methods of manufacture using double wrappers are known and may include, for example, simultaneously feeding each wrapper from pairs of bobbins or laminating the wrappers and feeding in the manner of a single wrap. In either case the resulting double-wrapped smoking article will have the desired reduced ignition proclivity.
EXAMPLES OF THE INVENTION
Example 1 (Single-wrap configuration)
A cigarette wrapper material was manufactured by employing conventional Fourdrinier papermaking techniques for lightweight papers using Kraft cooked, bleached flax pulp and containing 14% by weight of the anitase form of Titanium Dioxide (Unitane 0-110 from American Cyanamid). The paper was treated so as to contain 90 mg of anhydrous potassium citrate per gram of bone-dry base paper. This paper had the following characteristics: Tappi opacity of 68%, tensile strength of 3800 g/29 mm, permeability of 4 cm/min at 1 centibar, as measured by the CORESTA method, basis weight of 21 g/m 2 , and BMI of 2.5 cm -1 .
Cigarettes made with the wrapper at a tobacco column density of 13.2 mg/mm, free burned at 3.8 mm/min, required an atmosphere with 20% oxygen to burn continuously, and self-extinguished in 3 minutes in the simulated upholstered furniture test. Example 1(M) is a repetition with tobacco column density of 9.2 mg/mm.
Example 2 (Single-wrap configuration)
An alternative cigarette wrapper material in accordance with the invention was made as in Example 1 using standard northeastern softwood bleached Kraft pulp with 25% by weight of precipitated calcium carbonate with average particle size of 0.75 micron, consisting of barrel-shaped prisms terminated by rhombohedrons (marketed under the trade name Albaglos, obtained from Pfizer, Inc., Minerals, Pigments and Metals Division). The paper was treated so as to contain 17 mg of anhydrous potassium citrate per gram of bone-dry paper. This paper had the following properties: Tappi opacity of 77%, tensile strength of 5200 g/29 mm, CORESTA permeability of 1.5 cm/min, basis weight of 33 g/m 2 , and BMI of 3.5 cm -1 .
Cigarettes made with this wrapper and a tobacco column density of 13.2 mg/mm free-burned at 3.7 mm/min, required an atmosphere with at least 19% oxygen to burn continuously, and self-extinguished in 4 minutes in the simulated upholstered furniture test. Example 2(M) is a repetition with tobacco column density of 9.2 mg/mm.
Example 3 (Single-wrap configuration)
A third embodiment of the cigarette wrapper material of the present invention was made as in Example 1 using Kraft cooked, bleached flax pulp including 12% by weight of the TiO 2 described in Example 1 and 2% by weight of the calcium carbonate filler of Example 2. The paper was treated so as to contain 36 mg of anhydrous potassium citrate per gram of bone-dry base paper. This paper had the following characteristics: Tappi opacity of 73%, tensile strength of 4600 g/29 mm, CORESTA permeability of 2 cm/min, a basis weight of 24 g/m 2 and BMI of 3.5 cm -1 .
Cigarettes made with this wrapper and a tobacco column density of 13.2 mg/mm free burned at 3.8 mm/min, required an atmosphere with at least 19% oxygen to burn continuously and self-extinguished in 4 minutes in the simulated upholstered furniture test.
Example 4 (Single-wrap configuraion)
To illustrate the use of alternative base sheets for the wrapper of the present invention, the base sheet of Example 3 was selected for further treatment to lower its BMI. The BMI of the untreated sheet was 3.5 cm -1 . This sheet was treated by roll coating to achieve an add-on of 1% by weight of Ethylex 2005 (a hydroxy-ethyl starch obtained from A. E. Staley Manufacturing Company) and potassium citrate at a level of 90 mg of anhydrous potassium citrate per gram of bone dry base paper. The resulting paper had a BMI of 2.5 cm -1 . Cigarettes made with wrappers of this material had properties similar to those of Example 1.
Thus, conventional wrapper materials having typically high BMI values can be coated or saturated with suitable water soluble, film-forming materials, reducing the BMI to a level useful as base paper in accordance with the present invention. Examples of useful coating or impregnating materials include cellulose ethers such as methyl cellulose and carboxymethyl cellulose; starch or chemically modified starches such as hydroxyethylated or acetylated starch; guar gum, sodium alginate, or other vegetable gums; dextrin; and proteins, such as gelatin or refined vegetable proteins. The application can be made on the paper machine, for example, at the size press, or it can be applied to the formed paper by separate operation such as coating or saturation techniques. Where the composition containing both the sealing material and the alkali metal additive is unstable, separate treatment steps may be used in either order.
Example 5 (Double-wrap configuration)
To illustrate the double-wrapped embodiment of the invention, cigarettes were made using an inner wrapper with a BMI of 1.0 cm -1 and no alkali metal salt and an outer wrapper, a commercially available cigarette paper, treated as to contain 60 mg of anhydrous potassium citrate per gram of bone dry base paper. The inner wrapper was manufactured in the same manner as the paper in Example 1. The physical properties of the inner wrapper were: Tappi opacity 68%, tensile strength of 4,000 g/29 mm, CORESTA permeability of 1 cm/min, basis weight of 21 g/m 2 , and BMI of 1 cm -1 . The outer wrapper was a commercial cigarette paper containing 30% calcium carbonate (trade name Albacar from Pfizer, Inc.) further treated to contain 60 mg of anhydrous potassium citrate per gram of bone-dry paper. The physical properties of the outer wrapper were: opacity of 74%, tensile strength of 2400 g/29 mm, CORESTA permeability of 55 cm/min, basis weight of 24 g/m 2 , and BMI of 20 cm -1 . Cigarettes made with the combination of these two wrappers at a tobacco column density of 13.2 mg/mm free burned at 4.7 mm/min, required an atmosphere with 20% oxygen to burn continuously and self-extinguished in 3 minutes in the simulated upholstered furniture test.
TABLES 1, 2, and 3
In Tables 1, 2, and 3 examples of the invention are identified by numbers and are compared to wrappers identified by letters, with BMI values lying outside the range of the invention, 1.5-5.0 cm -1 for single wrapped and 0.1-4.0 cm -1 for the inner wrapper of double-wrapped cigarettes.
As Table 1 demonstrates, use of wrappers in accordance with the invention produces desired free-burn rates and reduced ignition proclivity when the BMI is within the defined range. Also illustrated is the surprising effect of treatment with elevated amounts of an alkali-metal burn promoter when the BMI is in the lower range of the invention. In addition, it is shown that no departures from standard cigarette packing density and circumference are required which is contrary to what might have been expected.
Table 2 contains oxygen concentration limit tests and cooling extinction times for Examples 1, 2, and 5 and wrappers A and B. As shown, minor reductions in oxygen are effective in causing the cigarettes of the invention to self-extinguish.
To demonstrate that these beneficial results are obtained while yet managing smoke delivery properties, the cigarettes of Examples 1, 2, and 5 were tested for puff count, dry particulate matter, (DPM), and carbon monoxide. These results, along with the results for conventional unfiltered cigarettes wrappers A and B, are shown in Table 3. Filter ventilation was simulated by reducing the puff volume in a normal F.T.C. smoking regime by the indicated degree of filter ventilation. All cigarettes were smoked for 47 mm. In contrast to earlier attempts, Table 3 demonstrates that the wrappers of the invention do not excessively elevate smoke delivery. This is shown by comparing dry particulate matter, carbon monoxide delivery, free burn rate, and puff count with the results of these tests on conventional cigarettes.
TABLE 1__________________________________________________________________________ Tobacco Column Alkali Metal Salt Density Free Wrappers with Content (mg of (mg/mm) Burn Ignition BMI < 1.5 cm.sup.-1 Perme- Basis anhydrous potassium Circum- Rate Proclivity or ability Weight BMI citrate/g of bone ference = (mm/ (min. BMI > 5.0 cm.sup.-1 (cm/min) (g/m.sup.2) (cm.sup.-1) dry base paper) 25 mm min) to__________________________________________________________________________ ext.)Single-Wrapped CigarettesExamples ofthe Invention(1.5 cm.sup.-1 ≦ BMI ≦ 5.0 cm.sup.-1)1 4.0 21 2.5 90 13.2 3.8 32 1.5 33 3.5 17 13.2 3.7 43 2.0 24 3.5 36 13.2 3.8 4 A 6.0 24 7.0 8 13.2 4.0 inf. B 25.0 24 15.0 8 13.2 4.7 inf. C 10.0 24 10.0 8 13.2 4.1 inf. D 68.0 24 20.0 8 13.2 4.9 inf. E 130.0 24 1.0 0 13.2 0 -- F 1.0 21 1.0 90 13.2 0 -- A (M) 6.0 24 7.0 8 9.2 4.8 inf. B (M) 25.0 24 15.0 8 9.2 6.2 inf.1 (M) 4.0 21 2.5 90 9.2 4.8 32 (M) 1.5 33 3.5 17 9.2 4.7 4Double-Wrapped Cigarettes - (Outer Wrapper/Inner Wrapper)Examples ofthe Invention(0.1 cm.sup.-1 ≦ BMI ≦ 4.0 cm.sup.-1)5 55/1.0 24/21 20/1 60/0 13.2 4.7 3__________________________________________________________________________
TABLE 2__________________________________________________________________________ Alkali Metal Salt Wrappers with Content (mg of Tobacco Oxygen BMI < 1.5 cm.sup.-1 anhydrous potassium Column Conc. Cooling or Permeability BMI citrate/g of bone Density Limit Extinction BMI > 5.0 cm.sup.-1 (cm/min) (cm.sup.-1) dry base paper (mg/mm) (%) (min.)__________________________________________________________________________Single-wrapped CigarettesExamples ofthe Invention(1.5 cm.sup.-1 ≦ BMI ≦ 5.0 cm.sup.-1)1 4.0 2.5 90 13.2 20 32 1.5 3.5 17 13.2 19 4 A 6.0 7.0 8 13.2 18 5 B 25.0 15.0 8 13.2 12 inf.Double-Wrapped Cigarettes - Outer Wrapper/Inner WrapperExamples ofthe Invention(0.1 cm.sup.-1 ≦ BMI ≦ 4.0 cm.sup.-1)5 55/1.0 20/1.0 60/0 13.2 20 3__________________________________________________________________________
TABLE 3__________________________________________________________________________ Tobacco Column Alkali Metal Salt Density Wrappers with Content (mg of (mg/mm) BMI < 1.5 cm.sup.-1 Perme- Basis anhydrous potassium Circum- or BMI ability Weight citrate/g of bone ference = BMI > 5.0 cm.sup.-1 (cm.sup.-1) (cm/min) (g/m.sup.2) dry base paper) 25 mm__________________________________________________________________________Single-Wrapped CigarettesExamples ofthe Invention(1.5 cm.sup.-1 ≦ BMI ≦ 5.0 cm.sup.-1)1 2.5 4.0 21 90 13.22 3.5 1.5 33 17 13.2 A 7.0 6.0 24 8 13.2 B 15.0 25.0 24 8 13.2Double-Wrapped Cigarettes - Outer Wrapper/Inner WrapperExamples ofthe Invention(0.1 cm.sup.-1 ≦ BMI ≦ 4.0 cm.sup.-1)5 20/1.0 55/1.0 24/21 60/0 13.2__________________________________________________________________________ Dry Wrappers with Free Filter Particu- BMI < 1.5 cm.sup.-1 Burn Ventila- late Carbon or Rate tion Puff Matter Monoxide BMI > 5.0 cm.sup.-1 (mm/min) (%) Count (mg/cig.) (mg/cig.)__________________________________________________________________________Single-Wrapped CigarettesExamples ofthe Invention(1.5 cm.sup.-1 ≦ BMI ≦ 5.0 cm.sup.-1)1 3.8 30 10.0 25.3 16.92 3.7 30 10.0 25.4 18.6 A 4.0 20 9.5 23.0 14.3 B 4.7 0 8.0 25.4 16.7Double-Wrapped Cigarettes - Outer Wrapper/Inner WrapperExamples ofthe Invention(0.1 cm.sup.-1 ≦ BMI ≦ 4.0 cm.sup.-1)5 4.7 30 8.0 20.8 17.9__________________________________________________________________________
Turning to FIG. 2, the single wrap embodiment will be described. As shown, tobacco column 10 is surrounded by wrapper 12. The lit end is shown partially broken away, and includes coal area 14 surrounded by char area 16. While the invention is not to be limited to a particular theory, it is believed that the balance of burn characteristics results from the ability to maintain the coal near the extinction point while allowing just sufficient oxygen availability to continue combustion. Contact with a surface, then, reduces available oxygen from the area of the contact and results in the self-extinction of the cigarette.
The same result occurs from the double wrapped structure of FIG. 3. Shown therein is a tobacco column 20 enclosed by an inner wrapper 22 and an outer wrapper 24. The lit end includes the coal area 26 surrounded by the char area 28. The availability of oxygen is again controlled with the result that the desired burn properties are attained.
Curve A in FIG. 4 shows that the alkali metal salt (as potassium citrate) required to obtain burn continuity decreases as BMI value increases for the single-wrapped configuration. Comparison of this graph with the extinction sensitivity test results shown in Table 2 demonstrates the higher reliability of self-extinction of cigarettes with wrappers of low BMI values. Curve B in FIG. 4 shows the approximate maximum level of anhydrous potassium citrate which can be added to a wrapper with a given BMI and still allow cigarettes made with that particular wrapper to self-extinguish in the simulated upholstered furniture test. The region enclosed by curves A and B shows the possible BMI and potassium citrate combinations for cigarette wrappers which will yield cigarettes that will self-extinguish in the simulated upholstered furniture test. The preferred range for the BMI and the potassium citrate levels is shown as a shaded region.
It is difficult for the cigarettes to pass, i.e., self-extinguish, in the simulated upholstered furniture test and only a rather narrow region of combinations of BMI and burn promoter levels will yield wrappers which allow cigarettes to pass this test. Relaxation of the test, for example by a change in the type of upholstery, would shift curve B to the right and therefore widen the region of allowable BMI and level of burn promoter combinations.
FIG. 5 is a graph similar to FIG. 4, but with respect to the double-wrapped configurations. Curve A shows the minimum amounts of potassium citrate required in the outer wrapper for continuous free-burn when the inner wrapper contains no burn promoters and has a BMI of 4.0 cm -1 . Curve B shows the maximum amount of potassium citrate which the outer wrapper may contain and still allow cigarettes made an inner wrapper with a BMI of 0.1 cm -1 to pass the simulated upholstered furniture test. The preferred region is shaded.
Thus, it is apparent that there has been provided in accordance with the invention a wrapping structure for smoking articles and resulting smoking articles that fully satisfy the objects, aims, and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims.
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The invention is an improved wrapper construction for smoking articles such as cigarettes resulting in a reduced tendency to ignite combustible materials accidentally or carelessly coming into contact with the lit cigarette. The wrapper constructions and smoking articles of the invention have a specially designed structure which causes a cigarette to go out quickly when in contact with a substrate, including many commonly-encountered substrates made of combustible materials. This structure is characterized by a Burn Mode Index ("BMI") as defined for the wrapper of between about 1.5 cm -1 and 5.0 cm -1 for a single wrap embodiment. For an alternative double wrapped embodiment, the outer wrap will have a BMI in the range of from about 2.0 cm -1 to about 40 cm -1 depending on the BMI of the inner wrap which may vary between about 0.1 cm -1 to 4.0 cm -1 . The preferred amount of burn promoter is at least 15 mg anhydrous potassium citrate per gram of bone dry paper or stoichiometrically equivalent amounts of other burn promoting salts.
Preferred substrate embodiments include paper made from flax or other cellulosic fibers, treated with elevated amounts of an alkali metal burn promoter such as alkali metal salts of carboxylic acids, especially potassium salts. In contrast to other attempts, these results are obtained without a significant sacrifice of desired taste and smoke deliveries, for example, without unacceptable increases in puff count or significant increases in delivered tar and carbon monoxide. Wrapper constructions and smoking articles of this invention may be manufactured using conventional cigarette paper processes and equipment.
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This invention is made in part with Government support under U.S. Department of Agriculture Grants 90-37153-5438 and 91-37300-6566. The Government has certain rights in the invention.
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of Ser. No. 08/665,966 filed on Jun. 21, 1996 U.S. Pat. No. 5,756,328, which claims the benefit of U.S. provisional application Ser. No. 60/008,948, filed on Dec. 20, 1995.
TECHNICAL FIELD
This invention is directed to isolation of acyltransferase for use in preparing sugar polyesters and to gene encoding acyltransferase for use in preparing sugar polyesters.
BACKGROUND OF THE INVENTION
Sugar polyesters are a diverse class of molecules including, but not limited to, glucose and sucrose esters of fatty acids and other carboxylic acids.
Partial acylation of the available hydroxyls in the sugar moiety provides feeding deterrent (pest repellent) properties (for use in agriculture), emulsification properties (for use in the food and cosmetic industries) and emollient properties (for use in the cosmetic industry). Six to eight fatty acids esterified to the eight available sucrose hydroxyls provides noncaloric fat substitute.
At present, the sugar polyesters are made through techniques of synthetic organic chemistry.
SUMMARY OF THE INVENTION
The present invention is based on isolation of an acyltransferase from a plant which catalyzes esterification reactions providing sugar esters and sugar polyesters.
In a first embodiment, the instant invention is directed to an essentially pure acyltransferase which comprises the sequence set forth in the Sequence Listing as SEQ ID NO: 8 and to an essentially pure acyltransferase which comprises the sequence set forth in the Sequence Listing as SEQ ID NO: 8 and also the sequences set forth in the Sequence Listing as SEQ ID NOS: 5 and 6.
Based on isolation of the acyltransferase, genes have been isolated which code for acyltransferase. These isolated genes are useful for preparing transgenic yeast or transgenic E. coli for use in manufacturing acyltransferase or for use in preparing transgenic plants transformed to contain gene coding for acyltransferase which produce sugar polyesters and which may be harvested to recover sugar polyesters.
In a second embodiment, the instant invention is directed to an isolated gene encoding an acyltransferase which comprises the sequence set forth in the Sequence Listing as SEQ ID NO: 9.
In a third embodiment, the instant invention is directed to a method of preparing palmitoyl esters of glucose which comprises reacting 1-O-palmitoyl-β-D-glucose with glucose or with palmitoyl partial ester of glucose in the presence of acyltransferase which comprises the sequence set forth in the Sequence Listing as SEQ ID NO: 8 or which comprises the sequence set forth in the Sequence Listing as SEQ ID NO. 8 and also the sequences set forth the Sequence Listing as SEQ ID NOS: 5 and 6.
The term "essentially pure" is used herein to mean meeting the criterion of purified to be free of contaminating protein, i.e., a single protein band or a plurality of protein bands representing different levels of glycosylation of the same protein or a plurality of protein bands representing a protein and subunit or subunits thereof, on a sodium dodecyl sulfate polyacrylamide gel submitted to electrophoresis under reducing, or fully denaturing, conditions and stained with Ponceau stain and/or meeting the criterion of having a specific activity of at least 35 nanokatals mg -1 .
DETAILED DESCRIPTION
Acyltransferase herein is coded for by gene of the genome of and is isolated and derived from the wild tomato species Lycopersicon pennelli (LA716), which is available from the Tomato Genetics Resource Center.
To purify this enzyme, leaf extract is prepared from leaves of L. pennelli (LA716) as described in Example I herein and the enzyme is obtained from the leaf extract and is purified therefrom in a succession of five purification steps. The first step in the purification is an ammonium sulfate precipitation step in which protein is precipitated by addition of solid ammonium sulfate, i.e., (NH 4 ) 2 SO 4 . Ammonium sulfate is added to the extract to 80% of saturation. This is followed by centrifugation. The supernatant is retained and dialyzed. The second step in the purification is a polyethylene glycol precipitation step. Polyethylene glycol is added to provide 0.15 g/ml. This is followed by centrifugation. After discarding of the pellet, polyethylene glycol is added again to a final concentration of 0.22 g/ml at which point protein precipitates and is collected by centrifugation. The third step in the purification involves ion exchange on DEAE (diethylaminoethoxy ion exchange moiety) sepharose. A suspension of protein from the second purification step is passed through a column containing DEAE sepharose and then elution is carried out using 0-250 millimolar KCl gradient. The active fractions are pooled and concentrated by ultrafiltration. The fourth step in the purification involves performing affinity chromatography on the concentrated active fractions from the third purification step in a column containing Concanavalin A (a protein which binds sugars, sometimes referred to as ConA). Proteins which are glycosylated bind, and since the acyltransferase being isolated is glycosylated, it binds. This fourth purification step involves washing with Tris-KOH (pH 7.5) plus 10% glycerol as loading buffer and then eluting first with the Tris buffer and 10% glycerol plus 50 mM α-methylglycoside to displace previously bound irrelevant protein and then eluting with the Tris buffer and 10% glycerol plus 100 mM α-methylglycoside to elute the enzyme of interest. The active fractions are pooled and concentrated by ultrafiltration. The fifth step in the purification involves performing HPLC on the concentrated active fractions from the fourth purification step on a chromatofocusing column under a pH gradient of 4-6. Again the active fractions are pooled and concentrated by ultrafiltration.
Assays for enzyme activity are readily carried out by measuring the disproportionation of 1-O-β-[ 14 C-isobutyryl]glucose to form 1-O-β-[ 14 C-isobutyryl]-di-O-[ 14 C-isobutyryl]-glucose, 1-O-β-[ 14 C-isobutyryl]-tri-O-[ 14 C-isobutyryl]-glucose, i.e., the transfer of the [ 14 C]isobutyryl group from 1-O-β-[ 14 C-isobutyryl]glucose to other 1-O-β-[ 14 C-isobutyryl]glucose, in the presence of sample for which enzyme activity is being determined. A preferred assay involving measuring acyl transfer is described in Example I hereinafter.
Assays for enzyme activity can also be carried out by measuring the anomeric transfer of isobutyryl from 1-O-isobutyryl-β-D-glucose to [U- 14 C]-glucose. A preferred assay involving measuring anomeric transfer is as follows. The assay is performed in a total volume of 15 μL which contains 50 mM Hepes pH 7.5, 10 mM dithiothreitol, 2 mM 1-O-isobutyryl-β-D-glucose, 40 μM [U- 14 C]- glucose (2×10 5 cpm) and 1 to 100 ng acyltransferase. The reaction is allowed to proceed at 37° C. for 30 minutes, and then loaded onto a silica gel thin-layer chromatography plate and eluted in chloroform/methanol/water (75:22:3). The thin layer plate is then dried, exposed to autoradiographic film, and upon development of the autoradiographic image, the silica gel at regions corresponding to the migration of di-, tri-, and tetra-[ 14 C-isobutyryl]-glucose is scraped from the plate, eluted with methanol and radioactively quantified by liquid scintillation.
The purification of the enzyme is described in detail in Example I hereinafter.
An acyltransferase enzyme purified by the above method was found to consist of two subunits of molecular mass 33 kDa and 22 kDa by sodium dodecylsulfate polyacrylamide gel electrophoresis after the enzyme was prepared under reducing conditions on comparison to migration of proteins of known molecular weight, and to have a native molecular weight of 100,000 Da on a gel permeation column, and an isoelectric point as determined by isoelectric focusing on a 5% polyacrylamide native gel with a 3.5 to 9 pH gradient, of 5.2.
Seven peptide fractions obtained from the acyltransferase by treatment with trypsin and separation of the resulting peptides by reversed-phase high pressure liquid chromatography (HPLC) were determined to have the sequences set forth in the Sequence Listing as SEQ ID NOS: 1-7. A sequence of portion of the acyltransferase consistent with the sequence of isolated gene obtained based on the seven peptide fractions is set forth in the Sequence Listing as SEQ ID NO: 8.
The acyltransferase is functional to catalyze anomeric transfer of the acyl substituent from 1-O-acyl-β-D-glucose to glucose, 2-deoxyglucose, 3-O-methyl glucose or partially acylated glucose and to catalyze disproportionation between two molecules of 1-O-acyl-β-D-glucose resulting in formation of diacylglucose and glucose. The acyl substituent including that in the partially acylated glucose can contain, for example, from 1 to 18 carbon atoms and can be branched or straight chain and saturated or unsaturated and can be, for example, isobutanoyl or lauroyl or palmitoyl.
Reaction with 1-O-palmitoyl-β-D-glucose is considered unexpected since this reaction has not been found in nature.
The reaction involving anomeric transfer of acyl from 1-O-acyl-β-D-glucose to glucose, 2-deoxyglucose, 3-O-methyl glucose or partially acylated glucose is readily carried out using a stoichiometric amount of 1-O-acyl-β-D-glucose in buffer or aqueous media at pH ranging from 6.5 to 7.5 at 20 to 40° C. for 10 to 60 minutes in the presence of a catalytically effective amount, e.g., 0.01 to 1 μg of purified acyltransferase per mmol 1-O-acyl-β-D-glucose.
The reaction involving disproportionation is readily carried out in buffer or aqueous media at pH ranging from 6.5 to 7.5 at 20 to 40° C. for 10 to 60 minutes in the presence of a catalytically effective amount, e.g., 0.01 to 1 μg of purified acyltransferase per mmol 1-O-acyl-β-D-glucose.
The 1-O-acyl-β-D-glucose starting material can be prepared, for example, by condensing α-acetobromoglucose and isobutyric acid followed by deacetylation with sunflower esterase. Alternatively, the 1-O-acyl-β-D-glucose can be prepared by reacting acyl chloride with tetrabenzylglucose in dry benzene at 62° C. and deprotecting according to the procedure of Pfeffer, P. E., et al., J. Org. Chem 41, 2925-2927 (1976).
We turn now to the isolation of gene coding for an acyltransferase which catalyzes esterification reactions providing sugar esters and sugar polyesters. Detached trichomes are prepared from L. pennelli leaves by the dry ice abrasion method as described in Yerger, E. H., et al., Plant Physiol 99, 1-7 (1992). The trichomes are suspended in buffer, total RNA extracted and mRNA purified according to the method described in Hunt, M. D., et al, Plant Molec. Biol. 21, 59-68 (1993). The acyltransferase gene is cloned following procedures described by Frohman, M. A., et al., Proc. Natl. Acad. Sci. USA 85:8998-9002 (1988), and Loh, E. Y., et al., Science 243:217-220 (1980). Gene fragment consisting of an internal portion of the gene coding for the acyltransferase is obtained as follows from the total purified mRNA. Total purified mRNA is reversed transcribed into cDNA using oligo (dT) 15 and reverse transcriptase. Aliquot of resulting mixture is then used for polymerase chain reaction in a reaction mixture containing a primer mix corresponding to the least degenerate two of the aforementioned seven peptide fragments and Taq polymerase. The polymerase chain reaction products are analyzed by agarose gel electrophoresis and the major amplification product is excised from the gel, eluted and purified and ligated into PCRII vector for sequencing and the sequence is determined. A gene fragment including the 5' end of the gene is then obtained as follows from the total purified mRNA. Aliquot of mixture resulting from reverse transcription of total purified mRNA is primed with a gene-specific primer (based on a portion of the sequence determined for the 5' end of middle fragment). The resulting cDNA is dc-tailed at the 5' end and the 5' end is amplified by polymerase chain reaction using a nested primer having sequence based on another portion of the sequence determined for the 5' end of middle fragment and an anchor primer and the major amplification product is excised and recovered as described above and cloned into pAMP1 for sequencing and the sequence of the 5' end is determined. Next a gene fragment including the 3' end of the gene is obtained as follows from the total purified mRNA. Aliquot of resulting mixture from reverse transcription of total purified mRNA is amplified using polymerase chain reaction using a gene specific primer (based on a portion of the sequence determined for the 3' end of middle fragment) and a second round of polymerase chain reaction using a nested primer is used to provide enrichment of 3' end cDNA fragment. The polymerase chain reaction product representing the 3' end of the cDNA is cloned into pAMP1 vector for sequencing and is sequenced. Having cloned and sequenced the 5' and 3' ends of the cDNA, primers are synthesized corresponding to these ends and also incorporating BamHI and EcoRI restriction sites and these are used to amplify the entire gene sequence following the procedures described above. The gene is then cloned into the E. coli vector pBluescript which has been prepared with BamHI and EcoRI and transformed into XL1-blue cells for sequencing and sequencing provides the sequence of the entire gene. A detailed description of the isolation and identification of gene coding for acyltransferase from L. pennelli (LA716) is set forth in Example II hereinafter. Sequencing of the gene provided the sequence set forth in the Sequence Listing as SEQ ID NO: 9. The amino acid sequence corresponding to base pairs 1-54 of the nucleic acid sequence of SEQ ID NO: 9 constitutes a signal peptide. Thus, the peptide of SEQ ID NO: 1 is the fragment at the N-terminus of the enzyme. The nucleic acid sequence of SEQ ID NO: 9 indicates a discrepancy in portion corresponding to the peptide fragment of SEQ ID NO: 4 in that it indicates that the amino acid for position number 3 of the sequence of SEQ ID NO: 4 is Phe instead of Ile. Furthermore, the nucleic acid sequence of SEQ ID NO: 9 indicates a discrepancy in portion corresponding to the peptide fragment of SEQ ID NO: 7 in that it indicates that the amino acid for the position number 14 in SEQ ID NO: 7 is Cys instead of Leu. The nucleic acid sequence of SEQ ID NO: 9 after the signal peptide corresponding to base pairs 1-54 is accounted for, indicates that the acyltransferase coded for by the remainder of the base pairs should contain 446 amino acids and have a molecular mass of about 49 kDa and have the sequence set forth in the Sequence Listing as SEQ ID NO.: 10. This indicates that the acyltransferase herein is encoded by a small gene family and that the gene that was isolated was slightly different from the gene encoding the acyltransferase that was isolated.
The difference between the molecular mass determined by sodium dodecylsulfate polyacrylamide gel electrophoresis (subunit molecular masses of 33 kDa and 22 kDa for a total of 55 kDa) and that predicted for the mature protein from the sequence of the isolated gene (49 kDa) is not an unusual observation and is not of concern. The protein is glycosylated and this may result in electrophoretic behavior inconsistent with the mass of the polypeptide. Also a skewed amino acid composition of a small fragment (≦20 kDa) may result in anomalous migration on sodium dodecyl sulfate polyacrylamide gel electrophoresis.
The isolated gene is transferred into yeast by inserting the entire acyltransferase cDNA sequence into the Saccharomyces cerevisiae expression vector pYES2, to generate a plasmid pYAGT2 and transforming pYAGT2 into S. cerevisiae; expression is achieved by induction with galactose. A suitable procedure is described in more detail in Example III.
The isolated gene is transferred into E. coli (e.g., E. coli XL-Blue supplied by Stratagene) by cloning into pBluescript and transforming the resulting plasmid into E. coli via electroporation; expression is achieved by induction of the lac promoter using X-Gal (supplied by Stratagene) according to supplier's instructions.
The isolated gene is used to transform a plant, e.g., a tobacco plant, by the procedures described in Fraley, R. F., et al., CRC Critical Reviews in Plant Sciences 4: 1-86 (1986).
The embodiments of the invention are illustrated in the following working examples:
EXAMPLE I
Isolation and Characterization of Acyltransferase from L. pennelli (LA716)
L. pennelli (LA716) seeds were obtained from Tomato Genetics Resource Center, Department of Vegetable Crops, University of California, Davis, Calif. 95616-8746, and were grown in the greenhouse. The "LA" designation is the Lycopersicon accession number. The original seed was collected on Feb. 16, 1958 by Donovan Correll at the Pacific face of the southern Peruvian Andes (latitude, 16 degrees S, by longitude 73-74 degrees W) and was deposited and accessioned in 1959. The plant of LA716 is described at pages 39-41 of Correll, Donovan Stewart, "The Potato and Its Wild Relative", Texas Research Foundation, Renner, Tex., 1962.
The following procedure was used to obtain leaf extracts: 200 g of frozen leaves and stem tissue was homogenized in 500 ml of 50 mm Hepes·NaOH, pH 7.0/250 mM sucrose (functions to stabilize protein)/10 mM dithiothreitol(inhibits oxidative browning of extract)/1% (w/v) acid-washed polyvinyl pyrrolidone (binds phenolics)/0.1% (w/v) diethyldithiocarbamate (inhibits polyphenol oxidases). The homogenate was centrifuged at 15,000×g for 20 minutes to remove debris. The supernatant was adjusted to 80% saturation with solid (NH 4 ) 2 SO 4 and, after 30 minutes on ice, was centrifuged at 20,000×g for 30 min. The pellet was suspended in 10 ml of 50 mM Hepes·NaOH, pH 7.0/1 mM dithiothreitol/0.5 mM phenylmethylsulfonylfluoride (inhibits protease activity)/10% (vol/vol) glycerol (functions to stabilize protein) and dialyzed against the same buffer. The specific activity of acyltransferase at this stage was 7.2×10 -3 nkatal/mg.
The dialyzed extract was then precipitated using 0.15 to 0.22 g/ml solid polyethylene glycol (mol. wt. 3,350). The pellet resulting after centrifugation at 20,000×g for 30 min. was resuspended in 50 mM Hepes-NaOH, pH 7.0, 1 mM dithiothreitol, 0.5 mM phenylmethylsulfonylfluoride, 10% (v/v) glycerol. This resulted in a 5-fold purification of the acyltransferase activity, i.e., to a specific activity of 3.7×10 -2 nkatal/mg. This preparation was loaded on a DEAE-Sepharose column equilibrated in the same buffer, washed with ten column volumes of buffer, and eluted with a 0 to 250 mM KCl gradient. Acyltransferase activity of each fraction was monitored by enzymatic activity, and the most active fractions, which eluted around 150 mM KCl, were pooled and concentrated by ultrafiltration, yielding a 23-fold purification, i.e., to a specific activity of 0.17 nkatal/mg. The sample was then loaded on a ConA column, and washed with ten volumes of loading buffer. The column was then washed with a 50 mL portion of loading buffer brought to 50 mM α-methyl glucoside. The acyltransferase activity was then eluted with 100 mM α-methyl glucoside. The sample was then dialyzed against 50 mM Hepes-NaOH, pH 7.0 and 10% (v/v) glycerol and concentrated by ultrafiltration, resulting in a 1,274-fold purification of acyltransferase activity, i.e., to a specific activity of 9.4 nkatal/mg. This preparation was then loaded on a Mono P high pressure liquid chromatography chromatofocusing column, from which it eluted at a pH of 4.8, resulting in a 5000-fold overall purification, i.e., to a specific activity of 36 nkatal/mg.
The acyltransferase enzyme product was determined to consist of two subunits of molecular mass 33 kDa and 22 kDa by sodium dodecyl sulfate polyacrylamide gel electrophoresis after the enzyme was prepared under reducing conditions on comparison to migration of proteins of known molecular weight. The standard proteins used to obtain this data were obtained from Sigma Chemical Co. and have molecular weights ranging from 66 to 14.3. These standard proteins and their molecular weights are bovine serum albumin (66 kDa), ovalbumin (45 kDa), glyceraldehyde-3-phosphate dehydrogenase (36 kDa), carbonic anhydrase (29 kDa), trypsinogen (24 kDa), trypsin inhibitor (20 kDa), and α-lactalbumin (14.3 kDa).
Molecular weight of the native enzyme was determined using Sephadex G100 column eluted with 50 mM Hepes-NaOH, pH 7.0 and 10% (v/v) glycerol. Molecular weight markers consisted of aprotinin (6.5 kDa), cytochrome c (12.4 kDa), carbonic anhydrase (29.0 kDa), serum albumin (66.0 kDa), and alcohol dehydrogenase (150 kDa). Under these conditions the acyltransferase exhibited a relative molecular mass of 100 kDa.
The isoelectric point of the enzyme was determined by electrofocusing on a 5% polyacrylamide native gel with a 3.5 to 9 pH gradient. When electrofocusing was complete, the gel was sliced horizontally into 2 mM bands each of which was suspended in H 2 O. The pH of these suspensions was measured directly and an aliquot of each tested for acyltransferase activity. The enzyme was shown to possess a pI of 5.2 under these conditions.
The 5000-fold purified acyltransferase was loaded on SDS-PAGE and electroblotted onto a poly (vinylidene difluoride) membrane following the art described by Matsudaira (Methods in Enzymology 182: 602-613 (1990). The membrane was stained with Ponceau stain and the band containing the enzyme excised and destained in methanol, and resuspended in H 2 O. The destained membrane was treated with trypsin and the resulting proteolytic products separated by high pressure liquid chromatography using a gradient from 0.1% aqueous trifluoroacetic acid to 100% acetonitrile, 0.1% trifluoroacetic acid. Seven of the resulting polypeptides were sufficiently homogeneous to sequence using automated Edman degradation procedures, and were determined respectively to have the sequences of SEQ ID NOS: 1-7.
The assays for enzyme activity in the purification steps were carried out by measuring the disproportionation of 1-O-β-[ 14 C-isobutyryl]glucose to di-, tri-, and tetra-isobutyryl glucose, i.e., the transfer of the [ 14 C]isobutyryl group from 1-O-β-[ 14 C-isobutyryl]glucose to other 1-O-β-[ 14 C-isobutyryl]glucose, in the presence of sample for which enzyme activity was being determined.
Disproportionation activity was measured by intermolecular transfer of the [ 14 C-isobutyryl] moiety from donor 1-O-β-[ 14 C-isobutyryl]-β-D-glucoses to recipient 1-O-β-[ 14 C-isobutyryl]-β-D-glucoses, resulting in formation of higher-order glucose esters of isobutyrate. Reactions were performed in a total volume of 15 μL which contained 50 mM Hepes, pH 7.5, 10 mM dithiothreitol, 1 mM 1-O-[ 14 C-isobutyryl]-β-D-glucose (10 5 cpm), and 1 to 100 ng acyltransferase. The reaction was allowed to proceed at 37° C. for 30 min., and then loaded onto a silica gel thin-layer chromatography plate and eluted in chloroform/methanol/water (75:22:3). The thin-layer plate was then dried, exposed to autoradiographic film, and upon development of the autoradiographic image, the silica gel at regions corresponding to the point of migration of di-, tri-, and tetra-[ 14 C-isobutyryl]-glucose was scraped from the plate, eluted with methanol, and radioactivity quantified by liquid scintillation.
The purified enzyme was tested for activity against the carboxypeptidase substrates carbobenzoxy-phe-ala, carbobenzoxy phe- leu, carbobenzoxy-gly-phe and carbobenzoxy-pro-phe. No activity was detected against any of these substrates.
EXAMPLE II
Isolation of Gene Coding for Acyltransferase from L. pennelli (LA716)
Detached trichomes were obtained from leaves of L. pennelli (LA716) by dry ice abrasion as described in Yerger, E. H., et al., Plant Physiol 99, 1-7 (1992) except that pulverized dry ice was first sieved through a fiberglass screen (1.4 mm 2 mesh). The trichomes were suspended in freshly prepared Tris·HCl, pH 7.0 (buffer)/1 mM MgCl 2 (stabilizer of protein structure and enzymatic activity)/0.1% diethyldithiocarbamate (acts as copper chelator to inhibit polyphenol oxidase)/0.1% dithiothreitol (acts as copper chelator to inhibit polyphenol oxidase and as scavenger of quinones, the reaction product of polyphenol oxidase)/2% polyvinylpolypyrrolidone (inhibitor of polyphenol oxidase; acts as scavenger of phenolics, the substrates for polyphenol oxidase).
Total RNA was extracted from the trichomic suspension and mRNA was purified according to the method described in Hunt, M. D., et al., Plant Molec. Biol. 21, 59-68 (1993).
Acyltransferase gene was cloned following procedures described by Frohman, M. A., et al., Proc. Natl. Acad. Sci. USA 85:8998-9002 (1988), and Loh, E. Y., et al., Science 243:217-220 (1980).
Sequence of an internal fragment of the gene coding for acyltransferase gene was determined as follows:
The purified mRNA was reversed transcribed into cDNA using olig (dT) 15 and reverse transcriptase (Superscript II RNase H-, Gibco-BRL, used with 0.1 μg mRNA in 10 μL reaction according to manufacturer's instructions).
One μL resulting mixture was then used for polymerase chain reaction in a 100 μL reaction mixture containing 10 mM Tris-HCl 8.3, 50 mM KC1, 1.5 mM MgCl 2 , 0.1% (w/v) gelatin, 200 μM dNTPs, 3.2 μM of 20 base primer PT 50 (having the sequence set forth in the Sequence Listing as SEQ ID NO: 11), 1.6 μM primer RE24 (having the Sequence Listing as SEQ ID NO: 12, and 2.5 Units Taq polymerase. In the sequence of SEQ ID NO: 12, N stands for inosine. The primers PT50 and RE24 correspond to the least degenerate two of the seven polypeptides referred to and described in terms of sequences in Example I. Polymerase chain reaction was carried out in 34 cycles of denaturing (92° C., 1 min.), annealing (50° C., 40 sec.), and polymerization (72° C., 1 min.) and one cycle of 72° C., 10 min. The polymerase chain reaction products were analyzed by agarose gel electrophoresis and the major amplification product was excised from the gel, eluted and purified using GeneCleanII nucleic acid clean up kit (available from Bio 101), following the manufacturer's instructions, and ligated into PCRII vector (supplied by Invitrogen) following the ATR cloning method (provided by Invitrogen). DNA sequencing was carried out to verify the amplified fragment as a component of the acyltransferase gene and to identify the sequences corresponding to the tryptic peptides (corresponding to the primers used) obtained from the purified enzyme and to provide sequencing information for primers to obtain the 5' and 3' ends of the acyltransferase gene as described below.
Gene fragment including the 5' end of the gene was then obtained as follows: Aliquot of mixture resulting from the reverse transcription of total purified mRNA was primed with a 20 base pair gene-specific primer having the sequence set forth in the Sequence Listing SEQ ID NO: 13 (based on a portion of the sequence determined as described above for 5' end of middle fragment). The resulting cDNA was dC-tailed at the 5' end and the 5' end was amplified by polymerase chain reaction using a 20 base pair nested primer having the sequence set forth in the Sequence Listing as SEQ ID NO: 14 (based on another portion of the sequence determined as described above for the 5' end of the middle fragment) and an anchor primer having the sequence set forth in the Sequence Listing as SEQ ID NO: 15 (Gibco-BRL catalog #18388-017). In the sequence of SEQ ID NO: 15, N is inosine. The major amplification product is excised and recovered as described above and cloned into pAMP1 (Gibco-BRL), following the manufacturer's instructions, and sequenced.
Next gene fragment including the 3' end of the gene was obtained as follows: cDNA was synthesized from purified mRNA using reverse transcription primed with Oligo (dT) primer attached to an adapter primer. The 3' end of the cDNA was amplified using Gibco-BRL 3' RACE (rapid amplification of cDNA ends) kit. In a first round of amplification, a 20 base pair primer (based on a portion of the sequence determined as described above for the 3' end of the middle fragment) having the sequence set forth in the Sequence Listing as SEQ ID NO: 16, was used. A second round of polymerase chain reaction was then carried out using a 20 base pair nested primer (based on another portion of the sequence determinated as described above for the 3' end of the middle fragment) having the sequence set forth in the Sequence Listing as SEQ ID NO: 17, to enrich the 3' end cDNA fragment. The polymerase chain reaction product was cloned into pAMP1 (Gibco-BRL) following the manufacturer's instructions, and sequenced.
Having cloned and sequenced the 5' and 3' ends of the cDNA, primers were synthesized corresponding to these ends and also incorporating BamHI and EcoRI restriction sites and these were used to amplify the entire acyltransferase gene sequence from the cDNA obtained from purified mRNA. The primers used respectively had the sequence set forth in the Sequence Listing as SEQ ID NO: 18 (includes a BamHI restriction site as the first nine bases of the sequence) and the sequence set forth in the Sequence Listing as SEQ ID NO: 19 (includes an EcoRI restriction site as the first seven bases of the sequence). The amplified entire gene was cloned into the E. coll vector pBluescript (supplied by Stratagene) which was prepared with BamHI and EcoRI and transformed into XL1-Blue E. coli cells (from Stratagene) according to the supplier's instructions, for sequencing.
The gene was sequenced by automatic DNA sequencing and was determined to have the sequence set forth in the Sequence Listing as SEQ ID NO: 9.
EXAMPLE III
Transformation of Gene Coding for Acyltransferase into S. cerevisiae and Induction of Expression of Acyltransferase
A. Construction of Expression Clone pYAGT2 by Inserting Entire Acyltransferase cDNA Seauence into the Saccharomyces cerevisiae Expression Vector pYES2, to Generate Plasmid pYAGT2
Oligonucleotide primers corresponding to the acyltransferase 5' and 3' ends and incorporating BamHI and EcoRI restriction sites were used to amplify the gene (isolated in Example II) directly from the cDNA by polymerase chain reaction. The primers respectively have the sequences set forth in the Sequence Listing as SEQ ID NO: 18 and as SEQ ID NO: 19. After purification and treatment with BamHI and EcoRI, the gene was ligated, using T4 DNA ligase, to the Saccharomyces cerevisiae expression vector pYES2 (Invitrogen), which was prepared by the same restriction enzymes. The resulting plasmid was designated pYAGT2. To verify that correct gene was ligated, the ligation reaction was transformed into XL-1Blue E. coli cells, and the correctly ligated products from transformants were verified by DNA sequencing. The plasmid pYAGT2 was deposited with the American Type Culture Collection, 12301 Parklawn Drive, Rockville, Md. 20852 on Jun. 15, 1996 under the terms of the Budapest Treaty and has been assigned accession number ATCC 97613.
B. Transforming pYAGT2 into S. cerevisiae
S. cerevisiae strain KT1115 (MATa leu2-3 leu2-112 ura-52) is used as the recipient cell type for pYES2 transformation following the procedures described by Gietz, D., et al., Nucleic Acids Research 20:1425 (1992). Uracil dropout medium (Short Protocols in Molecular Biology, A Compendium of Methods from Current Protocols in Molecular Biology, Ausubel, F. M., et al., editors, 2nd Edition, Green Publishing Associates and John Wiley and Sons, New York, 1992) was used as selective medium.
C. Induction of Expression of Protein Encoded by the Recombinant Plasmid
Baffled flasks were used to grow yeast cultures for the expression of the L. pennelli acyltransferase. Transformed yeast cells were inoculated in uracil dropout medium (with 5% (w/v) raffinose instead of 2% (w/v) glucose), until OD 600 reached 0.4 to 0.5. Galactose was then added to a final concentration of 2% (w/v) to induce expression of the protein. 10 mL samples were collected at 4, 8, 24 and 48 hours after the addition of galactose.
D. Determination of Expressed Protein as Being Acyltransferase
Induced cells were centrifuged, washed with cold H 2 O and then with cold FT buffer, i.e., freeze and thaw buffer: 100 mM Hepes, pH 7.5, 20% (v/v) glycerol, 0.1% (v/v) Triton X-100). The pelleted cells were resuspended in an equal volume of cold FT buffer and frozen at -80° C. overnight or longer. For assay for activity, the permeabilized cells were thawed quickly at 30° C. and an aliquot removed as described by Miozzari (Miozzari, G. F., et al., Analytical Biochemistry 90:220-233 (1978)). When 10 mL of cells were removed for assay under standard conditions for measurement of acyltransferase activity using 1-O-[ 14 C-isobutyryl]-β-glucose as described above, S. cerevisiae cells transformed with only the pYES2 vector do not possess detectable acyltransferase activity giving rise to higher-order glucose esters at any time-point after induction with galactose. However, S. cerevisiae cells harboring the pYAGT2 plasmid containing the acyltransferase gene exhibited the ability to form higher-order esters at 4, 8 and 24 hours after induction with galactose showing acyltransferase activity was expressed. Highest activity was found 24 hours after induction, and activity at 48 hours was slightly lower than at 24 hours.
EXAMPLE IV
Preparation of Monopalmitoyl Glucose from 1-O-Palmitoyl-β-D-glucose and Glucose
Tetrabenzylglucose (1.8 g, 3.3 mmol), Pfanstiehl Chemical Co., was reacted with palmitoyl chloride (Sigma Chemical Co.) in dry benzene at 62° C. and deprotected by the procedure of Pfeffer, P. E., et al., J. Org. Chem. 41, 2925-2927 (1976), to produce 1-O-palmitoyl-β-D-glucose.
A reaction mix was made up containing 2 mM 1-O-palmitoyl-β-D-glucose, 40 μM [U- 14 C] glucose (2×10 5 cpm) and 1 mg/ml of acyltransferase protein (specific activity of 4×10 -2 nanokatals mg -1 ) in 15 μl of a mixture of 50 mm Hepes-NaOH, pH 7.0 (buffer), 10 mM MgCl 2 (stabilizer of protein structure and enzymymatic activity), and 10 mM dithiothreitol (inhibitor of polyphenol oxidase; acts as copper chelator and as scavenger of quinones, the reaction product of polyphenol oxidase; also promotes higher order esterification presumably by maintaining essential Cys residues of the acyltransferase in reduced form) and incubation was carried out at 37° C. Reaction progress was monitored by TLC as described in Ghangas, G. S. et al., Proc. Natl. Acad. Sci. USA 90, 9911-9915 (1993). The % cpm in monoacyl-[ 14 C] glucose was 2.3 after 1 hour, 4.4 after 2 hours and 4.7 after 3 hours.
When 1-O-isobutyryl-β-D-glucose was substituted for the 1-O-palmitoyl-β-D-glucose, the % cpm in monoacyl-[ 14 C] glucose was 3.08 after 1 hour, 5.80 after 2 hours, and 6.20 after 3 hours.
EXAMPLE V
Preparation of Dipalmitoyl Glucose from 1-O-palmitoyl-β-D-glucose
1-O-Palmitoyl-β-D-glucose (0.1 mM) and 80 μM [U- 14 C] glucose (2×10 7 cpm) were incubated with 1 mg acyltransferase (specific activity of about 0.037 nanokatals mg -1 ) from L. pennelli in 0.5 ml 50 mM sodium Pi, pH 6.5, for 2 hours at 42° C. The reaction was stopped by addition of 1 ml of chilled ethanol, and after centrifugation, the supernatant was recovered, concentrated, and applied to a preparative TLC plate to isolate the 1-O-palmitoyl-β-D-[ 14 C-glucose] band.
Reaction mix was made up containing 3×10 4 cpm 1-O-palmitoyl-β-D-[ 14 C-glucose], 50 mM Hepes-NaOH, pH 7.0, 10 mM dithiothreitol (inhibits oxidation browning), 10 mM MgCl 2 (protein structure stabilizer) and acyltransferase (3.6 mg/mL protein; specific activity of about 0.037 nanokatal mg -1 ) from L. pennelli in 15 μl were incubated at 37° C. The products were separated and monitored by TLC as described in Ghangas, G. S., et al., Proc. Natl. Acad. Sci. USA 90, 9911-9915 (1993). The percent of total cpm in [ 14 C] glucose by-product was 40% indicating that the disproportion reaction had occurred to provide dipalmitoyl glucose.
When 1-O-isobutyryl-β-D-glucose was substituted for the 1-O-palmitoyl-β-D-glucose, the percent of total cpm in [ 14 C] glucose by-product was 44.8% indicating that the disproportion reaction had occurred to provide diisobutyryl glucose.
EXAMPLE VI
Preparation of Tripalmitoyl Glucose from 1-O-Palmitoyl-β-D-glucose
A 15 μL reaction containing 1-O-palmitoyl-β-D-glucose (1 mM), [U- 14 C]-glucose (2×10 5 cpm), and 2.5 mg L. pennelli LA716 crude leaf extract protein/ml in 100 mM sodium phosphate pH 6.5 was incubated for 28 hr at 37° C. The products were separated and monitored by TLC as described in Ghangas G S and Steffens J C, Proc. Natl. Acad. Sci. USA 90:9911-9915 (November, 1993). The percent of total cpm converted to tripalmitoylglucose was equivalent to 8 pmol. Formation of mono- and dipalmitoylglucose in the same reaction was 2660 and 459 pmol, respectively. Under the same conditions 1-O-isobutyryl-β-D-glucose yielded 3410, 34 and 14 pmol mono-, di- and triisobutryrylglucose, respectively.
Variations in the invention will be obvious to those skilled in the art. Therefore, the invention is defined by the claims.
__________________________________________________________________________# SEQUENCE LISTING - - - - (1) GENERAL INFORMATION: - - (iii) NUMBER OF SEQUENCES: 19 - - - - (2) INFORMATION FOR SEQ ID NO:1: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 12 amino - #acids (B) TYPE: amino acid (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: peptide - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:1: - - Glu His Phe Ile Val Glu Thr Leu Pro Gly Ph - #e His 1 5 - # 10 - - - - (2) INFORMATION FOR SEQ ID NO:2: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 8 amino - #acids (B) TYPE: amino acid (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: peptide - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:2: - - Leu Glu Leu Asn Ser Tyr Ser Trp 1 5 - - - - (2) INFORMATION FOR SEQ ID NO:3: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 11 amino - #acids (B) TYPE: amino acid (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: peptide - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:3: - - Ile Tyr Asp Gly Ile Glu Val Gly Asp Arg Pr - #o 1 5 - # 10 - - - - (2) INFORMATION FOR SEQ ID NO:4: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 11 amino - #acids (B) TYPE: amino acid (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: peptide - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:4: - - Gly Tyr Ile Gln Gly Asn Ala Leu Thr Asp Ar - #g 1 5 - # 10 - - - - (2) INFORMATION FOR SEQ ID NO:5: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 7 amino - #acids (B) TYPE: amino acid (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: peptide - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:5: - - Ser Ile Asp Phe Asn Gly Arg 1 5 - - - - (2) INFORMATION FOR SEQ ID NO:6: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 11 amino - #acids (B) TYPE: amino acid (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: peptide - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:6: - - Tyr Ala Asn His Met Gly Leu Ile Ser Asp Ly - #s 1 5 - # 10 - - - - (2) INFORMATION FOR SEQ ID NO:7: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 17 amino - #acids (B) TYPE: amino acid (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: peptide - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:7: - - Asn Gly Asn Tyr Ile Asp Val Asp Pro Asn As - #n Ile Leu Leu LeuAsn 1 5 - # 10 - # 15 - - Asp - - - - (2) INFORMATION FOR SEQ ID NO:8: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 179 amino - #acids (B) TYPE: amino acid (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: peptide - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:8: - - Glu His Phe Ile Val Glu Thr Leu Pro Gly Ph - #e His Gly Lys Leu Pro 1 5 - # 10 - # 15 - - Phe Leu Thr Glu Thr Gly Thr Ile Ser Val Gl - #y Glu Glu Glu Lys Val 20 - # 25 - # 30 - - Gln Leu Phe Tyr Phe Phe Val Gln Ser Glu Ar - #g Asp Pro Arg Asn Asp 35 - # 40 - # 45 - - Pro Leu Met Ile Trp Leu Thr Gly Gly Pro Gl - #y Cys Ser Gly Leu Ser50 - # 55 - # 60 - - Ser Leu Val Tyr Glu Ile Gly Pro Leu Thr Ph - #e Asp Tyr Ala Asn Ser 65 - #70 - #75 - #80 - - Ser Gly Asn Phe Pro Lys Leu Glu Leu Asn Se - #r Tyr Ser Tyr Thr Lys 85 - # 90 - # 95 - - Val Ala Asn Ile Ile Phe Ile Asp Gln Pro Al - #a Gly Thr Gly Tyr Ser 100 - # 105 - # 110 - - Tyr Ala Asn Thr Ser Glu Ala Tyr Asn Cys As - #n Asp Thr Leu Ser Val 115 - # 120 - # 125 - - Thr Leu Thr Tyr Asp Phe Leu Arg Lys Trp Le - #u Met Asp His Pro Glu130 - # 135 - # 140 - - Tyr Leu Asn Asn Pro Leu Tyr Val Gly Gly As - #p Ser Tyr Ser Gly Ile 145 1 - #50 1 - #55 1 -#60 - - Phe Val Ala Leu Leu Thr Arg Lys Ile Tyr As - #p Gly Ile Glu ValGly 165 - # 170 - # 175 - - Asp Arg Pro - - - - (2) INFORMATION FOR SEQ ID NO:9: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 1604 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: double (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: cDNA - - (ix) FEATURE: (A) NAME/KEY: CDS (B) LOCATION: 55..1392 - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:9: - - ATGGCGCGGG TCACACTGTT TCTATTGCTG CTACTTGTAT ACGGTGTAGT CT - #CC GAG 57 - # - # - # Glu - # - # - # 1 - - CAC TTC ATT GTT GAA ACT CTT CCT GGG TTT CA - #T GGA AAA CTT CCA TTT105 His Phe Ile Val Glu Thr Leu Pro Gly Phe Hi - #s Gly Lys Leu Pro Phe 5 - # 10 - # 15 - - ACA CTC GAA ACT GGT TAT ATT AGT GTT GGA GA - #A GAG GAA AAA GTG CAG153 Thr Leu Glu Thr Gly Tyr Ile Ser Val Gly Gl - #u Glu Glu Lys Val Gln 20 - # 25 - # 30 - - CTA TTT TAT TTC TTT GTA CAA TCT GAG AGA GA - #C CCA CGA AAT GAT CCT201 Leu Phe Tyr Phe Phe Val Gln Ser Glu Arg As - #p Pro Arg Asn Asp Pro 35 - # 40 - # 45 - - CTC ATG ATT TGG CTC ACC GGA GGT CCT GGT TG - #T TCT GGT CTG TCT TCC249 Leu Met Ile Trp Leu Thr Gly Gly Pro Gly Cy - #s Ser Gly Leu Ser Ser 50 - # 55 - # 60 - # 65 - - TTA GTA TAT GAA ATT GGC CCT TTA ACC TTT GA - #T TAT GCA AAT TCT AGT297 Leu Val Tyr Glu Ile Gly Pro Leu Thr Phe As - #p Tyr Ala Asn Ser Ser 70 - # 75 - # 80 - - GGA AAT TTC CCG AAA CTG GAG TTG AAC TCA TA - #T TCT TGG ACC AAG GTG345 Gly Asn Phe Pro Lys Leu Glu Leu Asn Ser Ty - #r Ser Trp Thr Lys Val 85 - # 90 - # 95 - - GCA AAC ATA ATA TTT ATA GAT CAA CCT GCT GG - #C ACA GGC TAC TCA TAT393 Ala Asn Ile Ile Phe Ile Asp Gln Pro Ala Gl - #y Thr Gly Tyr Ser Tyr 100 - # 105 - # 110 - - GCA AAC ACT TCA GAA GCT TAC AAC TGC AAT GA - #T ACC CTC TCT GTA ACT441 Ala Asn Thr Ser Glu Ala Tyr Asn Cys Asn As - #p Thr Leu Ser Val Thr115 - # 120 - # 125 - - CTA ACT TAT GAC TTC CTT AGA AAG TGG CTT AT - #G GAT CAT CCC GAG TAT489 Leu Thr Tyr Asp Phe Leu Arg Lys Trp Leu Me - #t Asp His Pro Glu Tyr 130 1 - #35 1 - #40 1 -#45 - - CTC AAC AAT CCA CTA TAT GTT GGT GGT GAT TC - #C TAC TCA GGC ATTTTT 537 Leu Asn Asn Pro Leu Tyr Val Gly Gly Asp Se - #r Tyr Ser Gly Ile Phe 150 - # 155 - # 160 - - GTT GCA CTG CTT ACT CGC AAA ATA TAC GAT GG - #T ATT GAA GTT GGT GAC585 Val Ala Leu Leu Thr Arg Lys Ile Tyr Asp Gl - #y Ile Glu Val Gly Asp 165 - # 170 - # 175 - - AGG CCT CGA GTT ATT ATC AAA GGA TAT TTC CA - #A GGA AAT GCT CTA ACA633 Arg Pro Arg Val Ile Ile Lys Gly Tyr Phe Gl - #n Gly Asn Ala Leu Thr 180 - # 185 - # 190 - - GAT AGA TCC ATC GAC TTC AAT GGT AGA GTC AA - #A TAT GCT AAT CAT ATG681 Asp Arg Ser Ile Asp Phe Asn Gly Arg Val Ly - #s Tyr Ala Asn His Met195 - # 200 - # 205 - - GGA CTT ATT TCA GAT AAG ATC TAT CAG TCT GC - #T AAA GCA AAT TGC AAC729 Gly Leu Ile Ser Asp Lys Ile Tyr Gln Ser Al - #a Lys Ala Asn Cys Asn 210 2 - #15 2 - #20 2 -#25 - - GGG AAT TAC ATT GAC GTT GAT CCA AAT AAC AT - #A TTA TGC CTA AATGAT 777 Gly Asn Tyr Ile Asp Val Asp Pro Asn Asn Il - #e Leu Cys Leu Asn Asp 230 - # 235 - # 240 - - CTT CAG AAA GTA ACA AGG TGT CTC AAG AAC AT - #A CGA CGG GCG CAA ATT825 Leu Gln Lys Val Thr Arg Cys Leu Lys Asn Il - #e Arg Arg Ala Gln Ile 245 - # 250 - # 255 - - TTA GAG CCT TAC TGT GAC CTT CCA TAT TTA AT - #G GGT ATT CTC CAA GAA873 Leu Glu Pro Tyr Cys Asp Leu Pro Tyr Leu Me - #t Gly Ile Leu Gln Glu 260 - # 265 - # 270 - - ACT CCT ACA AAT GGC CAG TCA GTA TTT CCA AT - #T GCA GGA CCA TGG TGT921 Thr Pro Thr Asn Gly Gln Ser Val Phe Pro Il - #e Ala Gly Pro Trp Cys275 - # 280 - # 285 - - CGA GAA AAG AAT TAC ATA TAC TCG TAT GTT TG - #G GCA AAT GAT AAA GCT969 Arg Glu Lys Asn Tyr Ile Tyr Ser Tyr Val Tr - #p Ala Asn Asp Lys Ala 290 2 - #95 3 - #00 3 -#05 - - GTC CAG AAA GCA CTA AGC GTT CGT GAG GGA AC - #A ACA TTG GAG TGGGTG 1017 Val Gln Lys Ala Leu Ser Val Arg Glu Gly Th - #r Thr Leu Glu Trp Val 310 - # 315 - # 320 - - AGA TGC AAT GAA AGC ATG CAT TAT AGA GGT AA - #G GAG AGA ACC GAG TCA 1065 Arg Cys Asn Glu Ser Met His Tyr Arg Gly Ly - #s Glu Arg Thr Glu Ser 325 - # 330 - # 335 - - TAT GTG TAT GAT GTC CCA AGT GTC ATT GAT GA - #T CAT CAA CAT CTC ACC 1113 Tyr Val Tyr Asp Val Pro Ser Val Ile Asp As - #p His Gln His Leu Thr 340 - # 345 - # 350 - - AGC AAA TCC TGT CGA GCA CTA ATT TAC AGT GG - #T GAC CAT GAC ATG GTT 1161 Ser Lys Ser Cys Arg Ala Leu Ile Tyr Ser Gl - #y Asp His Asp Met Val355 - # 360 - # 365 - - GTT CCT CAT TTG AGC ACG GAG GAA TGG ATA GA - #G ACT TTG AAA CTT CCA 1209 Val Pro His Leu Ser Thr Glu Glu Trp Ile Gl - #u Thr Leu Lys Leu Pro 370 3 - #75 3 - #80 3 -#85 - - ATT GCA GAT GAT TGG GAG CCT TGG TTT GTT GA - #C GAT CAA GTA GCAGGA 1257 Ile Ala Asp Asp Trp Glu Pro Trp Phe Val As - #p Asp Gln Val Ala Gly 390 - # 395 - # 400 - - TAC AAA GTG AAG TAT TTA CAA AAT GAT TAT GA - #A ATG ACA TAT GCA ACT 1305 Tyr Lys Val Lys Tyr Leu Gln Asn Asp Tyr Gl - #u Met Thr Tyr Ala Thr 405 - # 410 - # 415 - - GTT AAG GGT GCG GGG CAT ACT GCT CCT GAA TA - #C AAG CCA GAA CAA TGC 1353 Val Lys Gly Ala Gly His Thr Ala Pro Glu Ty - #r Lys Pro Glu Gln Cys 420 - # 425 - # 430 - - CTG CCC ATG GTT GAT AGG TGG TTT TCC GGT GA - #C CCT CTT TGATTTCACC 1402 Leu Pro Met Val Asp Arg Trp Phe Ser Gly As - #p Pro Leu435 - # 440 - # 445 - - CTTGCAAGAC ATTAATGTAC TCATTTGTTT CTCTGGATTG ACATAAGCTT GC -#TTCTTTGA 1462 - - GCAACATCAC ATTAAGCTTG TCTGTCATGT AATCTTGACA TGTAAAATCA CA -#CATTAAAA 1522 - - AGTATATATC ATTCGAGGTT GACGTTAAAA AAAAAAAAAA AAAAAAAAAA AA -#AAAAAAAA 1582 - - AAAAAAAAAA AAAAAAAAAA AA - # - # 1604 - - - - (2) INFORMATION FOR SEQ ID NO:10: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 446 amino - #acids (B) TYPE: amino acid (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: protein - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:10: - - Glu His Phe Ile Val Glu Thr Leu Pro Gly Ph - #e His Gly Lys Leu Pro 1 5 - # 10 - # 15 - - Phe Thr Leu Glu Thr Gly Tyr Ile Ser Val Gl - #y Glu Glu Glu Lys Val 20 - # 25 - # 30 - - Gln Leu Phe Tyr Phe Phe Val Gln Ser Glu Ar - #g Asp Pro Arg Asn Asp 35 - # 40 - # 45 - - Pro Leu Met Ile Trp Leu Thr Gly Gly Pro Gl - #y Cys Ser Gly Leu Ser 50 - # 55 - # 60 - - Ser Leu Val Tyr Glu Ile Gly Pro Leu Thr Ph - #e Asp Tyr Ala Asn Ser 65 - # 70 - # 75 - # 80 - - Ser Gly Asn Phe Pro Lys Leu Glu Leu Asn Se - #r Tyr Ser Trp Thr Lys 85 - # 90 - # 95 - - Val Ala Asn Ile Ile Phe Ile Asp Gln Pro Al - #a Gly Thr Gly Tyr Ser 100 - # 105 - # 110 - - Tyr Ala Asn Thr Ser Glu Ala Tyr Asn Cys As - #n Asp Thr Leu Ser Val 115 - # 120 - # 125 - - Thr Leu Thr Tyr Asp Phe Leu Arg Lys Trp Le - #u Met Asp His Pro Glu130 - # 135 - # 140 - - Tyr Leu Asn Asn Pro Leu Tyr Val Gly Gly As - #p Ser Tyr Ser Gly Ile 145 1 - #50 1 - #55 1 -#60 - - Phe Val Ala Leu Leu Thr Arg Lys Ile Tyr As - #p Gly Ile Glu ValGly 165 - # 170 - # 175 - - Asp Arg Pro Arg Val Ile Ile Lys Gly Tyr Ph - #e Gln Gly Asn Ala Leu 180 - # 185 - # 190 - - Thr Asp Arg Ser Ile Asp Phe Asn Gly Arg Va - #l Lys Tyr Ala Asn His 195 - # 200 - # 205 - - Met Gly Leu Ile Ser Asp Lys Ile Tyr Gln Se - #r Ala Lys Ala Asn Cys210 - # 215 - # 220 - - Asn Gly Asn Tyr Ile Asp Val Asp Pro Asn As - #n Ile Leu Cys Leu Asn 225 2 - #30 2 - #35 2 -#40 - - Asp Leu Gln Lys Val Thr Arg Cys Leu Lys As - #n Ile Arg Arg AlaGln 245 - # 250 - # 255 - - Ile Leu Glu Pro Tyr Cys Asp Leu Pro Tyr Le - #u Met Gly Ile Leu Gln 260 - # 265 - # 270 - - Glu Thr Pro Thr Asn Gly Gln Ser Val Phe Pr - #o Ile Ala Gly Pro Trp 275 - # 280 - # 285 - - Cys Arg Glu Lys Asn Tyr Ile Tyr Ser Tyr Va - #l Trp Ala Asn Asp Lys290 - # 295 - # 300 - - Ala Val Gln Lys Ala Leu Ser Val Arg Glu Gl - #y Thr Thr Leu Glu Trp 305 3 - #10 3 - #15 3 -#20 - - Val Arg Cys Asn Glu Ser Met His Tyr Arg Gl - #y Lys Glu Arg ThrGlu 325 - # 330 - # 335 - - Ser Tyr Val Tyr Asp Val Pro Ser Val Ile As - #p Asp His Gln His Leu 340 - # 345 - # 350 - - Thr Ser Lys Ser Cys Arg Ala Leu Ile Tyr Se - #r Gly Asp His Asp Met 355 - # 360 - # 365 - - Val Val Pro His Leu Ser Thr Glu Glu Trp Il - #e Glu Thr Leu Lys Leu370 - # 375 - # 380 - - Pro Ile Ala Asp Asp Trp Glu Pro Trp Phe Va - #l Asp Asp Gln Val Ala 385 3 - #90 3 - #95 4 -#00 - - Gly Tyr Lys Val Lys Tyr Leu Gln Asn Asp Ty - #r Glu Met Thr TyrAla 405 - # 410 - # 415 - - Thr Val Lys Gly Ala Gly His Thr Ala Pro Gl - #u Tyr Lys Pro Glu Gln 420 - # 425 - # 430 - - Cys Leu Pro Met Val Asp Arg Trp Phe Ser Gl - #y Asp Pro Leu 435 - # 440 - # 445 - - - - (2) INFORMATION FOR SEQ ID NO:11: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 20 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: cDNA - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:11: - - GARCAYTTYA TYGTKGARAC - # - # - # 20 - - - - (2) INFORMATION FOR SEQ ID NO:12: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 20 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: cDNA - - (ix) FEATURE: (A) NAME/KEY: misc.sub.-- - #feature (B) LOCATION: 3 (D) OTHER INFORMATION: - #/note= "N is inosine" - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:12: - - ARNCCCATRT GRTTWGCRTA - # - # - # 20 - - - - (2) INFORMATION FOR SEQ ID NO:13: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 20 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: cDNA - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:13: - - ATCTGTTAGA GCATTGCCTT - # - # - # 20 - - - - (2) INFORMATION FOR SEQ ID NO:14: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 20 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: cDNA - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:14: - - GCCTGTCACC AACTTCAATA - # - # - # 20 - - - - (2) INFORMATION FOR SEQ ID NO:15: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 48 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: cDNA - - (ix) FEATURE: (A) NAME/KEY: misc.sub.-- - #feature (B) LOCATION: 36 (D) OTHER INFORMATION: - #/note= "N is inosine" - - (ix) FEATURE: (A) NAME/KEY: misc.sub.-- - #feature (B) LOCATION: 37 (D) OTHER INFORMATION: - #/note= "N is inosine" - - (ix) FEATURE: (A) NAME/KEY: misc.sub.-- - #feature (B) LOCATION: 41 (D) OTHER INFORMATION: - #/note= "N is inosine" - - (ix) FEATURE: (A) NAME/KEY: misc.sub.-- - #feature (B) LOCATION: 42 (D) OTHER INFORMATION: - #/note= "N is inosine" - - (ix) FEATURE: (A) NAME/KEY: misc.sub.-- - #feature (B) LOCATION: 46 (D) OTHER INFORMATION: - #/note= "N is inosine" - - (ix) FEATURE: (A) NAME/KEY: misc.sub.-- - #feature (B) LOCATION: 47 (D) OTHER INFORMATION: - #/note= "N is inosine" - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:15: - - CUACUACUAC UAGGCCACGC GTCGACTAGT ACGGGNNGGG NNGGGNNG - #48 - - - - (2) INFORMATION FOR SEQ ID NO:16: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 20 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: cDNA - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:16: - - GTTGGAGAAG AGGAAAAAGT - # - # - # 20 - - - - (2) INFORMATION FOR SEQ ID NO:17: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 20 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: cDNA - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:17: - - TACAATCTGA GAGAGACCCA - # - # - # 20 - - - - (2) INFORMATION FOR SEQ ID NO:18: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 29 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: cDNA - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:18: - - AAGGATCCAA TGGCGCGGGT CACACTGTT - # - # 29 - - - - (2) INFORMATION FOR SEQ ID NO:19: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 27 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: cDNA - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:19: - - AGAATTCTTA ACGTCAACCT CGAATGA - # - # 27__________________________________________________________________________
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Essentially pure acyltransferase is provided which is functional to catalyze reaction to form sugar esters. Also provided is isolated gene encoding acyltransferase. Additionally provided is method for forming palmityl esters of glucose comprising reacting 1-O-palmitoyl-β-D-glucose with itself, with glucose or with palmityl partial ester of glucose in the presence of a catalytically effective amount of acyltransferase.
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BACKGROUND OF THE INVENTION
[0001] The present disclosure relates generally to integrated gasification combined-cycle (IGCC) power generation systems, and more specifically to turbine power generation systems incorporating fuels generated from biomass materials.
[0002] At least some known IGCC systems include a gasification system that is integrated with at least one power producing turbine system. Many of these IGCC systems incorporate a gasifier that creates a combustible gas, or a combustible gas precursor, which undergoes further processing into a combustible gas (referred to as “syngas”). Such IGCC systems often further incorporate a gas turbine in which the syngas is combusted and/or which is driven by the combustion byproducts of the burning of the syngas.
[0003] A desirable source of syngas or syngas precursor feedstock is biomass material, as the use of biomass material reduces dependency on other sources of syngas feedstock, such as fossil fuel-based feedstocks like coal, coke, etc. However, the use of biomass material as a feedstock for syngas presents challenges for a number of reasons. Syngas produced from biomass material typically is contaminated with tar, ash, particulates or other contaminants, which contaminants are potentially damaging to the internal components of gas turbine engines. Furthermore, in order to be burned in a gas turbine engine, syngas typically must be compressed and/or cooled prior to injection into the gas turbine engine. Compression of the syngas requires expenditure of energy, thus lowering the efficiency of the IGCC system. Cooling of the syngas, typically by water scrubbing, likewise requires expenditure of energy, with a corresponding loss of efficiency.
[0004] Accordingly, it would be desirable to provide an IGCC powerplant system and method that uses biomass material as a feedstock for the production of syngas to take advantage of the benefits of deriving power from biomass material, including the reduction in dependency on fossil fuel-based feedstocks. It would also be desirable to provide an IGCC powerplant system and method that is fueled by syngas that has improved efficiency by reducing or eliminating the need for compression or cooling of the syngas.
BRIEF DESCRIPTION OF THE INVENTION
[0005] In one aspect, a power generation system for use in generating power from biomass feedstock is provided. The power generation system includes a biomass conversion reactor coupled to a source of biomass feedstock, the biomass conversion reactor configured to produce syngas. The power generation system also includes a combustor coupled to the biomass conversion reactor. The power generation system also includes a first heat exchanger element coupled in the combustor in flow communication with a source of working fluid that receives heat from combustion of syngas while the working fluid flows through the first heat exchanger element, wherein the working fluid is isolated from the syngas and from products of combustion. The power generation system also includes a turbine coupled in flow communication downstream from the first heat exchanger element, the turbine driven by the heated working fluid.
[0006] In another aspect, a method for generating power from biomass feedstock is provided. The method includes channeling biomass feedstock from a source of biomass feedstock to a biomass conversion reactor coupled to the source of biomass feedstock. The method also includes converting the biomass feedstock into syngas. The method also includes channeling the syngas to a combustor coupled to the biomass conversion reactor. The method also includes channeling working fluid from a source of working fluid through a first heat exchanger element coupled in the combustor. The method also includes transferring heat from combustion of the syngas into the working fluid while the working fluid flows through the first heat exchanger element, such that the working fluid is isolated from the syngas and from products of combustion. The method also includes channeling the heated working fluid to a turbine coupled in flow communication downstream from the first heat exchanger element, the turbine driven by the heated working fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic diagram of an exemplary system for generating power using biomass-generated syngas.
[0008] FIG. 2 is a schematic diagram of another exemplary system for generating power using biomass-generated syngas.
[0009] FIG. 3 is a schematic diagram of another exemplary system for generating power using biomass-generated syngas.
[0010] FIG. 4 is a schematic diagram of another exemplary system for generating power using biomass-generated syngas.
DETAILED DESCRIPTION OF THE INVENTION
[0011] Although specific features of various exemplary embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.
[0012] FIG. 1 is a schematic diagram of an exemplary system 100 for generating power using biomass-generated syngas. System 100 includes a biomass dryer 102 , which receives biomass from a source 104 . A biomass conversion reactor 106 receives dried biomass 108 from biomass dryer 102 . Biomass conversion reactor 106 may be any suitable device that may be used to convert biomass into a syngas that will enable the systems described herein to function as described. For example, biomass conversion reactor 106 may be a biomass gasifier or a steam-biomass reformer. Biomass conversion reactor 106 discharges a syngas 110 . Syngas 110 is comprised chiefly of hydrogen (H 2 ), carbon dioxide (CO 2 ) and carbon monoxide (CO). Syngas 110 is channeled into an external combustor 112 , where syngas 110 is combusted with air 114 (typically ambient air) supplied by a blower 116 . In an alternative embodiment, a compressor (not shown) may be used in place of blower 116 . External combustor 112 discharges an external combustor exhaust 136 , which is channeled through an exhaust gas cleanup device 135 . External combustor 112 includes a heat exchanger element 118 , which is coupled in flow communication with a compressor 120 and a turbine 122 . Compressor 120 is rotationally coupled to turbine 122 by a transmission structure 132 . System 100 further includes an electrical generator 124 , which is rotationally coupled to turbine 122 by a transmission structure 123 .
[0013] Ambient air 126 is channeled into compressor 120 , which discharges a compressed air 128 , which is, in turn, channeled into external combustor 112 . External combustor 112 discharges a heated compressed air 130 , which is channeled to turbine 122 , and subsequently discharged from turbine 122 as a turbine exhaust 134 . Heated compressed air 130 is expanded in turbine 122 , causing rotation of turbine 122 , and in turn, rotation of electrical generator 124 . Turbine exhaust 134 is combined with external combustor exhaust 136 to supply exhaust gases 138 for biomass dryer 102 . After flowing through a heat exchanger 140 , cooled gases 142 are then discharged through a vent 144 coupled to biomass dryer 102 to be released to atmosphere, or to be channeled to such additional gas cleaning equipment (not shown) as may be required.
[0014] In system 100 , syngas 110 and external combustor exhaust 136 are isolated from compressor 120 and turbine 122 . Accordingly, compressor 120 and turbine 122 are protected from the damaging effects of tar, ash and other particulates, and other contaminants found in biomass-generated syngas and the combustion products therefrom. In addition, biomass-generated syngas 110 is channeled to external combustor 112 , without the requirement for any specific provisions for cooling or contaminant removal.
[0015] FIG. 2 is a schematic diagram of an alternative exemplary system 200 for generating power using biomass-generated syngas. System 200 includes a biomass dryer 202 , which receives biomass from a source 204 . A biomass conversion reactor 206 receives dried biomass 208 from biomass dryer 202 and discharges a syngas 210 . Biomass conversion reactor 206 also includes a heat exchanger element 250 , which is coupled in flow communication with a compressor 220 and with a turbine 222 . Syngas 210 is channeled into an external combustor 212 , where syngas 210 is combusted with air 214 (typically ambient air) supplied by a blower 216 . In an alternative embodiment, a compressor (not shown) may be used in place of blower 216 . External combustor 212 discharges an external combustor exhaust 236 . External combustor 212 includes a heat exchanger element 218 , which is coupled in flow communication with compressor 220 , heat exchanger element 250 , and turbine 222 . Compressor 220 is rotationally coupled to turbine 222 by a transmission structure 232 . An electrical generator 224 is rotationally coupled to turbine 222 by a transmission structure 223 .
[0016] Ambient air 226 is channeled into compressor 220 , which discharges a compressed air 228 , which in turn is channeled into biomass conversion reactor 206 . Specifically, compressed air 228 is channeled through heat exchanger element 250 in the biomass conversion reactor 206 , acquiring heat released during the gasification process. Biomass conversion reactor 206 discharges a heated compressed air 229 , which is channeled to external combustor 212 , where heated compressed air 229 acquires further heat while flowing through heat exchanger element 218 .
[0017] Heat from the combustion of syngas 210 is transferred to heated compressed air 229 , resulting in a further heated compressed air 230 . Further heated compressed air 230 is channeled to turbine 222 and expanded, causing rotation of turbine 222 , and in turn, rotation of electrical generator 224 . Turbine 222 discharges a turbine exhaust 234 . External combustor 212 is coupled in flow communication with heat exchanger 252 . External combustor exhaust 236 is channeled to heat exchanger 252 to release heat to a boiler feed water 254 , creating a heated boiler feed water 255 . External combustor exhaust 236 is then channeled to an exhaust gas cleanup device 235 . Heated boiler feed water 255 is channeled to a heat exchanger 256 coupled in flow communication with turbine 222 , where heated boiler feed water 255 acquires further heat from turbine exhaust 234 , and is converted into a steam 258 . Steam 258 , in turn, is then channeled to a steam turbine (not shown) to generate further electrical or mechanical power, or is exported for other purposes. Turbine exhaust 234 and external combustor exhaust 236 are combined to supply exhaust gases 238 , which are channeled through a heat exchanger 240 coupled to biomass dryer 202 . Afterward, cooled gases 242 are discharged through a vent 244 coupled to biomass dryer 202 to be released to atmosphere.
[0018] Similarly to system 100 described herein, in system 200 , syngas 210 and external combustor exhaust 236 are isolated from compressor 220 and turbine 222 . Accordingly, compressor 220 and turbine 222 are protected from the damaging effects of tar, ash and other particulates, and other contaminants found in biomass-generated syngas and the combustion products therefrom. In addition, biomass-generated syngas 210 is channeled to external combustor 212 , without the requirement for any specific provisions for cooling or contaminant removal.
[0019] FIG. 3 is a schematic diagram of another alternative exemplary system 300 for generating power using biomass-generated syngas. System 300 includes a biomass dryer 302 , which receives biomass from a source 304 . A biomass conversion reactor 306 receives dried biomass 308 from biomass dryer 302 , and discharges a syngas 310 . Biomass conversion reactor 306 also includes a heat exchanger element 350 , which is coupled in flow communication with a compressor 320 and with a turbine 322 . Syngas 310 is channeled into an external combustor 312 , where syngas 310 is combusted with air 314 (typically ambient air) supplied by a blower 316 . In an alternative embodiment, a compressor (not shown) may be used in place of blower 316 . External combustor 312 includes a heat exchanger element 318 coupled in flow communication with compressor 320 and turbine 322 . External combustor 312 discharges an external combustor exhaust 336 . Compressor 320 is rotationally coupled to turbine 322 by a transmission structure 332 . An electrical generator 324 is rotationally coupled to turbine 322 by a transmission structure 323 .
[0020] Ambient air 326 is channeled into the compressor 320 , which discharges a compressed air 328 , which in turn is channeled into biomass conversion reactor 306 . Specifically, compressed air 328 is channeled through heat exchanger element 350 , acquiring heat released during the gasification process. Biomass conversion reactor 306 discharges a heated compressed air 329 , which is channeled to external combustor 312 , where heated compressed air 329 acquires further heat while flowing through heat exchanger element 318 . A resulting further heated compressed air 330 is channeled to turbine 322 and expanded, causing rotation of turbine 322 , and in turn, rotation of electrical generator 324 . Turbine 322 discharges a turbine exhaust 334 .
[0021] External combustor 312 is coupled in flow communication with a heat exchanger 352 , which is also coupled in flow communication with turbine 322 to receive turbine exhaust 334 . External combustor exhaust 336 is channeled to heat exchanger 352 , wherein external combustor exhaust 336 transfers heat to a boiler feed water 354 . Turbine exhaust 334 also releases heat to boiler feed water 354 while flowing through heat exchanger 352 . Turbine exhaust 334 , being essentially only heated air, is channeled through a vent 360 to atmosphere. External combustor exhaust 336 is channeled through an exhaust gas cleanup apparatus 362 , for removal of particulates and other contaminants. Cleaned external combustor exhaust 336 is then channeled to a vent 364 to be released to atmosphere. Boiler feed water 354 , having flowed through heat exchanger 352 , is converted to a steam 366 . A portion 338 of steam 366 is channeled to biomass dryer 302 for use in drying the biomass feedstock. Another portion 368 of steam 366 is channeled to a steam turbine (not shown) for the generation of additional electrical or mechanical power, or otherwise exported to other locations where a supply of steam is needed. Steam portion 338 is channeled through a heat exchanger element 340 coupled to biomass dryer 302 . Cooled steam 342 is subsequently channeled to a vent 344 to be released to atmosphere or to be channeled to other equipment (not shown).
[0022] Similarly to systems 100 and 200 described herein, in system 300 , syngas 310 and external combustor exhaust 336 are isolated from compressor 320 and turbine 322 . Accordingly, compressor 320 and turbine 322 are protected from the damaging effects of tar, ash and other particulates, and other contaminants found in biomass generated syngas, and the combustion products therefrom.
[0023] FIG. 4 is a schematic diagram of another alternative exemplary system 400 for generating power using biomass-generated syngas. System 400 includes a biomass dryer 402 , which receives biomass from a source 404 . A biomass conversion reactor 406 receives dried biomass 408 from biomass dryer 402 , and discharges a syngas 410 . In the exemplary embodiment, biomass conversion reactor 406 is a steam-biomass reformer, and includes a shell 407 and a heat-exchanging coil 488 that extends through biomass conversion reactor 406 , through which biomass 408 is channeled. Syngas 410 is channeled into an external combustor 412 , where syngas 410 is combusted with air 414 (typically ambient air) supplied by a blower 416 . In an alternative embodiment, a compressor (not shown) may be used in place of blower 416 . The external combustor 412 includes a heat exchanger element 418 coupled in flow communication with a compressor 420 and a turbine 422 . External combustor 412 discharges an external combustor exhaust 436 . Compressor 420 is rotationally coupled to turbine 422 by a transmission structure 432 . An electrical generator 424 is rotationally coupled to turbine 422 by a transmission structure 423 .
[0024] Ambient air 426 is channeled into compressor 420 , which discharges a compressed air 428 , which in turn is channeled into external combustor 412 , where compressed air 428 acquires heat while flowing through heat exchanger element 418 . A resulting heated compressed air 430 is channeled to turbine 422 and expanded, causing rotation of turbine 422 , and in turn, rotation of electrical generator 424 . Turbine 422 discharges a turbine exhaust 434 .
[0025] In the exemplary embodiment, a portion 496 of external combustor exhaust 436 is channeled to biomass conversion reactor 406 to supply heat for a steam-biomass reformation reaction. Portion 496 may supply all heat requirements for biomass conversion reactor 406 . In an alternative embodiment, portion 496 may supply only part of the heat requirement of biomass conversion reactor 406 . In such a situation, a fuel 490 from a source 492 and an air 494 from a source 495 are channeled via blower 497 into shell 407 and combusted to supply the remainder of the heat requirement. In another alternative embodiment, a compressor (now shown) may be used in place of blower 497 . In another alternative embodiment, combustion of fuel 490 and air 494 provides all of the heat required by biomass conversion reactor 406 , and none of external combustor exhaust 436 is diverted to biomass conversion reactor 406 . In an embodiment in which external combustor exhaust 436 is not used to provide heat for biomass conversion reactor 406 , combustion products from the combustion of fuel 490 and air 494 are vented 500 as flue gas. In an embodiment in which portion 496 of external combustor exhaust 436 is used to provide heat to biomass conversion reactor 406 , cooled portion 499 is channeled through exhaust gas cleanup device 502 prior to being vented 504 to atmosphere, to ensure that syngas contaminants are removed prior to release to atmosphere. If a combination of external combustion exhaust gas portion 496 and combustion of additional fuel 490 and air 494 are used to supply heat to biomass conversion reactor 406 , the combustion of additional fuel 490 and air 494 acts as a second combustion stage for portion 496 , facilitating complete combustion of syngas contaminants present in portion 496 .
[0026] In the exemplary embodiment, external combustor 412 is coupled in flow communication with a heat exchanger 452 . A boiler feed water 454 from a source 456 of boiler feed water is channeled to heat exchanger 452 . If portion 496 amounts to less than all of external combustor exhaust 436 , a portion 460 of external combustor exhaust 436 is channeled to heat exchanger 452 , through heat exchanger element 458 , wherein portion 460 transfers heat to boiler feed water 454 to produce a steam 462 . Turbine exhaust 434 is channeled to a heat exchanger 464 , through a heat exchanger element 466 . A boiler feed water 468 from a source 470 is channeled through heat exchanger 464 , such that heat from turbine exhaust 434 is transferred to boiler feed water 468 to produce a steam 472 . Steams 462 and 472 are combined to form steam flow 478 .
[0027] A portion 480 of steam flow 478 may be used as excess export steam. Another portion 482 of steam flow 478 is supplied to biomass dryer 402 as steam portion 484 , and to biomass conversion reactor 406 as steam portion 486 . In the exemplary embodiment, steam portion 482 may be superheated steam. In alternative embodiments, other types of steam may be present in steam portion 482 . Steam portion 484 is channeled through heat exchanger element 506 , to transfer heat to biomass 408 , after which steam portion 484 is vented 508 to atmosphere. Steam portion 486 is mixed with biomass 408 and channeled through a coil (or other heat-exchanging conduit) 488 , coupled through biomass conversion reactor 406 , towards channeling syngas 410 to external combustor 412 . Heat generated from the combustion of fuel 490 and air 494 , and from the heat contained within a portion 496 of external combustor exhaust 436 , if present, is transferred into biomass 408 and steam portion 486 flowing through coil 488 .
[0028] Similarly to systems 100 , 200 , and 300 described herein, in system 400 , syngas 410 and external combustor exhaust 436 are isolated from compressor 420 and turbine 422 . Accordingly, compressor 420 and turbine 422 are protected from the damaging effects of tar, ash and other particulates, and other contaminants found in biomass generated syngas, and the combustion products therefrom.
[0029] In contrast to known integrated gasification combined-cycle (IGCC) power generation systems, the biomass conversion reactor power generation systems described herein enable biomass-generated syngas to be used for generating power, while protecting sensitive compressor and/or turbine components from the potentially destructive effects associated with syngas generated from biomass materials. This is accomplished by segregating the flow path of the biomass-generated syngas from the flow path of the working fluid used in the compressor and turbine. In addition, the biomass conversion reactor power generation system as described herein eliminates the need for cooling and/or compressing the syngas, which measures are required when syngas is combusted and the syngas combustion products are added directly to the working fluid in a compressor and turbine, as in combustion turbine applications.
[0030] Exemplary embodiments of a method and a system for generating power using biomass-generated syngas are described above in detail. The method and system are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods and systems described herein may also be used in combination with other power generation schemes, and are not limited to practice with only the components as described herein.
[0031] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
[0032] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
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Methods and systems for generating power using syngas created using biomass gasification are provided. Exemplary power generation systems include a biomass dryer for receiving biomass, a biomass conversion reactor (either a biomass gasifier or a steam-biomass reformer) for receiving the dried biomass and generating syngas therefrom, and an external combustor for combusting the syngas and heating a working fluid to drive a turbine connected to an electrical generator. The external combustor includes a heat exchanger element for transferring heat from combustion of the syngas into the working fluid, while maintaining the working fluid isolated from the syngas and from syngas combustion products.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of copending application Ser. No. 563,184 filed Mar. 28, 1975, now U.S. Pat. No. 3,938,073, issued on Aug. 22, 1975, which is a continuation of application Ser. No. 358,097, filed May 7, 1973, now U.S. Pat. No. 3,881,166, dated Apr. 29, 1975, entitled DATA ARRAY NETWORK SYSTEM. U.S. Pat. No. 3,881,166 is entered into this application by reference.
This application is related to two other copending applications assigned to the same assignee as this application. The titles of the other two applications are as follows: Ser. No. 358,077 filed May 7, 1973, DATA ACQUISITION AND STORAGE SYSTEM; Ser. No. 358,076 filed May 7, 1973, DATA COMPOSITING AND ARRAY CONTROL SYSTEM, now U.S. Pat. No. 3,930,145, dated Dec. 30, 1975. Application Nos. 358,076 and 358,077 are incorporated by reference into this application.
BACKGROUND OF THE INVENTION
This invention is in the field of data acquisition systems. More particularly, it is in the field of data gathering systems which involve a high plurality of separate detectors and channels, the signals from which are carried to the data storage means by a single pair of conductors.
While this invention is useful in the acquisition of any type of analog signals such as in the field of data collection, vibration analysis, sonar signaling, nuclear technology, and so on, it is most appropriately useful in the area of seismic prospecting and as a matter of convenience will be discussed in that application. This description in terms of a seismic system does not limit in any way the scope of this application and its use in other fields of data acquisition.
In the prior art, seismic operations have been carried out with field instrumentation systems which have, in general, been limited by size, weight and power requirements to 24-48 separate recording channels. Additional recording channels have been provided by the process of adding additional recording truck units, and so on. Although there have been suggestions in the technical press for multiplex recording systems whereby high pluralities of recording channels can be provided using a single conductor pair for the transmission of the separate traces there have been no practical ways shown for carrying out such suggestions. Furthermore, those that have been suggested call for control and processing devices in series with each signal channel at considerable complexity and cost.
SUMMARY OF THE INVENTION
It is a primary object of this invention to provide a system of data acquisition, and to provide a network of terminals for the acquisition, processing, and transmission of a large plurality of independent analog signals derived from a corresponding plurality of detectors spaced in a selected array on the surface of the earth.
It is a further object of this invention to provide means by which this large number of independent channels can be broken up into a plurality of groups which are connected into a plurality of terminals, and to provide means by which the sequence of data signals transmitted to the recording unit can be identified in terms of a specific array terminal and specific channels in that terminal.
These and other objects are realized and the limitations of the prior art are overcome in this invention, which permits the operation of recording units in the field with a large number (such as 250 to 1,000) of separate recording channels, all of which are multiplexed onto a single pair of conductors. This is accomplished by having a plurality of array terminals. These are data amplification, digitization, storage and transmission units which are designed to handle a selected number of recording traces, such as 16, for example.
Each array terminal has a housing out of which are provided multiple means to connect to each of the geophones, such as 16 separate conductor pairs, of selected length, each connected to at least one geophone, so that the geophones can be arrayed in a selected spacial pattern on the earth.
There may be a large plurality of array terminals, all essentially identical in construction. These can be placed in any geometrical pattern on the earth and interconnected by substantially identical multiple-conductor cable units. Each of the cable units includes signal and control conductors. Each of the array terminals has one input and one output port, so that all array terminals are connected in series operative connection.
The manner in which the seismic signals produced by the geophones are multiplexed and transmitted to the truck is described in said copending application Ser. No. 358,077.
Assume that the array terminals (AT) are numbered serially from l-M away from the recording truck. Each array terminal, say number N, receives an interrogation from the truck, answers it, then repeats the interrogation through to the next terminal N + 1 which answers it and passes it onto the next on N + 2, and so on. Similarly, the answers from succeeding series-connected terminals are received and repeated back to the truck, N + 2 to N + 1 to N to N - 1, and so on. The data signals, which are short duration square wave pulses, or bits, are reconstructed and pulse shaped at each re-transmission from each terminal, into new square waves. Therefore, since the transmission between separate array terminals and between the first array terminal and the truck are relatively short cable lengths, of the order of 1,000 feet or less, these signals can be transmitted on conventional cable conductors. Therefore, the complexity of handling plugs and connections to coaxial cables, as previously suggested in the art, is not necessary in practicing this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of this invention and a better understanding of the principles and details of the invention will be evident from the following description taken in conjunction with the appended drawing, which is a schematic diagram of the array terminal, and indicates the geophones, the analog portion of the signal handling circuits, the digital data circuits and the command circuits.
DESCRIPTION OF THE PREFERRED EMBODIMENT
This data array network system is ideally suited for gathering time domain information from a plurality of distributed locations, processing them into the form of digitized signals of one bit, that can be multiplexed from the entire plurality of separate channels onto a two conductor cable into the storage device. While this type of system can be used for any type of analog signals, it is ideally suited for a seismic geophysical system, and will, for convenience, be described in terms of such a system. However, the description of this invention in terms of a seismic system is purely coincidental and there are no limitations implied to the use of this system by its description in this manner.
The figure will be described in terms of three principal parts, a first part indicated by the numeral 10 which is the geophone portion, or the data gathering portion, each of the elements of which are outlined in dashed lines, numbered 58A, 58B . . . 58N.
A second portion of the array terminal network is indicated generally by the numeral 12 and is bounded by the dashed outline 56. This portion includes the analog signal apparatus.
The remaining portion of the diagram is devoted to the digital storage and transmission, and the command system, etc. and is indicated generally by the numeral 14.
The geophone terminals are indicated generally by the numerals 58A, 58B . . . 58N. Each of these geophone terminals includes a geophone 59A, 59B . . . 59N. The geophones are the sources of analog signals generated by the motion of the geophones in response to the arrival of an elastic wave in the earth, at the point of positioning of the geophones. This is fully described in said application Ser. No. 358,077. The geophones are connected into preamplifiers 60A, 60B . . . 60N. The purpose of the preamplifiers is to convert the voltage signal of the geophone into a current signal for impressing upon the cable, which are low impedance circuits. The cables, indicated by the numbers 63A, 63B . . . 63N, are connected between the outputs of the preamplifiers and the inputs 62A, 62B . . . 62N to the analog section of the array terminal, 56.
The inputs to the analog section, 62A, 62B . . . 62N are connected into optical couplers numbered 64A, 64B . . . 64N. The optical couplers comprise light emitting diodes (L.E.D) which are controlled by the analog current received from the cable. The light emitted by the LED's impinges on a photo sensitive transistor, which controls the amount of current flowing through the transistor and therefore converts the light, which was proportional to the current in the cable, into a voltage which is proportional to the light emitted by the LEDs.
The analog voltage outputs of the transistors in the optical couplers connect to high gain amplifiers 66A, 66B . . . 66N, for the purpose of amplifying the analog signal and converting it into a square wave signal, which is sent by conductor 68A, 68B . . . 68N to individual logic AND gates 70A, 70B . . . 70N. The gates connect through leads 72A, 72B . . . 72N to the parallel inputs of a parallel to serial convertor 74, also called a data storage register or data shift register. The second inputs to the gates 70 are connected to a line 54 which originates in a control 32. When a momentary positive pulse is placed on the line 54 the gates 70 are enabled, and simultaneously each of the outputs of the amplifier are connected to the data shift register. A logical 1 or a logical 0 are stored in the shift register, depending upon whether the square waves on the lines 68 are positive or negative at the moment the gates 70 are enabled. If the lines are positive, a logical 1 appears. If the square wave is in the negative phase, a logical 0 is impressed on the shift register. By this means, the analog signals are sampled, and the sample then, by its sign, enters the proper digital values into the converter 74.
There are a plurality of control conductors which go from the input of the array terminal to the next preceding array terminal, and a corresponding plurality of control conductors that go from the output of the array terminal to the next succeeding terminal. As shown in the drawing there is an arrow 85 indicating the direction to the preceding array terminals and the array controller, that is, to the left in the drawing. Corresponding arrow 86 labeled "from outer array terminals" indicates that the succeeidng, or more distant array terminals are on the right side of the array terminal pictured. There are also a single pair of data conductors which are connected directly between the array terminals so that data from each of the array terminals can be sent on these two conductors through the intermediate array terminals to the array controller.
Inside of the array terminal all of the circuits are voltage controlled circuits. On the lines connecting the array terminals, it is desired that the lines be at low impedance to minimize the pickup of noise in these lines. Thus, coupling devices, called differential line drivers (DLD), or differential line receives (DLR), which convert for outgoing signals, the voltage on their input to current on their output, and vice versa, for incoming signals, they convert the incoming current signals to voltage signals for use inside of the array terminal. The DLD's and DLR's are commercial devices which are essentially amplifiers similar to those labeled 60 which couple the voltage output of the geophones to the cable, which goes to the array terminal. No further description is needed. The differential line receivers are numbered 16A, 16B, 16C, 16D, etc. and the differential line drivers are numbered 18A, 18B, 18C, 18D, etc.
Differential line receiver (DLR) 16A receives from the array controller, in accordance with the input arrow, interrogation commands, and passes this on by means of line 20 to a shift register 22 and out by line 24 to the DLD 18A. The interrogation command on 16A includes the digital address, A, of the array terminal for which the command is intended, and from which a response is expected. The address A (as a series of pulses) passes from the shift register 22 as a digital word representing the address of the array terminal being called, by line 26 to a counter 28, which adds one count to the value of the address received, and outputs an address number (A + 1) which is one more than the address received. This goes by line 38, and gate 36 to the shift register, which puts out that new address (A + 1) on the line 24, and through the DLD 18A to the next array terminal.
The same address that is received at 22 goes by line 26 and line 27 to an address comparator 44. One input of the address comparator 44 is stored in the address register 40 and is labeled N, being the address of this array terminal. This is unloaded from the address register and goes by line 42 into the address comparator 44, at the same time that the address received, A, goes by line 27 into the address compartor. If these two addresses are not equal, that is, if A is not equal to N, there is a signal on line 46 which goes to gate 48 and by line 49, to the DLD 18A and is passed on to the next array terminal. In other words, if the address A does not agree with the address N of the array terminal, the interrogation command is automatically passed on to the next array terminal.
On the other hand, if the address A is the same as N, then a signal is passed on by way of line 50 into the control 32. This provides the signal to digitize the analog signals and store the digitized values in the data shift register 74. This signal goes by line 54 to momentarily open the gates 70, and loads digital bits into the shift register 74, corresponding to the instantaneous sign of the analog signals at the time the gates 70 are open. Also there is a signal that passes by line 43 from the address register 40, to load the address N in an address shift register 78, which is in series, in advance of the DSR 74.
Therefore, on the reception of the command at the shift register 22 several things happen. If the incoming address A is not equal to the address N of the station, it is automatically passed on to the next array terminal. If the address A of the interrogation equals the address N of the station then the command address is incremented by 1 and pased on, and then the signal to the control on line 50 tells it to proceed with the digitization and loading of the data shift register 74, and the address shift register 76. The control 32 then tells the clock 35 to provide clock signals on 82 to shift out from the address register, and from the data shift register 74 the address N and the data, through the line 79 to the DLD 18B and on to the next preceding array terminal, and eventually to the array controller.
This is the procedure by which the data from the geophones at the array terminal N are digitized to one bit, and transmitted to the next array terminal. Once this has been done then the command which was passed onto array terminal (N + 1) in that array terminal, which is off to the right of this terminal N, the data from the geophones connected to that array terminal will be digitized, and will be inserted into the data shift register and the address word placed into the address shift register. They will then be shifted out of the registers in accordance with the clock of that array terminal, and will be delivered to the DLR 16B, which is the response data input, from an outer array terminal N + 1. This goes directly through lines 75 to the shift register 74 and data register 78 which are now empty, the data therein having been sent out previously. However, the incoming address word and data word cannot be shifted into the registers 78 and 74 until clock pulses are available.
As the data come in on line 75, they also go by line 80 into the clock 35. The clock 35 regenerates the clock pulses from the data, and with those pulses, shifts the incoming data into the registers 74 and 78. The clock 35 has its own clock rate which is used as the rate for shifting the address and data out of the registers 74 and 78. At the next preceding array terminal N - 1, the clock in that terminal will again regenerate the clock rate so that the data it receives can be shifted into the registers in that terminal, and so on.
Assuming that the address received, A, is that of the array terminal N, and data are being digitized and loaded into the registers prepartory to being transmitted out by the line 79 and DLD 18B. During this time, the terminal N is busy preparing and transmitting its own data. Consequently, the incoming line from AT (N + 1) through DLR 16B is not available. Consequently, there must be a signal prepared and sent to the next succeeding terminal, N + 1, that is preparing to send data in to terminal N, that the terminal N is busy, and to withhold transmission until a clear signal is delivered. The way that this is done is that when the clock 35 is outputting the shift pulses on line 82 to the shift registers 74 and 78, the same pulses go by line 81 to the DLD 18D. This provides a signal which says, "we are busy." The station terminal N + 1 will correspondingly withhold transmission when the busy signal is provided, and when the busy signal is not present, it will proceed to transmit to the DLR 16B, and into array terminal N.
DLR 16C is labeled interrogation busy input. When a signal comes to this input from N + 1 it says "don't send any more interrogation, we're busy." This puts a blocking signal on the gate 48, which prevents the transmission of any further commands which would have gone through line 46, line 49 and DLD 18A into the next terminal N + 1.
While this AT N is digitizing its analog signals preparatory to transmitting them to AT (N - 1), array terminal (N - 1) having received its command before AT N, has been busy sending its data on to AT (N - 2), and while it is transmitting its data, it sends out its busy signal on its DLD 18D. This busy signal arrives at AT N on DLR 16D. This line goes to the clock 35. So if DLR 16D says "we're busy", the clock 35 signal on 82 is disabled. Thus the transmission of the data from AT N is held up until that sent by AT (N - 1) is cleared to the next AT (N - 2). Now AT (N - 1) is ready to receive. The clock pulses are enabled, and the registers 78, 74 are shifted out, and transmitted to AT (N - 1) and to the array controller and to storage.
By the procedure described, all that the array controller needs to do is command the first array terminal AT1. This AT1 passes on the same command to AT2, while it proceeds to respond to the command. AT2 passes on the command to AT3 and proceeds to respond to the command. But AT2 can't transmit to AT1 until AT1 is clear, and AT3 can't respond until AT2 is clear, and so on. So the array terminals, by their internal logic do the work of signaling and timing all of the terminals. Thus a continuous stream of short trains of address and data are received at the array terminal in sequence from ATl to ATM.
This application describes the invention which relates to the array terminal circuitry and includes everything from the point at which the geophone cables enter the terminal, to the command and data inputs and outputs. There are two main ports. One outward to succeeding terminal N + 1, and the other preceding outward to array terminal N - 1. The DLR's and the DLD's are the boundary of the circuitry of the terminals, and the connecting cables between terminals are connected to the DLD's and DLR's.
The details of the circuitry in portions 10 and 12 of the drawing are fully described in our companion copending application Ser. No. 358,077 which is made part of this application by reference. All of the apparatus such as the shift registers, counters, address comparators, gates, DLD's and DLR's etc. are standard pieces of integrated circuit logic, which are available on the market, and need not be described in detail. Consequently, further detail of this diagram and of the operation of the data array network system is not necessary.
Also the array controller which is a part of the overall system from which data commands and interrogations are received and to which data signals and responses are sent is fully described and claimed in another companion copending application Ser. No. 358,076, which is inserted into this application by reference.
Very little has been said about the data processing of the input channels, shown at the bottom of the figure. This processing can be of any desired type so long as the input analog signals are converted to digital signals that can be stored in the data register 74. However, this system of array terminals is ideally suited to a processing system in which the analog signals are amplified, and digitized to 1 bit to provide a train of digital bits for storage in the parallel-to-serial convertors. This is fully described in copending application Ser. No. 358,077.
Also, very little has been said about the cable systems which can be used with the array terminals of this invention. Reference is made to FIG. 1 of U.S. Pat. No. 3,881,166, which is entered by reference into this application, for one type of cable system which is fully applicable. Other cable connections are also possible, so long as the array terminals in any one cable array are connected in series. Means are provided in the array controller for handling a plurality of cable arrays, whereby, in each array the terminals are connected in series.
While we have shown the geophone conductors as separate two conductor cables, it is well known to cable these separate conductors into a multi-conductor cable. Also, the data conductors can be a twisted conductor pair, or other type of conductors, separate from, or incorporated in the multi-conductor cable.
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. It is understood that the invention is not to be limited to the specific embodiments set forth herein by way of exemplifying the invention, but the invention is to be limited only by the scope of the attached claim or claims, including the full range of of equivalency to which each element or step thereof is entitled.
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A system for the field recording of seismic data in which a large plurality of geophones are arrayed on the earth and divided into groups, and each group is connected to an array terminal. All of the array terminals are connected in series, by cables, with the last terminal connected to a recording unit. In each of the terminals there are means to process the geophone analog signals by amplifying at constant gain and digitizing to 1 bit to provide a plurality of 1 bit pulses, which are stored in parallel in a parallel to serial convertor. On command from the recording unit, the bits stored in the convertors are read out in series and are transmitted by a pair of signal conductors to the next in series terminal for storage in the convertor, and from there to the convertor in the next in series terminal, and so on, until all of the bits stored in each of the terminals are transmitted as a plurality of short trains of single bit signals, to the recording unit, where they are recorded on a magnetic digital storage means. Each of the array terminals has an address register in which an address is stored, which is transmitted as a heading to the data stored in that convertor.
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BACKGROUND OF THE INVENTION
Surge arresters of the type containing zinc oxide varistors and series gaps within an insulating housing or closure are currently available for mounting both in the vicinity of distribution transformers to protect the distribution transformers from voltage surges, and on riser poles in the vicinity of underground electrical substations, to protect the substation equipment from voltage surges.
Since zinc oxide varistors are currently being used in place of silicon carbide varistors in distribution arrester applications, some means must be provided to prevent the arrester housing from catastrophically rupturing upon varistor failure. When silicon carbide varistors are used within polemounted distribution protection applications, a gas-pressure release outlet can be provided in order to expel the hot ionized gases generated to the exterior of the arrester housing forming an external arc which causes the housing to fracture into a relatively few pieces.
Distribution arresters are employed on voltage distribution systems to protect the electrical equipment from overvoltage surges. Although the failure of distribution surge arresters is infrequent, it is possible that such failure can result in gas pressure buildup within the arrester housing. Subsequent rupture of the housing can cause damage to adjacent electrical equipment and personnel. The purpose of this invention is to provide an improved arrester that will rupture in a predetermined manner at lower internal pressures than previous designs to reduce the danger to equipment and personnel.
SUMMARY OF THE INVENTION
An arrester housing is provided with a frangible section structured to cause the housing to break at a predetermined section upon the occurrence of gas-pressure buildup within the housing. Embodiments of the arrester housing include a housing having a predetermined section that is thinner than the remainder of the arrester housing as well as housings which are cut into two separate portions and re-cemented into a unitary structure.
A further embodiment comprises an arrester assembly wherein the arrester is mounted in such a manner that the frangible section of the arrester housing is proximate a grounded mounting clamp to facilitate striking of an arc to the grounded clamp.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side sectional view of one embodiment of the frangible arrester housing of the invention;
FIG. 2 is a front sectioned view of a polemounted arrester utilizing the frangible arrester housing of FIG. 1;
FIG. 3 is a side perspective view of an arrester according to the invention after becoming fractured upon the occurrence of a varistor failure; and
FIGS. 4A-4C show different embodiments of the frangible section of the arrester housing in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a lightning arrester housing 10 made of a suitable insulating material such as porcelain, plastic, hard rubber or glass. Housing 10 contains a portion 11 which includes a plurality of skirts 12 in order to provide voltage creep along the outsides of the housing. Hole 6 is provided at the top of the housing to accommodate a top mounting electrode and the housing is open at the bottom. A flat section 9 is provided near the bottom of the housing to facilitate mounting the arrester to a distribution pole. In order to provide a predetermined breakpoint within the housing wall, a pair of frangible sections 13 is provided by making the thickness t of wall 11 between the two skirts 12 immediately adjacent flat portion 9 thinner than any where else along the housing. The thickness t of housing wall 11 indicated at one of the frangible sections 13 is less than half the thickness T of the remainder of wall 11. This is to insure that when a varistor failure occurs within housing 10, causing gas pressure to build up within the housing, the housing will break preferentially along frangible sections 13 before the pressure builds up to such an extent that the housing totally ruptures. Although frangible sections 13 are located proximate flat portion 9, the frangible sections can be located at any predetermined location on the arrester housing. Frangible sections 13 are preferentially located proximate flat portion 9 in order to cause the hot ionized gases, which rapidly build up within the arrester housing upon the occurrence of a varistor failure, to vent to the atmosphere when frangible section 13 becomes ruptured.
A voltage surge arrester 14 containing frangible sections 13 is shown in FIGS. 2 and 3. A plurality of varistors 15 and gap assemblies 16 are contained within arrester 14 and electrical contact with the varistors is made by means of a top electrode connection 17 and a bottom electrode connection 18. Spring 19 assures good electrical contact between the bottom of varistors 15 and disconnect unit 20. Disconnect 20 is of the type specifically employed with zinc oxide varistors and described within U.S. Patent Application Ser. No. 39,825 filed May 17, 1979, now abandoned, which Application is incorporated herein for purposes of reference. A mounting bracket 21 and clamp 7 encompassing housing 10 is fixedly attached to pole 22 by means of hanger 23 and bolts 8. In operation top electrode connection 17 is attached to line 24 by means of lead 25 and bottom electrode connection 18 is connected with ground.
Upon the occurrence of an arrester failure and subsequent buildup of pressure exerted by the hot ionized gases, housing 10 ruptures at frangible section 13 and vents the gases to the atmosphere. In most applications, hanger 23 is connected to ground potential and in such cases the vented gases immediately strike this hanger to form a short circuit from the line potential of lead 25 to ground eliminating the bottom section of housing 10 from the arc path.
FIG. 3 shows arrester 14 immediately after fracture wherein arrester housing 10 becomes separated into top and bottom portions, 10A, 10B, the bottom portion 10B is retained by means of clamp 7, bracket 21 and hanger 23 which is fixedly held to pole 22 by means of bolts 8. The top housing portion 10A of arrester 14 is held by means of line lead 25 connecting between top electrode connection 17 and line 24. Line 24 is supported by means of an electrical insulator 26 attached to pole 22 at one end and at an opposite end to line 24 by means of connector 27. Bottom electrode connection 18 connects with arrester 14 through disconnect 20 and is grounded by means of ground lead 28 fixedly attached to a pole 22 by means of bracket 30. It can be seen from FIG. 3 that clamp 7 extending around flat portion 9 of housing 10 serves to hold the bottom housing portion 10B of arrester 14 after the arrester becomes fractured along at least one of the predetermined frangible sections 13 of the invention.
Housing 10 described within the embodiments of FIGS. 1-3 is fabricated from a porcelain material but this is for purposes of description only. Other electrically insulating materials which can provide a preferential frangible section, such as glass, hard rubber and plastic can also be employed. A reinforced fiber glass housing having a predetermined frangible section can operate in a similar manner as described for porcelain.
FIG. 4A shows another frangible section 13 on wall 11 of arrester housing 10. In this embodiment, a portion of wall 11 between a pair of skirts 12 is cut completely through to divide the housing into two sections 10A and 10B. The two sections are then rejoined by means of a cement 31 which can comprise a glass frit or a porcelain glaze. Frangible section 13, consisting of the rejoined housing portions 10A, 10B breaks preferentially relative to the remaining wall 11. In place of a layer of porcelain cement 31 a different type of cementatious material can be employed. When an epoxy, other plastic, glass or a silicone based meltable cement is used to rejoin the separate portions 10A, 10B the properties of the adhesive provides an added benefit. The temperature rapidly builds up within arrester 14, upon varistor failure, and causes the wall portions to become separated when the gas pressure builds up to a predetermined amount. The physical properties of the cement can be tailored to cause the break to occur at any desired pressure.
The embodiment depicted in FIG. 4B comprises an inner groove 32 formed on wall 11 between a pair of skirts 12 on housing 10. The frangible section 13 comprises the section of reduced thickness of wall 11 resulting from the inner groove opposite the region between the pair of skirts.
The embodiment depicted in FIG. 4C comprises a thin cut or slice 33 between a pair of skirts 12 on wall 11 of housing 10. Frangible section 13, provided by cut or slice 33 behaves in a manner similar to that of the embodiment depicted in FIGS. 4A and 4B.
Although the embodiments depicted herein describe the frangible section as completely circumscribing the arrester housing, this is by way of example only. The frangible section can extend only partially along the housing circumference when it is preferred for example to have the housing break in a particular direction relative to the grounded support clamp.
Other methods for forming the frangible section of the housing include indenting the housing top 5 or by cementing housing top 5 to housing 10. These methods provide pressure relief, but do not provide for the advantage of the electric arc transfer to ground as the earlier embodiments.
Although the frangible section housings of the invention are described relative to pole mounted distribution arresters, this is by way of example only. The arrester of the invention finds application whereever surge arresters may be exployed.
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Surge voltage arresters are provided with a frangible housing to cause the housing to break at a predetermined section into a relatively few pieces upon varistor failure. The breaking of the housing deters excessive pressure buildup within the arrester.
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CLAIM OF PRIORITY
This application claims priority on U.S. Provisional Patent Application Ser. No. 61/417,836 on Nov. 29, 2010.
BACKGROUND OF THE INVENTION
The present invention is directed to a system, e.g. an entertainment system, which generates electricity from the movement of at least a portion of a seat in an arena and, preferably, combines electricity generated by the movement of a plurality of seats to create usable quantities of electrical energy.
SUMMARY OF THE INVENTION
As a person sits down in a seat there is typically wasted energy. This energy that is typically wasted is turned into usable electrical energy by utilizing forces acting on the seat. When a seat is turned/lowered, only a small amount of electrical energy will be generated, however, when thousands of seats are generating energy, such as in a stadium, a more significant amount of electrical energy will be generated. The various embodiments of the present invention generate electricity from the movement of at least a portion of a seat in an arena and, preferably, combines electricity generated by the movement of a plurality of seats to create usable quantities of electrical energy.
BRIEF DESCRIPTION
FIG. 1 illustrates a plurality of seats according to one embodiment of the present invention.
FIG. 2 illustrates a side view of one of the seats of FIG. 1 with a base in a raised position.
FIG. 3 illustrates a side view of one of the seats of FIG. 1 with a base in a lowered position.
FIG. 4 illustrates a plurality of seats according to a second embodiment of the present invention.
FIG. 5 illustrates a single base of a seat according to a third embodiment of the present invention.
FIGS. 6-8 are side, front perspective and top views, respectively, of a base of a fourth embodiment of the present invention with the base in a raised position.
FIGS. 9-11 are side, front perspective and top views, respectively, of a base of a fourth embodiment of the present invention with the base in a lowered position.
FIGS. 12-14 are side, front perspective and top views, respectively, of a base of a fourth embodiment of the present invention with the base in a lowered position and a spring which has been tripped.
FIGS. 15-19 are schematic views of movable bases of alternate embodiments of the present invention.
DETAILED DESCRIPTION
When a person sits down, almost all of their weight from their knees up is applied downwardly. For purposes of illustration, if an average person has a weight of 177 pounds, after subtracting their weight below their knees, for present purposes estimated to be 37 pounds, the upper 140 pounds is applied to the seat. If this weight (140 lbs.) is multiplied by 45,000 seats in a stadium, the result is 6,300,000 pounds of force.
If the distance between a person's knees and hips is 18 inches, this is the approximate distance a person's weight travels during the act of sitting. Therefore, 6,300,000 pounds of force is applied for a distance of about 18 inches. This occurs if the people in the stadium sit down once. During an exciting event, many people will stand up and sit down many times, e.g. 10-20 times. The resulting foot-pounds is converted to electrical energy which is used for different things. One example is lighting up lights, signs, or scoreboards around the stadium. Another example is powering electrical necessities in the stadium.
Another embodiment of the present invention utilizes the generated electricity for entertainment purposes. Fans in certain stadium sections of the stadium compete with fans in other sections to see who can generate the most electricity which can be displayed visually or broadcast audibly with the amount of signage illuminated or the brightness or the audible volume, related to the amount of electricity generated. As used herein, the term arena is used to include venues such as stadiums, theaters, and or other venues comprising a large number of seats, e.g., 50 or more seats.
With reference to FIG. 1 , the electricity generated by electrical generator 15 can be directed to one or more discernible signal generators 17 and 18 . In this illustrated embodiment discernible signal generator 17 provides illumination through a series of lights 17 ′. Preferably, the number of lights illuminated and/or the brilliance of the illumination corresponds to the amount of electricity generated by one or more electrical generators 15 . Discernible signal generator 18 is a speaker which generates sounds. The electricity used to power one or more discernible signal generators can be amplified or otherwise controlled by controller 19 which comprises one or more amplifiers if desired. In this manner, fans can compete to generate greater signals or sound which is broadcast in a manner which indicates which seats have generated more electricity.
The following embodiments illustrate seats which generate electricity individually or collectively. There are many methods to produce electricity from moving mechanical parts. The illustrated embodiments provide just a few examples.
FIGS. 1-3 illustrate one embodiment of the present invention. As illustrated in FIG. 1 , seats 10 each comprise a movable base 11 . As best shown in FIGS. 2 and 3 , the base is pivotal and is connected to a bellows 12 . When the seat is in the raised position as in FIG. 2 , the bellows 12 is expanded. When a person sits or otherwise applies force to base 11 in the generally downward direction, the bellows 12 is compressed forcing air through tube 13 into conduit 14 . Suitable one-way valves, not shown, control the flow of air according to this embodiment of the present invention in order to always direct the air out of the bellows through tube 13 and into conduit 14 which is connected to an electrical generator 15 . Though not illustrated in FIGS. 2 and 3 , tube 13 is connected to bellows at connection point 13 ′. The pressurized air entering conduit 14 causes a turbine 15 ′ in electrical generator 15 to spin thereby generating electricity which, according to this embodiment, is transferred to one or more devices via electrical conductor 16 .
FIG. 4 illustrates an alternative embodiment of the present invention wherein each seat 20 is connected to an individual electrical generator 25 which generates electricity which is transmitted through conductors 26 to a common conductor 28 .
FIG. 5 illustrates an alternative embodiment of the present invention wherein a seat base 31 is connected to a bellows 32 . This embodiment comprises a sub-base 33 and a plurality of springs 34 which is connected to a turbine 36 in an electrical generator 35 . According to this embodiment of the present invention, springs 34 return base 31 to a storage position. According to this embodiment of the present invention turbine 36 is caused to spin in both directions, i.e., both clockwise and counterclockwise, as base 31 is moved downwardly and upwardly, respectively, in order to generate electricity when base 31 is moving in either of two directions. As in the embodiments described above, electrical generator 35 is connected to a desired device or signal generator, e.g., a discernible signal generator.
While the embodiments illustrated in FIGS. 1-5 utilize pneumatic forces, it is also within the scope of the present invention to use hydraulic forces. From the present description, it will be appreciated that the particular form of electrical generator can vary and that one or more different types of electrical generators can be used within the scope of the present invention.
FIGS. 6-14 illustrate a base of a fourth embodiment of the present invention comprising a flywheel. FIGS. 6-14 illustrate a series of views of a base, namely, a side view, a front perspective view and a top view of the base in an upright or storage position, a lowered position, and a lowered position wherein the flywheel had been caused to spin. According to this embodiment of the present invention a base 41 comprises a flywheel 42 comprising ratchet teeth 43 . The base also comprises a spring actuated drive mechanism comprising a rotatable but linearly stationary spring support 44 connected to one end of compression spring 45 . Spring support 44 comprises a trip pin 46 . Connected to the other end of the compression spring 45 is a rotationally stationary but linearly movable spring support 47 which is movable along the longitudinal axis of pivotal support 50 . According to this embodiment of the present invention, when base 41 is lowered from the raised position shown in FIGS. 6-8 , spring 45 is compressed between spring supports 44 and 47 thereby exerting an outwardly directed force on spring support 47 . Spring support 47 comprises an engagement member which is positioned between the ratchet teeth 43 of flywheel 42 as the base is lowered to its lower position. Also, as base 42 is lowered to its lowest position, trip pin 46 trips a release (not shown) which allows spring support 47 to slide linearly and axially along pivotal support 50 thereby driving flywheel 42 . This flywheel 42 has magnets which will spin around a coiled wire to generate electricity or is connected to another type of generator (not shown).
FIGS. 15 through 19 each illustrate a series of movements of a seat or the base portion of a seat. The movement can be caused by the downward movement of the mass of a person. Each of FIGS. 15-19 comprises a series of schematics. Each individual schematic comprises two lines. The line of the left illustrates the backrest of a seat while the line to the right illustrates the base portion of the seat on which a person sits. The portion of the seat on which a person's buttocks will rest is referred to herein as the base, in order to distinguish it from the entire seat which includes a base, a backrest and preferably armrests.
With reference to FIG. 15 , the base of the seat is normally biased upwardly, e.g. by a spring. The weight of a person will move the base from the position shown in FIG. 15( a ) downwardly through the position illustrated in FIG. 15( b ) to the final position shown in FIG. 15( c ).
With reference to FIG. 16 , the backrest and base move downwardly together from a position shown in FIG. 16( a ) to the position shown in FIG. 16( c ).
FIG. 17 illustrates an embodiment more similar to a conventional arena or stadium seat wherein the base pivots downwardly. It will be appreciated that the spacing between the base and the backrest is usually sufficient for a person to position at least part of his buttocks on the base to apply weight and downward force to the base thereby moving the base from the position generally illustrated in FIG. 17( a ) through the position shown in FIG. 17( b ) to the final position shown in FIG. 17( c ).
FIG. 18 illustrates an alternative embodiment wherein the base is pivoted about an axis located forwardly whereby the seat pivots downwardly and rearwardly toward the backrest when a person's weight is applied.
FIG. 19 illustrates an embodiment wherein the base moves both downwardly and slide forwardly from the position shown in FIG. 19( a ) through the positions shown in FIGS. 19( b ) and 19 ( c ) to the final position shown in FIG. 19( d ).
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A system which generates electricity from the movement of at least a portion of a seat in an arena and, preferably, combines electricity generated by the movement of a plurality of seats to create usable quantities of electrical energy.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. patent application Ser. No. 10/664,556 entitled INTELLIGENT POSITIONING OF ITEMS IN A TREE MAP VISUALIZATION, filed Sep. 19, 2003, the entire disclosure of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] As computer technology advances, computing systems have undertaken the management and processing of larger data systems. With data systems ranging from massive standalone databases to vast distributed networks, oftentimes the limiting factor in analyzing the state of a given system rests not with computing resources, but with the human operator. Specifically, though the computing system may aggregate vast quantities of data in near real-time, in many cases, a human being must visualize the compilation of data to draw effective conclusions from the visualization. Yet, the ability of the end user to digest compiled information varies inversely with the amount of data presented to the end user. Where the amount of compiled data becomes excessive, it can be nearly impossible for a human being to adequately analyze the data.
[0003] In an effort to address the foregoing difficulties, tree-map visualization methods have been developed. Initially proposed by Brian Johnson and Ben Shneiderman in the paper, Johnson et al., Tree-Maps: A Space-Filling Approach to the Visualization of Hierarchical Information Structures, Dept. of Computer Science & Human-Interaction Laboratory (University of Maryland June 1991), tree-map visualization techniques map “hierarchical information to a rectangular 2-D display in a space-filling manner” in which the entirety of a designated display space is utilized. Additionally, “[i]nteractive control allows users to specify the presentation of both structural (depth bounds, etc.) and content (display properties such as color mappings) information.” Tree-map visualization techniques can be compared in a contrasting manner to traditional static methods of displaying hierarchically structured information.
[0004] According to conventional static methods, a substantial portion of hierarchical information can be hidden from user view to accommodate the view of the hierarchy itself. Alternatively, the entire hierarchy can be visually represented, albeit vast amounts of display space can be obscured, hence wasted, simply to accommodate the structure without regard to the hierarchical data in the hierarchy itself. In the tree-map visualization technique, however, sections of the hierarchy containing more important information can be allocated more display space while portions of the hierarchy which are deemed less important to the specific task at hand can be allocated less space. More particularly, in operation, tree-maps partition the display space into a collection of rectangular bounding boxes representing the tree structure. The drawing of nodes within the bounding boxes can be entirely dependent on the content of the nodes, and can be interactively controlled. Since the display space size is user controlled, the drawing size of each node varies inversely with the size of the tree, for instance the number of nodes. Thus, trees having many nodes can be displayed and manipulated in a fixed display space, yet still be visible even when dealing with 1 million objects.
[0005] FIG. 1 illustrates a conventional tree map display 10 . As seen in FIG. 1 , a 10 by 10 display grid is filled with bounding boxes 12 through 68 representing the display of a data set containing twenty-nine entries. Data values associated with the twenty-nine entries establish the size of the bounding boxes and the color of the box, as represented by the different cross-hatch patterns illustrated in FIG. 1 . Thus, a first data value may establish the size of the bounding box, for example, market capitalization if the data set represents different stocks, and a second data value may establish the color of the bounding box, for example, the change in stock price. Thus, in the example illustrated in FIG. 1 , the tree map display 10 is created from the data set of Table 1 below.
[0000]
TABLE 1
Exemplary Data
Bounding Box
First Data Value
Second Data Value
12
20
1 (no cross-hatch)
14
12
4 (diagonal left-right)
16
8
4 (diagonal left-right)
18
8
1 (no cross-hatch)
20
8
4 (diagonal left-right)
22
6
1 (no cross-hatch)
24
6
3 (diagonal right-left)
26
4
3 (diagonal right-left)
28
4
3 (diagonal right-left)
30
4
2 (vertical cross-hatch)
32
2
1 (no cross-hatch)
34
1
4 (diagonal left-right)
36
1
1 (no cross-hatch)
38
1
1 (no cross-hatch)
40
1
3 (diagonal right-left)
42
1
1 (no cross-hatch)
44
1
4 (diagonal left-right)
46
1
2 (vertical cross-hatch)
48
1
1 (no cross-hatch)
50
1
4 (diagonal left-right)
52
1
2 (vertical cross-hatch)
54
1
3 (diagonal right-left)
56
1
1 (no cross-hatch)
58
1
1 (no cross-hatch)
60
1
4 (diagonal left-right)
62
1
3 (diagonal right-left)
64
1
3 (diagonal right-left)
66
1
1 (no cross-hatch)
68
1
2 (vertical cross-hatch)
[0006] A further example of the use of a tree map visualization is provided by Fidelity Investments' map of the stock market (which may be found at activequote.fidelity.com/rtmews/market_map.phtml). In the Fidelity market map, the market is divided into sectors and the sectors are populated with bounding boxes for individual stocks. The size of the bounding boxes is based on the market capitalization of the stock and the color of the boxes are based on the price activity of the stock.
BRIEF SUMMARY OF THE INVENTION
[0007] Embodiments of the present invention provide for a system for displaying a tree map visualization including a processor, a memory device, and program code resident in the memory device. The program code is executable by the processor to prioritize data in a data set so as to associate a priority with respective elements of the data in the data set, where the associated priorities designate a desired sequence to the respective elements of the data set. The program code is further executable by the processor to predefine a pattern that reflects a desired display pattern for the associated priority of the elements of the data in the data set. The program code is additionally executable by the processor to generate the tree map visualization that positions within a display space, a combination of bounding boxes corresponding to the elements of the data in the data set and void regions where no information is displayed, such that each bounding box in the tree map visualization is arranged in priority order based upon the sequence designated by the priority associated with its corresponding element and the predefined pattern and the void regions fill in the remainder of the display space where no bounding box is present. The program code is also executable by the processor to display the tree map visualization on a display device.
[0008] In further embodiments of the present invention, a system for displaying data from a data set in a tree map visualization is provided. The system comprises processor means for prioritizing the data in the data set so as to associate a priority with respective elements of the data in the data set. The associated priorities designate a desired sequence to the respective elements of the data set and predefining a pattern that reflects a desired display pattern for the associated priority of the elements of the data in the data set. The processor means further for generating the tree map visualization that positions within a display space, a combination of bounding boxes corresponding to the elements of the data in the data set and void regions where no information is displayed, such that each bounding box in the tree map visualization is arranged in priority order based upon the sequence designated by the priority associated with its corresponding element and the predefined pattern and the void regions fill in the remainder of the display space where no bounding box is present. The system further comprises display means for displaying the tree map visualization on a display device.
[0009] In still further embodiments of the present invention, a computer program product for displaying data from a data set in a tree map visualization is provided. The computer program product comprises a computer-usable storage medium having computer readable program code embodied therewith. The computer readable program code comprises computer readable program code configured to prioritize the data in the data set so as to associate a priority with respective elements of the data in the data set, where the associated priorities designate a desired sequence to the respective elements of the data set. The computer readable program code further comprises computer readable program code configured to predefine a pattern that reflects a desired display pattern for the associated priority of the elements of the data in the data set. The computer readable program code additionally comprises computer readable program code configured to generate the tree map visualization that positions within a display space, a combination of bounding boxes corresponding to the elements of the data in the data set and void regions where no information is displayed, such that each bounding box in the tree map visualization is arranged in priority order based upon the sequence designated by the priority associated with its corresponding element and the predefined pattern and the void regions fill in the remainder of the display space where no bounding box is present. The computer readable program code also comprises computer readable program code configured to display the tree map visualization on a display device.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] FIG. 1 is an illustration of the display of a set of data utilizing a conventional tree map.
[0011] FIG. 2 is a block diagram of a data processing system suitable for use in embodiments of the present invention.
[0012] FIG. 3 is a more detailed block diagram of aspects of a data processing system that may be used in embodiments of the present invention.
[0013] FIG. 4 is an illustration of the display of a set of data of FIG. 1 utilizing a tree map according to embodiments of the present invention.
[0014] FIG. 5 is a flowchart illustrating operations according to embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
[0016] As will be appreciated by one of skill in the art, the present invention may be embodied as a method, data processing system, or computer program product. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects all generally referred to herein as a “circuit” or “module.” Furthermore, the present invention may take the form of a computer program product on a computer-usable storage medium having computer-usable program code embodied in the medium. Any suitable computer readable medium may be utilized including hard disks, CD-ROMs, optical storage devices, a transmission media such as those supporting the Internet or an intranet, or magnetic storage devices.
[0017] Computer program code for carrying out operations of the present invention may be written in an object oriented programming language such as Java®, Smalltalk or C++. However, the computer program code for carrying out operations of the present invention may also be written in conventional procedural programming languages, such as the “C” programming language. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer. In the latter scenario, the remote computer may be connected to the user's computer through a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
[0018] The present invention is described in part below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0019] These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function/act specified in the flowchart and/or block diagram block or blocks.
[0020] The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0021] Embodiments of the present invention provide for displaying data in tree map format on an electronic display by prioritizing the data to be displayed and displaying the bounding boxes associated with the data in an order reflecting the prioritization. Such prioritized display of bounding boxes may provide a mechanism so as to add additional information to the display of the data so as to allow a user to more readily assess the information displayed. The priority criteria may be based on the data itself, associated data, a characteristic of the data itself and/or may be provided as metadata.
[0022] Various embodiments of the present invention will now be described with reference to the figures. FIG. 2 illustrates an exemplary embodiment of a data processing system 130 suitable for a server and network traffic associated with the replicated server in accordance with embodiments of the present invention. The data processing system 130 typically includes input device(s) 132 such as a keyboard, pointer, mouse and/or keypad, a display 134 , and a memory 136 that communicate with a processor 138 . The data processing system 130 may further include a speaker 144 , and an I/O data port(s) 146 that also communicate with the processor 138 . The I/O data ports 146 can be used to transfer information between the data processing system 130 and another computer system or a network. These components may be conventional components, such as those used in many conventional data processing systems, which may be configured to operate as described herein.
[0023] FIG. 3 is a block diagram of data processing systems that illustrates systems, methods, and computer program products in accordance with embodiments of the present invention. The processor 138 communicates with the memory 136 via an address/data bus 248 . The processor 138 can be any commercially available or custom microprocessor. The memory 136 is representative of the overall hierarchy of memory devices, and may contain the software and data used to implement the functionality of the data processing system 130 . The memory 136 can include, but is not limited to, the following types of devices: cache, ROM, PROM, EPROM, EEPROM, flash memory, SRAM, and DRAM.
[0024] As shown in FIG. 3 , the memory 136 may include several categories of software and data used in the data processing system 130 : the operating system 252 ; the application programs 254 ; the input/output (I/O) device drivers 258 ; and the data 256 , which may include hierarchical data sets. As will be appreciated by those of skill in the art, the operating system 252 may be any operating system suitable for use with a data processing system, such as OS/2, AIX or System390 from International Business Machines Corporation, Armonk, N.Y., Windows95, Windows98, Windows2000 or WindowsXP from Microsoft Corporation, Redmond, Wash., Unix or Linux. The I/O device drivers 258 typically include software routines accessed through the operating system 252 by the application programs 254 to communicate with devices such as the I/O data port(s) 146 and certain memory 136 components. The application programs 254 are illustrative of the programs that implement the various features of the data processing system 130 and preferably include at least one application that supports operations according to embodiments of the present invention. Finally, the data 256 represents the static and dynamic data used by the application programs 254 , the operating system 252 , the I/O device drivers 258 , and other software programs that may reside in the memory 136 .
[0025] As is further seen in FIG. 3 , the application programs 254 may include a tree map module 260 . The tree map module 260 may carry out the operations described herein for displaying a tree map diagram of a data set, such as the tree map data 262 . While the present invention is illustrated, for example, with reference to the tree map module 260 being an application program in FIG. 3 , as will be appreciated by those of skill in the art, other configurations may also be utilized. For example, the tree map module 260 may also be incorporated into the operating system 252 , the I/O device drivers 258 or other such logical division of the data processing system 130 . Thus, the present invention should not be construed as limited to the configuration of FIG. 3 but encompasses any configuration capable of carrying out the operations described herein.
[0026] One difficulty with tree map visualizations is that the tree map is created so as to utilize all of the available display area. As such, the location of bounding boxes in the tree map is typically established without reference to the nature of the underlying data. The bounding boxes are typically arranged to utilize all of the available display area. Accordingly, the location of items of interest to a user may change from map to map and related and/or important items may be spread out in the map depending on the distribution of bounding boxes that utilizes all of the available display area.
[0027] Embodiments of the present invention provide prioritized display of the data for a tree map visualization so as to display data in the tree map in a predefined pattern that reflects the priority of the item displayed. For example, the data set of Table 1 may be prioritized for display. The determination of priority may be based on the data itself, for example, increasing or decreasing data value, may be determined based on data associated with the data for display, may be based on a characterization and/or classification of the nature of the data being displayed and/or may be specified as a separate priority value. As used herein, the term priority refers to a sequence for display of data and does not necessarily refer to a judgment as to the importance of the data.
[0028] The predefined pattern for display based on priority may be any suitable pattern of display. For example, higher priority data may be displayed in an upper left hand corner of the tree map and lower priority data may be displayed in a lower right hand corner of the tree map. Thus, priority may decrease diagonally across the map from left to right and top to bottom. Alternatively, priority could increase or decrease diagonally and from top to bottom. Priority could also increase or decrease on a line by line basis with boxes closer to the left or right sides of a line having a higher priority. Furthermore, the particular pattern may take into account the way in which the data is prioritized so as to provide for a high utilization of the display area. These patterns of display based on a priority are provided as examples. Embodiments of the present invention should not be construed as limited to a particular pattern but is intended to encompass any pattern of display based on priority.
[0029] Returning to the example of Table 1, Table 2 below reflects a prioritization of the data from Table 1. The prioritization illustrated in Table 2 is arbitrary, however, as discussed herein, prioritization may be analytically determined and/or user defined. The display of the prioritized tree map data according to certain embodiments of the present invention results in the tree map of FIG. 4 .
[0000]
TABLE 2
Exemplary prioritized data set
Bounding Box
First Data Value
Second Data Value
Priority
412
20
1 (no cross-hatch)
1
414
12
4 (diagonal left-
4
right)
416
8
4 (diagonal left-
5
right)
418
8
1 (no cross-hatch)
6
420
8
4 (diagonal left-
7
right)
422
6
1 (no cross-hatch)
8
424
6
3 (diagonal right-
9
left)
426
4
3 (diagonal right-
10
left)
428
4
3 (diagonal right-
2
left)
430
4
2 (vertical cross-
11
hatch)
432
2
1 (no cross-hatch)
12
434
1
4 (diagonal left-
13
right)
436
1
1 (no cross-hatch)
14
438
1
1 (no cross-hatch)
15
440
1
3 (diagonal right-
16
left)
442
1
1 (no cross-hatch)
17
444
1
4 (diagonal left-
3
right)
446
1
2 (vertical cross-
18
hatch)
448
1
1 (no cross-hatch)
19
450
1
4 (diagonal left-
20
right)
452
1
2 (vertical cross-
21
hatch)
454
1
3 (diagonal right-
22
left)
456
1
1 (no cross-hatch)
23
458
1
1 (no cross-hatch)
24
460
1
4 (diagonal left-
25
right)
462
1
3 (diagonal right-
26
left)
464
1
3 (diagonal right-
27
left)
466
1
1 (no cross-hatch)
28
468
1
2 (vertical cross-
29
hatch)
[0030] As seen in FIG. 4 , a tree map visualization is generated based on the first and second data values, the prioritization of those values and the pattern in which priority is displayed. In FIG. 4 , higher priority items are placed closer to the top of the map and closer to the left side of the map.
[0031] As seen in FIG. 4 , in comparison to FIG. 1 the sequence of the bounding boxes for the corresponding elements of the data set of Table 1 in the tree map 400 has changed. In FIG. 4 , the reference numerals of the bounding boxes 412 to 468 correspond to those of FIG. 1 increased by 400 . Thus, for example, the bounding box 412 corresponds to the bounding box 12 of FIG. 1 , the bounding box 414 corresponds to the bounding box 14 of FIG. 1 , etc. Because the bounding boxes are arranged in a prioritized pattern, the tree map of FIG. 4 not only displays a visualization of the first and second data values, it also displays a visualization of a third value, the priority value.
[0032] Utilizing the tree map 400 of FIG. 4 , a user may quickly ascertain the priority relationship between the data represented by the tree map 400 . Furthermore, because the data is arranged in a predefined priority pattern, the user may also know where to look in the tree map 400 for the information that may be most critical to monitor.
[0033] Because the bounding boxes 412 to 468 are arranged in priority order, it may not be possible to completely utilize the display area of the tree map 400 . Thus, the tree map 400 has void regions 480 , 482 and 484 where no information is displayed. Accordingly, embodiments of the present invention provide a modified tree map where bounding boxes of data elements are arranged in a predefined priority pattern and where all of the available display area is not necessarily utilized to display a bounding box.
[0034] FIG. 5 is a flowchart illustration that depicts operations for prioritized display on a tree map pursuant to embodiments of the present invention. As shown in FIG. 5 , a data set of tree map data is obtained (block 500 ). The data in the tree map data set is prioritized so that a priority is associated with data elements in the data set (block 502 ). The tree map is then generated such that the bounding boxes of the elements of the data set are arranged in a predefined pattern based on the priority associated with the corresponding element (block 504 .
[0035] The criteria for prioritizing the data from the tree map data set may be a statically defined criteria or may be a dynamically generated criteria. The data may be prioritized based on any suitable analysis of the data, for example, the data may be prioritized based on a series of threshold values. The priority criteria or priority values may be statically set, user specified and/or dynamically determined. The dynamic determination of priority may be provided based on an evaluation of the data values and/or a desired tree map characteristic. For example, the priority may be dynamically set based on an evaluation of the data set.
[0036] As mentioned above, the priority of an element of the data set may be based on the values of data that is displayed in the tree map, data associated with the data that is displayed in the tree map and/or metadata associated with the tree map data set. In the first instance, the data may be prioritized based on one or more of the data values that are used in generating the tree map. For instance, in the stock market example, the data may be prioritized based on market capitalization and/or a minimum change in stock price.
[0037] The data set could also be prioritized based on additional data associated with the data that generates the tree map. For instance, in the stock market example, the data may be prioritized based on stock market activity where the priority is based on trading activity of a stock.
[0038] The data set could also be prioritized based on metadata (i.e. data about the data) associated with the data set that generates the tree map. For example, the data set could be prioritized based on deviation from a standard or average of values of the data in the data set. Similarly, the metadata may directly indicate a priority associated with elements of the data set. For instance, in the stock market example, stocks owned by a user and/or tracked by the user could be identified and prioritized based on whether a stock was owned, tracked and/or not prioritized.
[0039] In further embodiments of the present invention, multiple priorities may be used to arrange the bounding boxes in the tree map. For example, right to left could indicate increasing value of a first priority category while bottom to top would indicate increasing priority in a second priority category. In such a case, the upper left corner would contain the bounding box with the highest priority in both categories. In such a case, a hierarchy of the priority categories may need to be defined so as to determine a location between to equally situated bounding boxes.
[0040] Embodiments of the present invention have been illustrated with reference to a unique priority being assigned to each data element of the tree map data set. However, in further embodiments of the present invention, different data elements in the tree map data set may have the same priority. In such a case, the location of display within the priority pattern of bounding boxes having the same priority may be established arbitrarily or based on another criteria, such as to maximize display utilization or a second priority criteria. However, such bounding boxes will still be displayed in priority order with respect to bounding boxes having a higher or lower priority. Accordingly, the present invention should not be construed as limited to the assignment of unique priorities.
[0041] The flowcharts and block diagrams of FIGS. 2 , 3 and 5 illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products for selectively controlling tree map graphical user interfaces according to various embodiments of the present invention. In this regard, each block in the flow charts or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the blocks may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be understood that each block of the block diagrams and/or flowchart illustrations, and combinations of blocks in the block diagrams and/or flowchart illustrations, can be implemented by special purpose hardware-based systems which perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
[0042] In the drawings and specification, there have been disclosed typical illustrative embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims.
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A system for displaying a tree map visualization including a processor, a memory device, and program code resident in the memory device. The program code is executable by the processor to prioritize data in a data set so as to associate a priority with respective elements of the data in the data set, to predefine a pattern that reflects a desired display pattern for the associated priority of the elements of the data in the data set, to generate the tree map visualization that positions within a display space, and to display the tree map visualization on a display device.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2004-159952, filed May 28, 2004, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a nonvolatile semiconductor memory device, and more particularly to a flash memory with a floating gate.
[0004] 2. Description of the Related Art
[0005] Various structures and fabrication techniques relating to flash memories with floating gates have been proposed. Jpn. Pat. Appln. KOKAI Publication No. 2002-176114, for instance, discloses a nonvolatile semiconductor memory device wherein the gate structure of a transistor, other than a memory cell transistor, has the same stacked-gate structure as the memory cell transistor. In this nonvolatile semiconductor memory device, the gate structure is configured such that a floating gate and a control gate are connected via an opening, i.e. a slit, that is formed in an ONO film.
[0006] When such a slit is formed in the ONO film, however, the width of the slit varies greatly, leading to difficulty in control of dimensions. Thus, an exact slit width cannot be obtained.
BRIEF SUMMARY OF THE INVENTION
[0007] According to a first aspect of the present invention, there is provided a nonvolatile semiconductor memory device whose gate structure of a transistor other than a memory cell transistor has a same stacked gate structure as the memory cell transistor, the gate structure comprising: a semiconductor substrate; a first insulation film provided on the semiconductor substrate; a first conductive film provided on the first insulation film; a second insulation film, provided on the first conductive film, having an opening; a spacer provided on the second insulation film to define the opening; and a second conductive film provided on the spacer and electrically connected to the first conductive film via the opening.
[0008] According to a second aspect of the present invention, there is provided a method of manufacturing a nonvolatile semiconductor memory device whose gate structure of a transistor other than a memory cell transistor has a same stacked gate structure as the memory cell transistor, the method of making the gate structure comprising: successively depositing a first insulation film, a first doped polysilicon film and a second insulation film on a semiconductor substrate; depositing a second undoped polysilicon film on the second insulation film; selectively removing the second undoped polysilicon film until the second insulation film is exposed, using a photoresist film having a first opening with a first opening width; depositing, after the photoresist film is removed, a third doped polysilicon film on a surface of the substrate; selectively removing, by RIE, the third doped polysilicon film and the second insulation film in a vertical direction from a bottom of the first opening, using the third doped polysilicon film as a spacer, to define a second opening with a second opening width that is less than the first opening width; and forming a conductive film on the surface of the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a plan view showing a nonvolatile semiconductor memory device according to embodiments of the present invention;
[0010] FIGS. 2A and 2B to 8 A and 8 B are cross-sectional views that schematically show a gate structure of a cell transistor and a gate structure of a transistor other than the cell transistor in a fabrication process of the nonvolatile semiconductor memory device according to a first embodiment of the invention;
[0011] FIGS. 9A and 9B to 11 A and 11 B are cross-sectional views that schematically show a gate structure of a cell transistor and a gate structure of a transistor other than the cell transistor in a fabrication process of the nonvolatile semiconductor memory device according to a second embodiment of the invention;
[0012] FIG. 12 is a graph showing variations in ONO slit width between the embodiments and a reference example;
[0013] FIGS. 13A and 13B to 17 A and 17 B are cross-sectional views that schematically show a gate structure of a cell transistor and a gate structure of a transistor other than the cell transistor in a fabrication process of the nonvolatile semiconductor memory device according to the reference example;
[0014] FIG. 18 is a graph showing the relationship between a BSG film thickness x and a slit width y;
[0015] FIG. 19 is a graph showing the relationship between a taper angle x of a BSG film and a slit width y; and
[0016] FIG. 20 is a graph showing the relationship between a resist dimension x and a slit width y.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0017] Prior to a description of embodiments of the present invention, a reference example is first described. In the Figures, (A) and (B) correspond to an X 0 -X 0 cross section and a Y 0 -Y 0 cross section in a plan view of FIG. 1 .
[0018] As is shown in FIGS. 13A and 13B , a first gate oxide film 32 with a thickness of 8 nm, a first P (phosphorus) doped polysilicon film 33 that is formed to a thickness of 160 nm by reduced-pressure CVD, and a first silicon nitride film 34 with a thickness of 70 nm are successively deposited on a P-type semiconductor substrate 31 or a P-type well that is formed in a semiconductor substrate.
[0019] A photoresist is processed to have a desired pattern by a lithography technique, and it is used as a mask to perform RIE (Reactive Ion Etching). By the RIE, the first silicon nitride film 34 , polysilicon film 33 , first gate oxide film 32 and semiconductor substrate 31 are processed to form a trench 35 .
[0020] The trench 35 is filled with a second silicon oxide film 36 , which is deposited to a thickness of 550 nm by an HDP (High Density Plasma) method. Then, the second silicon oxide film 36 is planarized by CMP (Chemical Mechanical Polishing) until the first silicon nitride film 34 is exposed. After heating the semiconductor substrate 31 at 900° C. in a nitrogen atmosphere, the first silicon nitride film 34 is removed by a phosphoric-acid process at 150° C. The second silicon oxide film 36 that is buried in the trench 35 is etched back so as to expose a part of an inner wall of the doped polysilicon film 33 .
[0021] As is shown in FIGS. 14A and 14B , an ONO film 37 is deposited on the surface of the substrate. The ONO film 37 comprises a silicon oxide film with a thickness of 5 nm, a silicon nitride film with a thickness of 7 nm and a silicon oxide film with a thickness of 5 nm, and has a total thickness of 17 nm. The resultant structure is heated in an oxidizing atmosphere.
[0022] Subsequently, a second undoped polysilicon film 38 is grown to a thickness of 400 Å (angstrom) by reduced-pressure CVD, and a BSG (Boron-doped Silicate Glass) film 39 with a thickness of 500 nm is formed by reduced-pressure CVD.
[0023] As is shown in FIGS. 15A and 15B , a photoresist film is processed by the lithography technique to have a pattern 40 with a space of 220 nm, and the pattern 40 is used as a mask to etch back, by RIE, the BSG film 39 so as to form a taper having an angle of, e.g. about 83°.
[0024] As shown in FIGS. 16A and 16B , the photoresist film is removed, and the BSG film 39 is used as a mask to vertically etch, by RIE, the second undoped polysilicon film 38 and ONO film 37 . Thereby, the ONO film 37 has a slit width w 2 of about 100 nm.
[0025] As is shown in FIGS. 17A and 17B , the BSG film 39 is removed by a hydrofluoric-acid process, following which a third P doped polysilicon film 41 is deposited to a thickness of 60 nm by reduced-pressure CVD. Further, a tungsten silicide film 42 is formed to a thickness of 800 Å by sputtering or CVD.
[0026] When the above technique is used, however, the slit width w 2 in an inter-poly insulation film, i.e. the ONO film 37 , varies greatly due to a change in thickness of the BSG film 39 or a change in taper angle at the time of etching back the BSG film 39 .
[0027] FIG. 18 shows the relationship between the thickness x of the BSG film 39 and the slit width y. The slit width y is given by y=−0.2399x+220. FIG. 19 shows the relationship between the taper angle x of BSG film 39 and the slit width y that is given by y=18.769x−1468. FIG. 20 shows the relationship between the resist dimension x and the slit width y that is given by y=1.0469x−136.44.
[0028] Specifically, if the BSG film thickness varies ±10%, the slit width varies ±12 nm for a target value of 100 nm. If the taper angle varies ±1%, the slit width varies ±17 nm. If the resist dimension varies ±10%, the slit width varies ±22 nm. In the worst case, the variation becomes ±54 nm. In short, the control of dimensions is very difficult in consideration of misalignment in the lithography technique and etching of the inter-poly insulation film at the side wall of the slit due to the hydrofluoric-acid process for removing the BSG film. Furthermore, the number of process steps increases due to the process of forming and removing the BSG film.
[0029] A nonvolatile semiconductor memory device with a floating gate and a method of manufacturing the same will now be described with reference to the accompanying drawings. FIG. 1 is a plan view showing a part of a nonvolatile semiconductor memory device according to a first embodiment of the invention. An SG/FG line, an SG/FG space, an SG/FG line, a GC/FG space, a GC/FG line, a GC/FG space and a GC/FG line are provided in the row direction. Active areas AA and shallow trench isolation regions STI are alternately arranged. The active areas AA and shallow trench isolation regions STI are successively arranged in the column direction.
[0030] Symbol SG designates a select gate, FG a floating gate, and GC a gate conductor. In the Figures that are referred to below, (A) corresponds to an X 0 -X 0 cross section in an X-direction in FIG. 1 , and (B) corresponds to a Y 0 -Y 0 cross section in a Y-direction. (A) and (B) show, respectively, a gate structure of a cell transistor, and a gate structure of a transistor other than the cell transistor, for example, a select transistor in a peripheral circuit section.
[0031] As is shown in FIGS. 2A and 2B , a first gate oxide film 12 with a thickness of 8 nm, a first P (phosphorus) doped polysilicon film 13 with a thickness of 160 nm deposited by reduced-pressure CVD, and a first silicon nitride film 14 with a thickness of 70 nm are successively deposited on a P-type semiconductor substrate 11 (or a P-type well formed in a semiconductor substrate). The first polysilicon film 13 will serve as a floating gate in the memory cell transistor. A photoresist film 15 is formed on the first silicon nitride film 14 . The photoresist film 15 is processed to have a desired pattern by the lithography technique.
[0032] As is shown in FIGS. 3A and 3B , the photoresist film 15 is used as a mask to perform RIE (Reactive Ion Etching). By the RIE, the first silicon nitride film 14 , polysilicon film 13 , first gate oxide film 12 and semiconductor substrate 11 are processed to form a trench 16 . Then, the trench 16 is filled with a second silicon oxide film 17 , which is deposited to a thickness of 550 nm by an HDP (High Density Plasma) method.
[0033] As is shown in FIGS. 4A and 4B , the second silicon oxide film 17 is polished and planarized by CMP (Chemical Mechanical Polishing) until the first silicon nitride film 14 is exposed.
[0034] As is shown in FIGS. 5A and 5B , after heating the semiconductor substrate 11 at 900° C. in a nitrogen atmosphere, the first silicon nitride film 14 is removed by a phosphoric-acid process at 150° C. The second silicon oxide film 17 buried in the trench 16 is etched back so as to expose a part of an inner wall of the doped polysilicon film 13 .
[0035] As is shown FIGS. 6A and 6B , an ONO film 18 with a thickness of 17 nm is deposited on the surface of the substrate by reduced-pressure CVD. The resultant structure is heated in an oxidizing atmosphere. Subsequently, a second undoped polysilicon film 19 is deposited to a thickness of 40 nm by reduced-pressure CVD. A photoresist film 20 is processed by the lithography technique to have a space (opening width) of 220 nm. The photoresist film 20 is used as a mask to etch, by RIE, the second undoped polysilicon film 19 until the ONO film 18 is exposed.
[0036] The second undoped polysilicon film 19 is formed in order to prevent, as much as possible, diffusion of the impurity such as P into the vicinity of a tunnel oxide film that requires a high withstand voltage. The second undoped polysilicon film 19 will be finally doped by the diffusion of P from a P-doped polysilicon film.
[0037] As is shown FIGS. 7A and 7B , the photoresist film 20 is removed, and a third P-doped polysilicon film 21 is deposited to a thickness of 60 nm on the ONO film 18 by reduced-pressure CVD. Using the third polysilicon film 21 as a spacer, RIE is performed to vertically process both the third polysilicon film 21 and ONO film 18 at the bottom of the slit as it is. Thereby, the ONO film 18 has a slit width w 1 of about 100 nm. The third polysilicon film 21 will serve as a control gate in the memory cell transistor.
[0038] As has been described above, the slit width w 1 is adjusted by the thickness of the third polysilicon film 21 that serves as the spacer. This will provide a much better controllability than the taper controllability of RIE.
[0039] As is shown FIGS. 8A and 8B , a tungsten silicide film 22 is deposited to a thickness of 800 Å by sputtering or CVD. Thereby, a gate electrode of the transistor other than the cell transistor, which comprises the doped polysilicon film 13 and tungsten silicide film 22 , is formed. Thus, the device is completed.
[0040] Next, a second embodiment of the invention is described. The second embodiment is common to the first embodiment with respect to the fabrication steps illustrated in FIG. 2A through FIG. 5B . The common parts are denoted by like reference numerals, and the description is omitted.
[0041] As is shown in FIGS. 9A and 9B , an ONO film 18 with a thickness of 17 nm is deposited on the surface of the substrate by reduced-pressure CVD. The resultant structure is heated in an oxidizing atmosphere. Subsequently, a second undoped polysilicon film 19 is deposited to a thickness of 40 nm by reduced-pressure CVD. A photoresist film 20 is processed by the lithography technique to have a space of 180 nm. The photoresist film 20 is used as a mask to etch the second undoped polysilicon film 19 until the ONO film 18 is exposed.
[0042] As is shown in FIGS. 10A and 10B , the photoresist film 20 is removed, and a third undoped polysilicon film 211 is deposited to a thickness of 40 nm on the ONO film 18 by reduced-pressure CVD. Using the third polysilicon film 211 as a spacer, RIE is performed to vertically process the third polysilicon film 211 and ONO film 18 at the bottom of the slit. Thereby, the ONO film 18 has a slit width w 1 of about 100 nm.
[0043] Similarly with the third polysilicon film 21 , the slit width w 1 is adjusted by the thickness of the third polysilicon film 211 that serves as the spacer. This will provide a much better controllability than the taper controllability of RIE.
[0044] As is shown in FIGS. 11A and 11B , a fourth P-doped polysilicon film 23 with a thickness of 20 nm is formed on the exposed surface of the substrate, and a tungsten silicide film 22 is deposited to a thickness of 800 Å by sputtering or CVD. Thereby, a gate electrode of the transistor other than the cell transistor, which comprises the doped polysilicon film 13 and tungsten silicide film 22 , is formed. Thus, the device is completed.
[0045] Other conductive material such as tungsten may be used as material of the control gate. Aside from the tungsten silicide that is used in the first and second embodiments, tungsten or doped polysilicon may be used.
[0046] In the above-described reference example, due to a variation in thickness of the BSG film and a variation in taper angle resulting from RIE processing of the BSG film, the dimensional precision in ONO slit width is low, as illustrated in FIG. 12 . Specifically, the ONO slit width varies ±54 nm with respect to a target value of 100 nm. According to the present invention, however, the ONO slit width depends only on a variation in resist dimension and a variation in thickness of the polysilicon film 21 , 211 . The variation in the first embodiment is 34 nm, and that in the second embodiment is 26 nm. By processing the polysilicon film 21 , 211 as a spacer, the dimensional controllability can remarkably be improved. Moreover, the fabrication steps are simplified, and the manufacturing cost can advantageously be reduced by 32%.
[0047] If a desired ONO slit width is secured, the resist dimension or the thickness of the polysilicon in process steps after the formation of the ONO film is not limited to the set value in the first and second embodiments.
[0048] Instead of the ONO film, a high-dielectric-constant film such as Al 2 O 3 may be used.
[0049] The present invention is not limited to the above-described embodiments, and various modifications may be made, as is obvious to a person skilled in the art.
[0050] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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A nonvolatile semiconductor memory device whose gate structure of a transistor other than a memory cell transistor has a same stacked gate structure as the memory cell transistor, the gate structure comprising a semiconductor substrate, a first insulation film provided on the semiconductor substrate, a first conductive film provided on the first insulation film, a second insulation film, provided on the first conductive film, having an opening, a spacer provided on the second insulation film to define the opening, and a second conductive film provided on the spacer and electrically connected to the first conductive film via the opening.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit of co-pending U.S. Provisional Patent Application Ser. No. 60/450,432, filed on Feb. 27, 2003, which application is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention generally relate to the field of well drilling, particularly to the field of well drilling for the extraction of hydrocarbons from sub-surface formations, wherein the drill string is used as the well casing.
[0004] 2. Description of the Related Art
[0005] The drilling of wells to recover hydrocarbons from subsurface formations is typically accomplished by directing a rotatable drilling element, such as a drill bit, into the earth on the end of tubing known as a “drill string” through which drilling mud is directed to cool and clean the drilling face of the drill bit and remove drilled material or cuttings from the borehole as it is drilled. After the borehole has been drilled or bored to its desired depth and location, the borehole is typically cased, i.e., metal tubing is located along the length of the borehole and cemented in place to isolate the borehole from the surrounding earth, prevent the formation from caving into the borehole, and to isolate the earth formations from one another. The casing is then perforated at specific locations where hydrocarbons are expected to be found, to enable their recovery through the borehole.
[0006] It is known to use casing as the drill string, and, when drilling is completed to a desired depth, to cement the casing in place and thereby eliminate the need to remove the drill string from the borehole. However, when casing is used in place of the drill string, any equipment or tooling used in the drilling of the well must be removed from the interior of the casing to allow an additional, smaller diameter casing and drill bit to drill the borehole further into the earth. Thus, the drill bit or drill shoe located at the end of the drill string must be eliminated as an obstacle, without pulling the casing from the borehole. Removal of the drill shoe is typically accomplished by drilling through the drill shoe with a second drill shoe or drill bit extended into the previously cemented casing, and thence into the earth beyond the just drilled drill shoe. Thus the drill shoe needs to be configured of a drillable material, which limits the loading which can be placed on the drill shoe during drilling and thus limits the efficiency of drilling with the drillable drill shoe. Typically a “drillable” drill shoe is configured of a relatively soft metal, such as aluminum, with relatively hard inserts of materials such as synthetic diamond located thereon to serve as the cutting material. Additionally, although the main body of the drillable drill shoe is configured of a readily drilled material, the hard cutters of the drill shoe tend to cause rapid wear and physical damage to the drill shoe being used to drill through the previous drill shoe, thus reducing the life of the drill bit, and thus the depth of formation the drill shoe can penetrate before it too must be drilled through by an additional drill shoe directed through the casing.
[0007] It is also known to provide a drill shoe having a relatively soft metal body, within which a plurality of stronger metal blades are received, upon which blades are supplied the cutters for cutting into the earth as the borehole progresses and which blades may be moved out of the area through which the drill shoe is drilled and subsequent casing penetrates, as is disclosed in U.S. Pat. No. 6,443,247, assigned to the assignee of the present invention and incorporated by reference herein in its entirety. This drill shoe includes an integral piston assembly therein, which, upon actuation by a drilling operator, pushes through the drill shoe and physically presses the harder metal blades, with the cutters thereon, into the annular area and/or the adjacent formation and out of the area through which the next drill shoe will pass. Thereafter, an additional drill shoe is passed down the existing casing to remove the remaining, relatively soft, metal mass of the drill shoe, and into the formation beyond the just drilled through drill shoe. Although this drill shoe configuration solves the problem encountered when the drill shoe would otherwise need to engage and grind up hard metal parts, the drill shoes still suffer from limited lifetimes because the blades will extrude or otherwise become separated from the relatively soft metal body of the drill shoe if the loading thereon exceeds a certain threshold. Thus, although this style of drill shoe has gained a high degree of commercial acceptance, the capability of the drill shoe remains limited.
SUMMARY OF THE INVENTION
[0008] The present invention generally provides methods and apparatus for drilling of boreholes, wherein the drill string is used as the casing for the borehole, wherein the drill shoe used for drilling the borehole includes an integral displacement element whereby the cutting elements of the drill shoe are displaceable into the formation surrounding the drill shoe when the well is completed. The drill shoe includes one or more blades having cutters thereon, and each of the blades includes an engagement profile for secure engagement with the body of the drill shoe during drilling operation yet is readily deformed to be embedded into the formation adjacent the drill shoe when drilling is completed.
[0009] In one embodiment, the blades include an outer axial section, a transverse section, and a generally axial base section that are received in a continuous slot formed within the body of the drill shoe. The slot and the blade include complementary profiles for maintaining the blades in position against the loading of the blades caused by the engagement thereof with the formation being drilled, while allowing the blades to be displaced into the formation after drilling is completed.
[0010] To enable displacement of the blades into the formation, the drill shoe preferably includes a passageway therein through which the drilling mud is flowed, and which is selectively blocked while the drilling mud is continued to be pumped into the drill string. The blocking of the mud passages completes a piston structure, which is actuated through the drill shoe and thereby pushes the blades into the adjacent formation.
[0011] In another aspect, the present invention provides an earth removal apparatus comprising a first body portion and a second body portion at least partially receivable within the first body portion. A profile is formed on an outer surface of the second body portion and a cutting member is engaged with the profile, wherein the profile is adapted to maintain the cuffing member on the profile during operation.
[0012] In another aspect, the present invention provides an earth removal apparatus comprising a drillable body portion and at least one profile formed on an outer surface of the drillable body portion. The at least one profile including at least two intersecting faces, wherein one of the faces includes a projection thereon. A blade is matingly engageable with the at least one profile.
[0013] In another aspect, the present invention provides a drill bit comprising a first body portion and a drillable second body portion. At least one profile is formed integral with at least one of the first body portion and the drillable second body portion, the at least one profile having at least two opposed segments having a discernable orientation. A cutting member is received in the at least one profile and having the discernable orientation and the discernable orientation including an included angle between the opposed segments of less than ninety degrees.
[0014] In another aspect, the present invention provides a method of drilling with casing, wherein a drillable drill bit is provided, comprising providing a drill bit support at a lower end of the casing, locating a drillable body portion within the drill bit support, and providing a blade receiving member integral with at least one of the drill bit support and the body portion. The receiving member including a profile. The method also includes positioning a blade having a mating profile on the receiving member and using the drill bit to form a wellbore, wherein the profile is adapted to substantially maintain the blade on the blade receiving member during drilling.
[0015] In another aspect, the present invention provides a method of completing a wellbore comprising providing an earth removal apparatus at a lower of a drill string. The earth removal apparatus having a first body portion and a drillable portion disposed in the first body portion, the drillable portion including a bore. The method also includes forming the wellbore, blocking the bore from fluid communication, moving the drillable portion relative the first sleeve portion, and re-establishing fluid communication between an inner portion of the earth removal apparatus and the wellbore.
[0016] In another aspect, the present invention provides a downhole valve comprising a first body portion, a bore disposed through the first body portion, and an obstruction member retainer at least partially disposed in the bore, wherein the obstruction member retainer is adapted to cooperate with an obstruction member to provide selective fluid communication through the bore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0018] [0018]FIG. 1 is a perspective view of a drill shoe of the present invention;
[0019] [0019]FIG. 2 is a sectional view of the drill shoe of FIG. 1 in a downhole location;
[0020] [0020]FIG. 3 is a sectional view of the drill shoe of FIG. 2, after the drill shoe has reached total depth and the drill shoe is prepared to be drilled through;
[0021] [0021]FIG. 4 is a perspective view of a blade portion of the drill shoe of FIG. 1;
[0022] [0022]FIG. 5 is a sectional view of the blade portion disposed on the notch of the drill shoe;
[0023] [0023]FIG. 6 is a further sectional view of the blade portion disposed on the notch of the drill shoe;
[0024] [0024]FIG. 7 is a sectional view of the drill shoe as shown in FIG. 2, after having been drilled through
[0025] [0025]FIG. 8 shows another embodiment of a drill shoe according to aspects of the present invention;
[0026] [0026]FIG. 9 shows yet another embodiment of a drill shoe according to aspects of the present invention; and
[0027] [0027]FIG. 10 shows the drill shoe of FIG. 9 after the ball has extruded though the ball seat to re-establish circulation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] Referring initially to FIG. 1, there is shown in perspective an earth removal apparatus such as a drill shoe 10 of the present invention, for placement on the end of a string of casing for drilling a borehole into the earth, primarily for the recovery or potential recovery of hydrocarbons from sub-surface locations. The drill shoe 10 generally includes a support, such as a sleeve portion 20 , into which is received a drillable member, such as a body portion 30 , and over which are secured a plurality of cutting members or blades 26 (only four of a total of six to be so located) in notches 70 formed on the exterior of the drill shoe 10 . The drill shoe 10 is specifically configured to enable the drilling of a borehole with the drill shoe 10 , with subsequent cementing of the casing into the borehole, and then subsequent drilling through of the drill shoe 10 with a subsequent drill shoe 10 .
[0029] Referring now to FIGS. 2 and 3, there is shown, in cross section, the drill shoe 10 of the present invention, suspended upon casing 12 located within a borehole 14 , which casing 12 is rotated by a drilling table, top drive, or similar apparatus (not shown) at the earth's surface to enable the drill shoe 10 to drill or cut into the formations encountered thereby and thus form the borehole 14 . The drill shoe 10 generally includes an outer, tubular sleeve 20 upon which a plurality of blades 26 are secured, and within which is positioned a body portion 30 of a drillable material, such as aluminum. In operation, the body portion 30 provides rigidity to prevent deformation of the sleeve 20 and maintain the drill shoe 10 on a threaded connection on the lower most extension of the casing in the wellbore as drilling operations are carried out, and also provides an extrusion element which may be pushed through the sleeve 20 and thereby push the blades 26 into the adjacent formation in the annular area and/or sides of the borehole 14 to enable drilling through of the drill shoe 10 during subsequent operations in the borehole 14 .
[0030] Sleeve 20 is generally configured as a tubular or cylindrical element, and includes a first, threaded end 22 for threaded receipt upon the lowermost extension of the casing 12 , an outer, cylindrical face 24 upon which a plurality of blades 26 (preferably 6) are disposed, and a lower open end 28 . The inner cylindrical face of sleeve 20 includes a first, major diameter bore 34 extending from first end 22 , and a second smaller diameter bore 36 extending from a ledge 38 formed at the intersection of these two, collinear, bores. Within sleeve 20 is received the body portion 30 of a drillable material, such as aluminum, which forms a mass within the sleeve to maintain the shape of sleeve 20 as the drill shoe 10 is pushed against the bottom 16 of the borehole 14 and rotated. Sleeve 20 further includes a plurality of mud vents 37 , disposed radially through the sleeve 20 at the major diameter bore 34 .
[0031] Body portion 30 is a generally right circular mass of drillable material, having features formed therein such as by machining, to provide a mass of material to back up the relatively thin wall of the sleeve 20 during drilling, to enable the extrusion of the body portion 30 through any potentially borehole interfering sections of the sleeve 20 and the blades 26 when the drilling is completed with the drill shoe 10 , and to provide a readily drillable material for removal of the mass from the borehole 14 . Body portion 30 generally includes a main counterbore 40 extending inwardly of the first end 42 thereof, and ending at a generally conically concave base 44 from which a mud bore 46 extends inwardly of the backup portion of body portion forming backup mass to limit the deformation of the sleeve 20 and the blades 26 during drilling operations. Mud bore 46 splits into a plurality of mud passages 50 , which terminate at the lower surface of the body portion 30 . Mud bore 46 also includes a tapered seat portion 52 , into which a ball 51 (FIG. 2) may be seated, as will be further described herein. The outer surface of body portion 30 includes a generally right circular outer face 54 , and an end portion 56 which is profiled and machined to receive a portion of the blades 26 therein, as will be described further herein. Outer face 54 includes, at the opening of the counterbore 40 , a outwardly extending lip 58 which sealingly, or at least is substantially closely, fits to the inner face of major diameter bore 34 , as well as at least one axial slot 60 , extending along the outer face 54 from the end portion 56 . A pin 62 is secured within sleeve 20 and extends into slot 60 , and serves to prevent rotation of the body portion 30 within sleeve 20 when a different drill bit introduced down the casing interior drills the body portion 30 out.
[0032] To retain the body portion 30 within sleeve 20 , the sleeve 20 includes a retainer ring 64 , located within major diameter bore 34 generally above the body portion 30 and secured thereto with pins or the like, which prevents retraction of the body portion 30 from the sleeve 20 , and an inwardly projecting lip 66 , extending inwardly at the lower open end thereof, which is received into an annular recess 68 machined or cast into the face of body portion 30 about its perimeter (best shown in FIG. 3). Lip 66 may be a continuous inward projection on the end of the sleeve 20 , or may be a separate retainer ring which is affixed at its inboard end to the end of sleeve 20 .
[0033] Referring again to FIG. 1, a general overview of the structure of the blades 26 , as well as their attachment to the drill shoe 10 , is shown. Generally, the blades 26 are received within a profile which extends along the outer surface of the sleeve 20 and the base of body portion 30 . An exemplary profile is a notch 70 configured to interact with the blade 26 to keep the blade 26 in position on the sleeve 20 during drilling operation. Each blade 26 is formed of a single length of steel, or similar material having both relatively high strength, rigidity and ductility, bent to form opposed first and second linear sections 72 , 74 , which are interconnected by curved shoulder segment 76 . A plurality of cutters 78 are located on the outer face of the blades 26 , to be engaged with, and cut into, the formation as the borehole extends therein. Although six blades 6 are shown in the Figures, it is contemplated that any suitable number of blades 26 may be disposed on the drill shoe 10 . For example, the drill shoe 10 may include four blades or five blades.
[0034] The interface and interconnection of the blade 26 and notch 70 is shown in detail in FIGS. 5 and 6, wherein the blade 26 is generally rectangular in cross section, and includes a multifaceted base 80 which contacts a multifaceted first face 82 of the notch 70 , and a sidewall 84 which abuts against a second face 86 of the notch 70 . Multifaceted base 80 includes a centrally located, generally rectangular, slot 88 extending therein over the length thereof, into which a mating rectangular projection 90 of the notch 70 extends, along the entire length of the blade 26 . Projection 90 , being generally rectangular in cross section, forms in conjunction with multifaceted first face 82 a first compression face 104 extended upwardly on projection 90 , and first and second lower compression faces 106 , 108 , disposed to either side of first compression face 104 , an anti-rotation flank 100 in facing relationship to second face 86 of notch 70 , and a secondary abutment face 93 , on the opposed flank of the projection from anti rotation flank 100 and generally parallel thereto and to second face 86 of the notch 70 .
[0035] Referring again to FIG. 1, to create the multifaceted notch 70 , a continuous groove (not shown) is cut into the outer face of both the sleeve 20 and body 30 , into which preforms 112 and 114 , having the specific geometry of the notch 70 provided therein, are inserted and welded into place. Alternatively, the preform 114 in body portion 30 may be created by directly molding a boss into the body portion 30 when the body portion 30 is initially configured such as by aluminum casting, and then machining the specific geometry of the notch 70 therein. Alternatively still, the preforms 112 , 114 may be formed into both the sleeve 20 and the body portion 30 by machining. Additionally, the outer surface of the sleeve 20 includes stabilizers or standoffs 132 , positioned at the uppermost terminus of the notch 70 , having a height corresponding generally to the height of the cutters 78 on the first linear section 72 of the blades 26 , to center or stabilize the drill shoe 10 in the borehole 14 .
[0036] Referring now to FIGS. 5 and 6, the blade 26 includes geometry complimentary to the notch 70 , such that slot 88 projecting into multifaceted base 80 creates a multi level engagement surface, including a recessed face 91 and two extended faces 92 , 94 , generally parallel thereto and extended therefrom by the depth of the slot 88 , as well as first projecting face 96 and second projecting face 98 , formed as the flanks of the slot in a facing, generally parallel relationship to one another and to the sidewall 84 . The depth of slot 88 is variable, such that the slot 88 is deeper, and thus the area of faces 96 and 98 are greater, in second linear section 74 of the blade 26 which, in use, is located within the notch 70 received in the body portion 30 of the drill shoe 10 . Likewise, as shown in FIG. 5, the height of sidewall 84 is increased to maintain a larger area for full depth contact between sidewall 84 and second face 86 . As it is specifically contemplated that the body portion 30 is configured from an easily drillable material, which will likely have a lower shear or yield resistance than the material used for the sleeve 20 , this larger area of the faces (and correspondingly of sidewall 84 ) helps distribute the load in the notch 70 over a greater area in the body portion 30 as compared to the sleeve 20 , and thereby reduce the likelihood of plastic failure of the notch 70 as it extends in the body portion 30 under drilling conditions. As shown in FIGS. 5 and 6, the aspect ratio of the slot 88 (and correspondingly in the mating surfaces of the notch 70 ), and likewise of the projection 90 , defined as the height of the projection (or depth of slot) to its width, ranges in the embodiment shown from slightly over 1:1 at the first linear section 72 of the blade 26 , to approximately 2:1 at the second linear section 74 of the blade 26 . It is contemplated that higher aspect ratios are appropriate, for example, where the blade is very large in width, i.e., the circumferential direction of the sleeve 20 , for example on the order of 5 inches wide, a slot depth of only 0.010 inches may be appropriate, resulting in an aspect ratio of 0.002:1. Likewise, were the blade made relatively tall, a high aspect ratio on the order of 500:1 may be appropriate.
[0037] Received upon the outer surface of the blade 26 are a plurality of cutters 78 , typically hardened synthetic diamond compacts, which are attached thereto using welding, high strength adhesives, threaded engagement into bores in the blade 26 , or the like. To secure the blade 26 and fill the gaps or clearances between the blade 26 in the notch 70 , adhesive or filler, such as Tubelok available from Weatherford Corporation of Houston, Tex., is applied to the blade 26 and notch 70 , and the blade 26 pushed therein. It is specifically contemplated that the fit of the blade 26 in the notch 70 not be an interference fit at ambient temperatures, and that a clearance on the order of a few thousands of an inch between the slot 88 and projection 90 is allowable as long as the fit is snug.
[0038] During drilling operation, the drill shoe 10 rotates generally about axis 120 (FIG. 2) such that, as shown in FIG. 5, the blade 26 moves in the direction of arrow 122 into engagement with the formation. As a result, force will be imparted against the blade 26 as shown by arrow 124 , tending to cause the blade 26 to rotate (or load in the notch 70 ) as shown by arrow 126 . The configuration of the blade 26 and notch 70 are specifically provided to prevent such motion. Thus, as this loading occurs, sidewall 84 is pushed against second face 86 of the groove, and first projecting face 96 bears against secondary abutment face 93 of groove, to provide lateral or direct support against the primary load of the formation, simultaneously, second projecting face 98 is coupled, by the moment caused by the loading of the blade 26 at the cutters 78 , against anti-rotation flank 100 , and each of the faces 91 , 92 and 94 of the blade 26 are loaded by the moment against their respective compression faces 104 , 106 and 108 , thereby preventing significant movement of the blade 26 in the notch 70 . Thus, as force is imparted against the blade 26 in the direction of the arrow 126 , any tipping or rotation of the blade 26 will be absorbed by the notch 70 . To secure the blade 26 on the sleeve 20 , the blade 26 is welded thereto at one or more locations along its length.
[0039] The blade geometry, in addition to the blade profile helps maintain the blade 26 on the sleeve 20 . During drilling operations, it is unlikely that the entire length of a blade 26 will be simultaneously engaged against the formation. Furthermore, the presence of standoffs 132 on the sidewall of the sleeve 20 limits the penetration of the cutters 78 on the first linear section 72 of the blade 26 . Thus, when the drill shoe 10 is pushing against the bottom of the borehole 14 , the second linear section 74 of the blade 26 will be engaged with the formation, whereas the other portions may not. Thus, force will be imparted against the second linear section 74 of the blade 26 , tending to cause it to tip or rotate in the notch 70 in the direction of arrow 126 (FIG. 5). However, it can be seen from FIG. 4 that the geometry of the blade 26 results in the first linear section 72 and curved segment 76 being levers, with respect to the second linear section 74 , and the placement of these portions of the blade 26 within the notch 70 will cause these portions of the blade 26 , along with the structural rigidity of the blade 26 , to help the blade 26 resist rotating out of the notch 70 . Additionally, the included angle 136 between the two linear sections 72 , 74 , is preferably maintained below 90 degrees, which further enhances the likelihood of maintaining the blade 26 in the notch 70 . As the outer face 138 of the blade 26 is preferably parallel with the recessed face 91 and two extended faces 92 , 94 of the blade 26 which rest at compression faces 104 , 106 and 108 of the notch 70 , the included angle 136 is repeated between these faces as well.
[0040] Referring again to FIGS. 2 and 3, the operation of the drill shoe 10 for using the casing 12 as drill string is shown. Specifically, when the borehole 14 has reached total depth for the specific drill shoe 10 in use, which is a function of the wear of the drill shoe 10 , the casing 12 is pulled upwardly in the borehole 14 , to leave a space between the drill shoe 10 and the bottom of the hole 14 as shown in FIG. 2. In this position, drilling mud continues to flow down the middle of the casing 12 , and thence outwardly through the mud passages 50 in the drill shoe 10 and thence to the surface through the space between the drill shoe 10 and casing 12 and the borehole 14 .
[0041] To begin the operation ultimately leading to the elimination of the drill shoe 10 as an obstacle in the borehole 14 , a ball 51 is dropped through the casing 12 into the mud bore 52 from a remote location, which can include the earth's surface. When the ball 51 enters the mud bore 52 , it seals the mud bore 52 causing the mud to press down upon the body portion 30 , and causes the body portion 30 to slide within sleeve 20 from the position of FIG. 2 and FIG. 3. As the body portion 30 begins to slide, it deforms the base of sleeve 20 outwardly, and also deforms the second section 74 about the angled portion 76 of the blade 26 such that the blades 26 are bent into a generally linear condition as shown in FIG. 3. In one embodiment, the second section 74 may be embedded within the walls of the borehole along with the likewise deformed base of the sleeve 20 . In another embodiment, it may that a clearance exists between the wall of the borehole and the second section 74 . Movement of the body portion 30 within the sleeve 20 to the position shown in FIG. 3 also exposes the mud vents 37 to the drilling mud, thereby providing a new path for mud flow to re-establish circulation. In this respect, the new path may be used to introduce cement into the borehole to cement the casing 10 . In one embodiment, cement may be supplied through the mud vents 37 to cement at least a portion of the casing 10 into place. Additionally, re-establishing the new path also causes a pressure drop in the mud column, which indicates to the operator that the body portion 30 successfully moved within the sleeve 20 to bend the blades 26 outwardly. Thereafter, a subsequent drill bit or drill shoe is passed down the casing 12 , and is engaged into body portion 30 to drill through body portion and continue the drilling of the borehole 14 to further depth as shown in FIG. 7.
[0042] [0042]FIG. 8 presents another embodiment of the drill shoe according to aspects of the present invention. The drill shoe 10 includes a sleeve 220 having a body portion 230 disposed therein. The body portion 230 comprises a support sleeve 235 and an inner portion 240 . The inner portion 240 may include components such as the ball seat 252 and the inner core 245 . In one embodiment, the ball seat 252 and the inner core 245 may be two separate components, as shown in the Figure. In another embodiment, the inner portion 240 , e.g., the ball seat 252 and the inner core 245 , may be manufactured in one piece, as shown in FIG. 2. Preferably, the inner portion 240 comprises a drillable material such as aluminum, and the support sleeve 235 comprises steel or other composite material of sufficient strength to provide rigidity to the body portion 230 .
[0043] [0043]FIG. 9 presents another embodiment of the drill shoe 10 according to aspects of the present invention. As shown, the drill shoe 10 provides an alternative method of re-establishing circulation. The drill shoe 10 includes a body portion 330 disposed in an outer sleeve 320 . One or more blades are disposed on the outer surface of the outer sleeve 320 and the lower surface of the body portion 330 . The body portion 330 includes a bore 346 which splits into one or more passages for fluid communication with the borehole 14 . The bore 346 may include an obstruction member retainer for retaining an obstruction member. For example, the bore 346 may include a ball seat 352 for receiving a ball 351 . Preferably, the ball seat 352 comprises a flexible material such that the ball 351 may be pumped through the ball seat 352 when a predetermined pressure is reached. The bore 346 also includes a biasing member 360 such as a spring 360 disposed below the ball seat 352 . The spring 360 may be used to bias the ball 351 against the ball seat 352 to act as a valve to regulate fluid flow in the bore 346 . Although a ball seat is disclosed, other types of obstruction member retainer known to a person of ordinary skill in the art are contemplated, for example, an obstruction member retainer having a seating surface for receiving an obstruction member to regulate fluid flow.
[0044] [0044]FIG. 9 shows the drill shoe 10 after drilling has completed and the body portion 330 has deformed the base of the sleeve 320 outwardly. Particularly, a ball 351 landed in the ball seat 352 to allow pressure build up, thereby causing the body portion 330 to slide downward relative to the sleeve 320 . As a result, the second section of the blades is bent into a generally linear condition.
[0045] To re-establish circulation, pressure above the ball 351 is increased further to pump the ball 351 to through the flexible ball seat 352 , as shown in FIG. 10. The ball 351 lands on the spring 360 , which biases the spring 360 against the lower portion of the ball seat 352 , which acts as a second seating surface for the ball 351 . In this respect, a seal is formed between the ball 351 and the ball seat 352 , thereby closing off fluid communication.
[0046] When the pressure of the cement or other fluid in the casing 12 is greater than the biasing force of the spring 360 , the ball 351 may be caused to disengage the ball seat 352 , thereby opening up the bore 346 for fluid communication with the borehole 14 . In this manner, cement may be supplied to cement the casing 12 in the borehole 14 . After the cementing operation is completed, pressure in the casing 12 is relieved. In turn, the spring 360 is again allowed to bias the ball 351 against the ball seat 352 , thereby closing off the bore 346 for fluid communication. In this respect, the ball 351 and the ball seat 352 may act as a check valve to prevent cement or other fluid to re-enter the casing 12 .
[0047] Although the invention has been described herein with respect to a specific embodiment, these embodiments may be modified without affecting the scope of the claims herein. In particular, the groove and slot configuration may be modified. For example, the slot may be positioned in the groove and the blade may include the projection, or alternatively, several slots and mating projections may be provided.
[0048] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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A method and apparatus for a drilling with casing includes therewith a drill shoe configured for later drilling through thereof in situ, with cutters retainable thereon in response to the forces encountered during borehole drilling, yet moveable from the envelope through which the later drill shoe will pass when cutting through the in situ drill shoe. The drill shoe includes one or more profiles thereon, into which blades carrying the formation drilling cutters are disposed. The profiles include at least one projection thereon, which is received within a mating slot in the blades. The blades also may be configured to have opposed sections which are configured with respect to one another to have an included angle of less than ninety degrees.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is directed to a solar energy collection and storage apparatus including a storage container having a transparent covering and a dark absorbent bottom, as well as supply and offtake lines for fresh and household or industrial water.
2. The Prior Art
The discontinuous availability of sunlight makes storage equipment or reservoirs indispensable for autonomous systems or those that use the energy optimally. This is also true for the field of solar hot water production.
Especially in the period since 1973, variants of such solar hot water systems have been developed in virtually all the industrially developed countries. In principle, these systems can be classified as either large-surface-area systems with reservoirs of high volume and long storage time, or smaller systems with smaller reservoirs and a shorter storage time.
For economic reasons, variants in both classifications have recently appeared that feature a compact unit combining a solar energy collector and reservoir. In the field of the large systems, what is known as solar ponds have been developed, while in the field of smaller systems, combined collection and storage collectors, known as internal storage collectors, have been developed.
Solar ponds are based on a physical effect, discovered about 1900 in Hungary and technically improved in the 1950s in Israel (particularly by Tabor, et al.), according to which the surface water in a pond several meters deep is fresh water, while the layers below it are salt water, which increases in concentration toward the bottom. The sunlight penetrating to the dark bottom is absorbed there and converted into heat, but cannot--unlike the situation in typical freshwater ponds--be transported by convection to the surface, because the layers of water at the bottom are heavier. In this way, the lower portion of the solar ponds heats up and is relatively well insulated thermally by the fresh water layers located above it. The useful heat is then drawn from the lower portion of the solar pond, using a heat exchanger.
In practice, such solar ponds are used for instance to drive thermodynamic machines with drive fluids having a low boiling point; because of their function of solar energy storage around the clock, they can be used to produce mechanical energy or electric current even in periods of bad weather, if the solar pond is suitably dimensioned.
The internal storage collectors, in the simplest case, comprise black water-filled containers located inside an outer container that provides good insulation, the surface which is facing the sun may be provided with one or more glazed windows. The water that heats up in the interior of the black container may be delivered to the consumer either via heat exchangers or directly. An arrangement of this kind is known for instance from German Pat. No. 26 39 425.
Although the basic simplicity in design of the arrangements described greatly facilitates their actual manufacture, nevertheless they have very serious disadvantages, in particular because they still have a very low efficiency.
The substantial disadvantage of solar ponds is that at typical depths of three meters, the useful energy available at the bottom of the solar pond is only about 35%, because of the extinction of the longer-wave portion in the solar spectrum; this directly limits the maximum possible efficiency. Moreover, the stratification of such solar ponds with layers of salt water counterracts natural convection and must therefore be continuously maintained by pump circulation in order to keep the gradient constant. Finally, the free surface of the water is very vulnerable to the wind, especially when the surface area is large, as is desired, because the waves produced by the wind disrupt the stratification of the water layers and cause losses.
The substantial disadvantage of internal storage collectors is the great thermal inertia of the volume of water to be heated. Precisely in climatic regions having a fluctuating amount of sunshine, collectors of relatively small thermal capacity are advantageous, because they already furnish the required useful temperatures when the periods of sunshine are short. Storage collectors of the classic type are therefore limited in their use to countries that have a great deal of sunshine, and even then can be used only for applications in which hot water is not needed until the second half of the day.
This basic shortcoming of the system can be partly overcome, for example by isothermal heating in a storage collector of variable volume, such as that described in European patent application Ser. No. 0 219 566.
In this previously known arrangement, solar energy is absorbed continuously through an absorber hose that is transparent at the top and dark at the bottom; the fill level of the storage collector varies as function of the desired set temperature and the intensity of the incident sunshine. The system is now no longer thermally sluggish, and it operates at high efficiency. However, the water in the collector hose is not under pressure and must be brought to useful pressure with a supplementary pump. The heat losses of the reservoir toward the top are limited by a transparent insulation, but the the system still does not attain the insulating properties of nontransparent insulating materials such as polyurethane foam.
SUMMARY OF THE INVENTION
With this as its point of departure, the object of the present invention, while retaining a combined solar collector and storage apparatus of simple structure, is to provide for maximum possible collecting efficiency with respect to the incident solar spectrum, isothermal heating of the integrated reservoir volume, optimal thermal insulation of the reservoir volume, and the possibility of drawing heat from the pressureless reservoir volume through a heat exchanger acted upon by pressure.
This object is attained by embodying the dark bottom as an intermediate bottom dividing the container horizontally into a smaller upper water volume and a larger lower water volume, and by providing a device for attaining an equalization of heat between the upper volume and the top of the lower volume.
The device for heat equalization is embodied for instance by a pump arrangement that draws water from the upper volume and delivers it to the top of the lower volume, and at least one connecting line penetrating the intermediate bottom.
By means of this configuration, the smaller upper volume will heat up even with weak or brief sunshine, and this heated water is then moved for storage into the vicinity immediately below the intermediate bottom. There, the warm water can be stored with little loss, because of the good thermal insulating properties of the intermediate bottom that can be attained. Moreover, by means of the connecting lines, it is attained that when warm water is drawn from the upper, smaller volume, cold water will automatically follow after it from the bottom of the colder volume.
A favorable provision that a temperature sensor is assigned to the upper volume, and a comparison device is assigned to the sensor so that the temperature measured with the sensor can be compared with a pre-settable reference temperature; the pump of the pump arrangement is switched on whenever the measured temperature attains the reference temperature. In this way, isothermal heating can be accomplished.
To attain a laminar inflow of the water pumped into the lower volume, so that the stratification in the lower volume is disturbed as little as possible, the pump arrangement is followed by a delivery device which extends below the intermediate bottom, parallel to and spaced apart by a slight distance from it over the entire width of the container, is closed at the end, and is provided at the top with a plurality of outflow openings which become larger along the pressure drop as a function of this pressure drop.
Alternatively, the delivery device may include an inlet plate, on top of which transverse slits are arranged, which become wider along the pressure drop as a function thereof.
To suppress turbulence, it may also be provided that a horizontal grating be located just below the delivery device. As an alternative to the pump and line arrangement for bringing about thermal equalization, this device may have at least one heat conducting tube having heat exchanger fins. In this case, the heat exchange takes place solely by thermal conduction, without actually transporting water.
For drawing the thermal energy, a variant of the invention provides that a heat exchange device is disposed below the intermediate bottom, incorporated into a secondary circulation loop. Heat exchanger coils of conventional construction are possible for this purpose, preferably those that are arranged relatively flat.
As an alternative, it is also possible for a hot water offtake line to be disposed below the intermediate bottom, and for a cold water delivery line to discharge at the bottom of the lower volume, to compensate for the quantity of water taken out.
To store larger quantities of heat, it may be provided that the container is embodied as a float container anchored in a body of water. Such containers can be disposed in lakes and ponds, to store extraordinarily large volumes and thus considerable quantities of heat. It had already been recognized previously that by means of reservoirs disposed in bodies of water, considerable quantities of heat can be stored, for example to supply homes located in the vicinity with hot water and household water. However, it was previously assumed that heating of the reservoir volume would have to be accomplished by means of external collectors. By the embodiment according to the invention, a very economical combination of collector and reservoir is now devised.
For some applications, a particularly simple embodiment may be provided in which the intermediate bottom is embodied as a metal plate, which is dark on the top and can be covered by a heat insulating device as a function of sunshine. Such a metal plate reliably prevents turbulence of the two reservoir regions of different temperature and brings about the desired temperature stratification. The thermal conductivity of the metal plate per se enables conduction of heat between the reservoir regions, so that in this sense no separate device need be provided. In order to attain sufficient insulation of the same time, whenever there is no sunshine, especially at night, a correspondingly activatable covering is provided.
To attain good heat transmission, heat dissipation or conducting ribs can be provided on the underside of the metal plate, extending away from it. With these heat conducting ribs, such as those used in a similar configuration in electronic components with a high line consumption, good thermal conduction can be attained.
The variable heat insulating device can favorably include a plurality of adjustable insulating plates. These insulating plates may be arranged i a row, in the manner of a segmented roll-up window shutter of the type used in Germany, and drawn over the metal plate, or preferably they may be supported pivotably in such a manner that they can be pivoted from a covering and insulating position into a position in which they allow sunshine to penetrate. In particular, the plates may be made reflective on the surface. In the sunshine penetration position, it may be provided that the plates extend such that they reflect in the east-west direction and form a kind of mirror groove (booster mirror grooves), which weakly concentrate the sunlight without having to track the sun. In this way, effective exploitation of the solar energy is possible, especially in regions with little sunshine.
In accordance with a further characteristic of the invention this may advantageously be done by making the adjustment using so-called memory metals. These memory metals, which have been developed recently, are provided with a lattice structure, such that once a configuration has been imposed upon them, they resume it, after a temperature change and temporary deformation, whenever the original temperature is again established. This property can be very well exploited in order to adjust the thermal insulation, in particular of corresponding plates, as a function of the temperature, because in that case not only separate sensors but drive motors as well can be dispensed with, and the entire arrangement accordingly becomes completely maintenance-free, which appears extremely desirable for putting the invention to practical use.
Still other objects, features and attendant advantages of the present invention will become apparent to those skilled in the art from a reading of the following detailed description of the embodiments constructed in accordance therewith, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
Further characteristics, advantages and details of the invention will become apparent from the ensuing description of an exemplary embodiment, referring to the drawing, in which:
The drawing shows a schematic sectional view of an apparatus according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawing, a container 1 having an insulating outer wall is shown. This container may be embodied by the natural or artificial wall of a pond, in an embodiment as a kind of solar pond, or else by an insulating container wall of virtually arbitrary size, in an embodiment as an internal storage collector. In the exemplary embodiment, the top of the container 1 is closed and hence thermally insulated by three transparent layers of a transparent film.
A bottom which is dark on its top and hence absorbs thermal gradiation is embodied as an intermediate bottom 3 and extends horizontally transversely across the container 1, so that two volumes of water separated from one another are formed, the lower water volume A being greater than the upper water volume B. A line 4 penetrates the intermediate bottom 3 and connects the underside of the lower, larger volume A with the upper, smaller volume B. An outlet line 5 leads from the upper volume B to a pump 6, from which a return line 7 extends, discharging into a delivery device 8. The delivery device 8 is embodied by at least one tube closed at the ends and extending horizontally, transversely to and below the intermediate bottom 3, and having a plurality of outlet openings 9 through which water that gas been fed in can escape upward with as little turbulence as possible. Below the intermediate bottom 3, coils 10 of a heat exchanger that is incorporated into a secondary circulation loop indicated by the arrow 11 extend in a parallel, horizontal plane. A temperature sensor 12 is disposed in the upper volume B and connected to comparison device 13, which, although not shown in detail, has a device for setting a reference temperature T ref and compares it with the actual temperature T w ascertained by the temperature sensor 12 and triggers the pump 6 as a function of this comparison.
The pump is switched on whenever the temperature T w detected by the temperature sensor 12 drops below the set reference temperature T ref .
When sunlight reaches it, the upper water volume heats up very rapidly, because of its small quantity and the complete extinction of the light, partially in the water and partially at the dark intermediate bottom 3. This heated water, when the pump 6 is switched on, is stratified in laminar fashion via the delivery device 9 underneath the intermediate bottom 3, and mixing of the water is counteracted not only by the laminar inflow but also by a horizontal intermediate grating 14.
A corresponding volume equalization for the water pumped out by the pump 6 is performed via the line 4, which forms a riser pipe. The lower end of this line 4 discharges at the coldest point in the lower volume A, in fact, in order to avoid a "short circuit" between warm and cold water, at the side of the container 1 opposite the return line 7. As indicated by the arrows in the drawing, the water flows upward into the small volume B.
The laminar, non-mixing delivery of warm water directly below the intermediate bottom 3 leads to a quasi-isothermal heating. If no warm water is drawn from the reservoir, the warm water layer gradually spreads downward into the reservoir volume, until this volume is completely filled with warm water. With the above-described basic apparatus, virtually the entire solar spectrum is exploited, because besides the small portion of the spectrum that is absorbed or reflected by the transparent layers 2, all the light is converted into useful heat either directly in the water or at the dark top of the intermediate bottom 3. The transparent covering 2 prevents wind from affecting the surface of the water. The stratification of the water is attained without salt water, because of the natural stratification below the intermediate bottom 3.
If the reservoir is not discharged through a heat exchanger, as in the exemplary embodiment described above, but instead the hot water is taken off directly, for instance via a pump, then care must be taken that cold water will automatically flow in after it at the bottom of the storage container, regulated by a fill level monitor, whenever hot water is drawn off. According to a variant, which is again highly advantageous on its own, the apparatus according to the invention can also be used to produce and store cold water. Then the pump 6 is put into operation only at night. During the night, the volume B radiates heat through the "atmospheric window" to the cold night sky in the wavelength range from 8 to 13 μm. The water cools down as a result, and upon attaining a reference temperature detected by the temperature sensor 12 is pumped without turbulence by the pump 6, via the return line 7, into the lowermost part of the storage volume A. The inflow configuration selected is the mirror image of the inflow configuration described in connection with the drawing. It assures that a layer of cold water that spreads continuously upward will form on the bottom. The line 4, which serves to equalize the bottom between the volumes A and B, is substantially shorter in this variant and terminates directly below the intermediate bottom 3. Moreover, a multiple transparent covering of the volume B is intentionally omitted here, and instead a provision is made for a covering that is as transparent as possible. If a covering is omitted entirely, then the effect of evaporative cooling occurs as well, but this means that the resultant water flow must be compensated for.
In this apparatus, if cold water is drawn by means of a heat exchanger disposed in that case at the bottom of the volume A, then the originally stable stratification becomes unstable, analogous to the variant for hot water production. Because of the heating in the immediate vicinity of the heat exchanger, warm water rises, causing circulation currents, which improve the heat exchange performance.
This last variant may be used on the one hand purely for cooling purposes, for instance to air condition homes in hot countries, or on the other hand can be used in combination with hot water producing storage collectors in order to improve the usable temperature drop and hence the efficiency of thermodynamic machines with low-boiling-point working fluids as well.
The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.
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In an apparatus for collecting and storing solar energy, in order to improve the efficiency while maintaining a simple structure, a storage container is divided horizontally into a smaller upper water volume and a larger lower water volume by means of an intermediate bottom, and a device for attaining thermal equalization between the upper volume and the top of the lower volume is provided. This device is preferably embodied by a pump, which draws water from the upper volume and delivers it to the lower volume, and for volumetric equalization, a line penetrating the intermediate bottom is provided.
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BACKGROUND OF THE INVENTION
The present invention relates to a method for fabricating a semiconductor device and, more particularly, to a method for forming a polycrystalline silicon film or a polysilicon film.
A polysilicon film is essential to a semiconductor device. For example, the polysilicon film is used for an electrode of a capacitor provided in an insulating film covering a semiconductor substrate or conductive material for filling a contact hole provided in the insulating film. In that case, the polycrystalline silicon film is required to be deposited on a step portion of the insulating film made by the capacitor or the contact hole. The polysilicon film is further required to dope impurities therein to lower the resistivity thereof.
In order to decrease the steps in fabrication, it was reported in "JAPANESE JOURNAL OF APPLIED PHYSICS", vol. 23, No. 7, Jul. 1984, pp. L482-L484, that an impurity doping gas is introduced during the growth of the polysilicon film. The polysilicon film is thus grown on the step portion of the insulating film while doping impurities thereinto. This method is called hereinafter "in situ doping method".
However, the so-called step coverage of the doped polycrystalline silicon film thus made is very poor, so that the deviation of the capacitance value becomes large and the contact resistance value is made high.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention is to provide a method for forming a polycrystalline silicon film having impurities with a good step coverage.
A method of forming a polysilicon larger a step portion of an insulating film is featured by growing an amorphous silicon film on the surface of the trench portion in place of directly growing a polysilicon film, followed by heat treatment to convert the amorphous silicon film into a polycrystalline silicon film. The growth of the amorphous silicon film is preferably performed by a chemical vapor deposition method in which silane (SiH 4 ) or disilane (Si 2 H 6 ) is used as a source gas and a deposition temperature is designed in the range of 450° to 550° C.
The present invention is based on the inventor's discovering that the amorphous silicon film is grown with a good step coverage even if impurities are doped while growing the amorphous silicon film.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings, in which:
FIGS. 1a and 1b are sectional views respectively showing a part of a semiconductor device fabricated according to the prior art;
FIG. 2a and FIG. 2b are sectional views representative of an embodiment of the present invention;
FIG. 3 shows a sectional view to explain a step coverage of a amorphous or polycrystalline silicon film deposited on a step portion;
FIGS. 4a to 4c are sectional views to explain fabricating steps of a capacitor as a application of the present invention is applied;
FIGS. 5a and 5b are graphs showing a relationship between dielectric breakdown strength and frequency of sample; and
FIG. 6a and FIG. 6b are sectional views showing steps for fabricating a contact structure as another application of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Prior to describing in detail the present invention, the description on the prior art is made in order to facilitate the understanding of the present invention.
Referring to FIG. 1a, according to the prior art, a polycrystalline silicon film is deposited on well-shaped silicon oxide film 2 using a chemical vapor deposition applying silane (SiH 4 ) as a sourse gas and at deposition temperature in range of 600° to 750° C. Then, an diffusing source for impurity is formed on a surface of the film using phosphorus oxychloride (POCl 3 ), for example. In this case, the impurity is phosphorus (P). Then, after performing heat treatment to introduce the impurity into the polycrystalline silicon film at temperature in range of 800° to 1000° C., the diffusing source is removed and low resistance electrode is formed. Instead of the diffusion method, to simplify the doping step, the deposition is performed using the in situ doping at temperature about 600° C. applying phosphine (PH 3 ) or the like as doping gas as well as silane (SiH 4 ) as source gas. However, as shown in FIG 1a, in case of the deposited film using the in situ doping, a thickness of the film 2 formed on a bottom portion 13 of the film 2 is thinner than that of the film 2 formed on the sidewall portion 12 of the trench 10. Accordingly, a opening made and surrounded by the deposited film 4 at the trench 10 becomes narrow gradually.
Turning to FIG. 2a, according to an embodiment of the invention, a trench 30 of 1 μm of depth is formed in a silicon oxide film 2 having a thickness of 1.5 μm, followed by depositing an amorphous silicon film 3-1 on the film 2 having the trench 30. The deposition of the amorphous silicon film 3-1 is carried out by a chemical vapor deposition method using a vertical type low pressure chemical vapor deposition apparatus. In this embodiment, a disilane gas was employed as a source gas at flow rate of 100 sccm in conditions of the deposition temperature of 470° C. and the deposition pressure of 0.2 Torr. A phosphine (PH 3 ) gas diluted in 4% with a helium gas was simultaneously introduced at flow rate of 120 sccm together with a nitrogen gas at flow rate of 180 sccm. Thus, the amorphous silicon film of 200 nm in thick was deposited while doping the phosphorus impurities thereinto. Silane (SiH 4 ) may be used as the source gas.
After the deposition, heat treatment is performed to crystallize amorphous silicon. The amorphous silicon 3-1 is thus converted into a polycrystalline silicon film 3-2, as shown in FIG. 2. In this embodiment, the heat treatment was carried out in a nitrogen gas at temperature of 900° C. for 20 minutes.
After observing the obtained polycrystalline silicon film using a scanning electron microscope, a factor of step coverage is calculated. As shown in FIG. 3, each film thickness of the deposited frilm 3 or 4 formed on a surface of an outside portion 11 of the trench 10, on a surface of a sidewall portion 12 of the trench 10 and on a surface of a bottom portion 13 of the trench 10 is determined a, b and c, respectively in the present specification. For comparing, depositions of the polycrystalline silicon film was also performed using the conventional method. As to the in situ doping method, the deposition condition is same as the described above except that the deposition temperature is selected at 600° C. at this time. As to the diffusion method, a polycrystalline silicon film is grown at deposition temperature of 600° C. introducing disilane a flow rate of which is 100 sccm and nitrogen a flow rate of which is 300 sccm without doping. As the result of the observation, the fact is obtained that the step coverage factor by the in situ doping method is very poor such as b/a=0.37 and c/a=0.42. In addition, the step coverage factor by the diffusion method is also not so good such as b/a=0.82 and c/a=0.82. In the contrary, the method according to the present embodiment of the invention can improve the step coverage factor such as b/a=0.88 and c/a=0.90. In the embodiment, though the deposition temperature of the amorphous silicon film is selected at 470° C., the step coverage can be improved in case that the deposition temperature is selected in the range of 450° to 550° C.
Therefore, according to the present embodiment, while the impurity is doped, the step coverage can ameliorate comparing to the prior art and the embodiment can improves uniformity of the deposited film. Accordingly, the method can provides a doped polycrystalline silicon film having low resistance.
Referring to FIGS. 4a to 4c, a case which the present embodiment of the invention is applied to electrodes for a semiconductor memory device will be explained. As shown in FIG. 4a, a silicon oxide film 2 having a well-shaped opening of 1 μm 2 area and 1 μm in deep is formed on a silicon substrate 1. Then, an amorphous silicon film with thickness of 200 nm for a bottom electrode 5 is deposited while doping impurities therein. The fabrication condition is the same as described above. Them, as shown in FIG. 4b, a dielectric film 6 such as silicon oxide and/or silicon nitride with thickness of 10 nm is grown on it. After selectively removing the film 6, as shown in FIG. 4c, another amorphous silicon film for an upper electrode 7 is deposited on the film 6 while doping impurities therein. Then, the amorphous silicon films 5 and 7 are crystallized by heat treatment at temperature of 900° C. for 20 minutes to be converted into a polysilicon layer, respectively. Thus, a capacitor having a bottom electrode (5), an upper electrode (7) and a dielectric film 6 therebetween is obtained.
Then, dielectric breakdown strength of the capacitors made by the present invention was measured. The dielectric breakdown strength means the electric field strength that breaks down or destroys the dielectric film of a capacitor. FIG. 5a and FIG. 5b are frequency distribution charts showing the measurement results of it according to the present invention and the prior art in case of the diffusion method, respectively. In the charts, abscissas shows dielectric breakdown strength and ordinates show a relative frequency of measured samples. The relative frequency of samples means the ratio in number of sampled within a certain range to the total sample. As shown in the figures, relative frequency of the samples having dielectric breakdown strength larger than 9 MV/cm are 98% according to the present invention and 92% according to the diffusion method of the prior art, respectively. Consequently, the present invention can improves the insulating characteristic of the capacitor. In addition, according to the present embodiment, as the bottom electrode 5 can be formed with improved step coverage and uniformity, the insulating film 6 can also deposited with uniformity. Accordingly, decrease in the dielectric breakdown strength, caused by local electric field concentration at an extreme thin portion of the film 6, can be avoided. In addition, cut the film 6 itself also avoided.
Referring to FIG. 6 representative of another application of the invention, a contact hole 40 having a diameter of 0.4 μm is formed in a silicon oxide film 2 with thickness of 1 μm which is formed on a silicon substrate 1. Thereafter, an amorphous silicon film 3 is deposited to fill the contact hole 40 and extend over the oxide film 2 while doping impurities into the film 3 by the method described above. The heat treatment is then performed at temperature of 900° C. for 20 minutes. As a result, the amorphous silicon film 3-1 is converted into a polysilicon film 3-2, as shown in FIG. 6b. The polysilicon film 3-2 is thereafter subject to the selective etching process to form an interconnection wiring layer. Since the silicon film 3-1 has a good step coverage, there occurs no void in the contact hole 40.
On the other hand, in the case of directly depositing a polycrystalline silicon film 4 in the contact hole, as shown in FIG. 1b, since the film 4 thus deposited has a poor step coverage, a void 8 is generated in the contact hole. The void 8 results in increase of a resistance value between the silicon substrate and polycrystalline silicon film. In experiment, it was 1.5 kΩ. In contrast, the device shown in FIG. 6 has a resistance value of 450 Ω.
The crystallizations of amorphous silicon can be performed at temperature of 600° to 1000° C. However, it is not practical use to perform it at temperature below 600° C. because it requires a long time to crystallize. On the other hand, in case of high temperature heat treatment, there generates undesirable diffusion from the amorphous silicon film to underlying substrate or impurity diffusion at the other portions. Therefore, considering a harmful effect on semiconductor devices caused by the heat, it is preferable for the temperature of the heat treatment below 1000° C.
Moreover, regarding to control resistivity, as it is used for electrodes, it is preferable to be low resistance. Polycrystalline silicon films having a low resistivity smaller than 10 mΩ·cm may be used for a contact structure, as the preferable resistivity varies with a contact hole size or a electrodes size of semiconductor devices. In fact, the resistivity of the polycrystalline silicon film suffered the heat treatment according to the deposition condition of the present embodiment is in low such as 0.55 mΩ·cm.
Although the invention has been described with reference to specific embodiment, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiment will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore that the appended claims will cover any modifications or embodiments as fall within the true scope of the invention.
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A method of fabricating a semiconductor device, in particular of forming a polysilicon film on a step portion of an insulation film made by a trench or a contact hole is disclosed which includes the steps of depositing an amorphous silicon film on the step portion while doping impurities into the amorphous silicon film and carrying out heat treatment to convert the amorphous silicon film into a polycrystalline silicon film, thereby the polysilicon film on a step portion being formed.
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This is a division of application Ser. No. 221,906, filed Jan. 31, 1972, now U.S. Pat. No. 3,842,626, issued Oct. 22, 1974.
BACKGROUND OF THE INVENTION
The field of the invention is knitting needles of the type used in knitting machines such as circular knitting machines. Such needles have a hook and hinged latch at one end. A shaft extends from the hook portion and a foot protrudes outwardly from the shaft. A plurality of such needles are used in a knitting machine and various needle holding and guide members are used to position and move the needles. The axial position of a needle is governed by the locating of the needle foot in a needle foot guide channel which may comprise a groove cut in the inner surface of a cylinder. As the cylinder rotates with respect to the needle holding member which holds the needles, a needle is caused to move axially in a predetermined manner by the camming action of the needle foot riding in the needle foot guide channel.
In an effort to improve the output of a knitting machine, higher operating speeds, resulting in an increase of the axial oscillation of the knitting needles has to be achieved. An increase in the axial oscillation velocity of the knitting needle and its associated increase in vibration stresses causes unacceptable breakage, especially in the hook portion of the needle.
Various methods have been utilized to help reduce needle breakage and, therefore, allow higher operating speed. One approach has been the addition of several bends in the needle shaft to cause a small amount of spring or give between the needle foot and the hook. Another approach comprises molding a plastic covering over the needle foot. Nylon 6, 6 has been used for this purpose and although this approach has permitted an increase in the axial velocity of the knitting needle, without the concomitant increase in destructive vibration, the life of such coverings is limited and thus the ability to increase the knitting speed has not been achieved.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved knitting needle which may be oscillated at higher speed without breakage.
It is another object of the present invention to increase the production from high speed knitting machines.
According to the present invention there is provided an improved needle having a shoe covering at least a portion of the needle foot of knitting machine needles. The material from which the shoe is fabricated should have both a relatively high modulus (shear modulus greater than 10 6 pounds per square inch) and relatively good damping characteristics (loss tangent greater than 0.01). In nature most materials which have a high modulus also have poor damping characteristics and materials which have good damping characteristics tend to have a low modulus. Particular materials are disclosed herein, however, which achieve this unusual combination of attributes. The shoe may either be a metal having excellent damping characteristics or a metal-polymer laminate or composite. Examples of metals having excellent damping characteristics are certain alloys of titanium and nickel and certain alloys of copper including copper-manganese alloys; particularly appropriate alloys are discussed below.
When the shoe is a metal-polymer composite, it is not essential that the metal itself have excellent damping characteristics. For instance, the metal could be hardened steel and the polymer could be nylon 6, 6 or a polyurethane. Further details regarding these metal-polymer composites are given below.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevation of a knitting needle of the type used in knitting machines.
FIG. 2 is a side elevation of a needle foot guide having two needles positioned adjacent thereto.
FIG. 3 is an enlarged view taken along line 3--3 of FIG. 1 showing the needle foot.
FIG. 4 is a front elevation of the needle foot of FIG. 3 partially surrounded by a shoe.
FIG. 5 is a view taken along line 5--5 of FIG. 4.
FIG. 6 is a front elevation of a needle foot and shoe.
FIG. 7 is a front elevation of a needle foot and shoe.
FIG. 8 is a front elevation of a needle foot and shoe.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A knitting needle of the type used in knitting machines is shown in FIG. 1 and identified by reference character 10. The needle 10 has a hook 11 at one end and has a longitudinal shaft 12 which extends from a hook area down to the base 13. A foot 14 protrudes from one side of shaft 12 and longitudinal movement of the needle is brought about by forces exerted on foot 14 in a manner described below. Stress relief notches 15 and 16 are formed in the shaft adjacent foot 14.
Near the hook end of the needle 10 is a pivotally mounted latch 17 which opens when the needle moves upwardly through woven material and closes when the needle moves downwardly. Needles with such latches are known to those skilled in this art and a description of the details of their operation is not necessary for an understanding of the present invention.
A guide which regulates the movement of the needles may be seen in FIG. 2 which illustrates needles 10 and 20 positioned between side walls in the needle groove 22 of needle guide 21. The needles are commonly held in place by a cooperating series of grooves (not shown) located in a needle holding member which travels with respect to needle guide 21. These grooves position the needles in a constant spacing but permit the needles to move in a longitudinal direction. The needle guide 21 is then moved with respect to the needles in the direction of arrow "a". A needle foot, such as that identified by reference character 14 in FIG. 1, rides in needle groove 22 and the movement of needle guide 21 with respect to the needle can result in longitudinal movement of the needle. For instance, when guide 21 is moved in the direction of arrow a, needle 10 will move upwardly in the direction of arrow "b" as long as the needle foot is riding in the inclined portion 23 of needle groove 22. When the needle foot reaches the horizontal portion 24 of needle groove 22, the vertical position of the needle will remain constant until the needle foot reaches inclined portion 25 of groove 22. Similarly, the needle will remain in a constant vertical position when the needle foot is riding in horizontal portion 26 of groove 22 and will move downwardly when the foot is in section 27 of groove 22. The inclined portions of groove 22 may be at various angles with respect to the horizontal other than that shown in the drawing at 45°.
As can be seen, the desired increase in the movement of the needle results from a faster relative surface speed between the needle foot guide 21 and the needle. It has been found that the needles begin to break in the hook area if the needle movement becomes too rapid. The present invention is directed toward solving this breaking problem.
The needle foot 14 of needle 10 is shown in end view in FIG. 3. Stress relief notches 15 and 16 are used to decrease the stress and thus reduce breakage of the needle at the point between the needle foot and the needle shaft.
The tendency toward needle breakage can be significantly reduced by the provision of a shoe located in contact with the needle foot guide. One such shoe is shown in FIGS. 4 and 5 where a C-shaped shoe 30 is shown partially surrounding needle foot 14. Shoe 30 is composed of a metal having the desired combination of a shear modulus greater than 10 6 pounds per square inch and a loss tangent greater than 0.01.
The shear modulus is, of course, the ratio of the shearing stress to the corresponding shearing strain. It is expressed in force per unit area and in the present application specifically in pounds per square inch. The shear modulus can be determined for laminated materials and a laminate made from one layer of a metal and a layer of a typical polymer of equivalent thickness will have a shear modulus approximately one-half that of the metal used. That is, the strength of the laminate will depend almost entirely on the metal layer.
The ability of a material to perform a damping function is commonly expressed by the loss tangent. The loss tangent is expressed by the following formula: ##EQU1## where: A n = Amplitude of n th wave
A.sub. (n -1 ) = Amplitude of n th - 1 wave
The above amplitudes are determined at low frequency by the use of a torsional pendulum. Like shear modulus, the loss tangent of laminated materials can be determined by testing a sample of the laminate. The loss tangent of a laminate comprising an elastic layer and a viscous layer will, of course, be determined largely by the nature of the viscous material.
While the damping characteristics of nylon 6, 6 are satisfactory (loss tangent = 0.026) its shear modulus is below 10 6 psi (0.14 × 10 6 psi). Conversely, while steel of the type used in many needles has a sufficient shear modulus (8.7 × 10 6 psi) its damping characteristics are not satisfactory (loss tangent = 0.0019).
Shoe 30 should also have excellent wear characteristics so that it will not be abraded by contact with the needle foot guide. Metals having the requisite shear modulus and loss tangent levels together with acceptable wear characteristics include many alloys which also exhibit the characteristic of "memory", that is, a return to an original configuration with temperature change.
A particularly effective composition comprises alloys having as major ingredients the metals titanium and nickel. Many alloys have major proportions of titanium and nickel are known to possess the ability to transform from a martensitic crystal structure having excellent damping characteristics to an austenitic structure upon warming. Excellent damping characteristics are possessed by such alloys when in their martensitic state. Thus, the present invention includes the use of alloys having major proportions of titanium and nickel which alloys exist in the martensitic state at the operating temperature of the metallic member. Means for establishing a desired transformation temperature are known and include varying the percentage of titanium and nickel. Furthermore, the transformation temperature may be adjusted by the addition of small amounts of other metals such as cobalt, iron, aluminum and manganese. A more complete disclosure of the nature of such alloys may be found in an application filed July 2, 1970, by John D. Harrison, et al., Ser. No. 51,809, now abandoned and an application filed on the same day by Harrison, et al., Ser. No. 52,112, now U.S. Pat. No. 3,753,700, issued Aug. 21, 1973. Both the application and the patent are assigned to the assignee of the present invention. The disclosures of these two applications are incorporated by reference herein for purposes of background information. A typical alloy useful in the practice of the present invention contains the following metals expressed in atomic percent: 50% Ti, 50% Ni. Such an alloy has a loss tangent of 0.036, and a shear modulus of 2.87 × 10 6 pounds per square inch.
In general, metals to which the property of heat recoverability may be imparted have good damping characteristics when such metals are in their low temperature state. Beta copper alloys are useful in conjunction with the present invention. A shoe useful in the practice of the present invention can alternatively be achieved by the use of a metal-polymer composite. One such composite is shown in FIG. 6 where a C-shaped shoe is shown partially surrounding needle foot 14. The shoe comprises a metallic member 35 and quantities of polymer 36 and 37 are located between the upper and lower faces of needle foot 14 and the inner surface of metallic member 35. By the use of such configurations, the metallic member 35 need not be fabricated from a metal having good damping characteristics. Its wearing and friction characteristics may then be a major consideration. Polymer 36 should possess excellent damping characteristics and suitable polymers include polyurethane elastomers, nylon, such as nylon 6, 6, polytetrafluoroethylene copolymer elastomers, a polyamide whose repeating units comprise a tetravalent organic moiety and the residue of either 1, 12 diamino dodecamethylene or 1, 13 diamino tridecamethylene. The polymer should maintain its structural integrity at the operating temperatures of the shoe.
The metallic member 35 of such composites may be hardened steel, titanium-nickel alloys having an austenitic crystal structure, or other metal having relatively-high strength and wear characteristics. Stainless steel alloys may also be used.
A different location of polymer of a composite shoe is shown in FIG. 7 where metallic member 40 is separated from foot 14 by a C-shaped layer of polymer 41. This location of polymer prevents any rubbing contact between member 40 and foot 14 and tends to increase the damping characteristics of the composite.
The composite shoe shown in FIG. 8 is similar to that shown in FIG. 7 where metallic member 42 is separated from foot 14 by a C-shaped layer of polymer 43. The upper and lower surfaces 44 and 45 of member 42 are coated with a hardened composition such as tungsten carbide in order to improve the wearing characteristics of member 42. The tungsten carbide may be flame plated when the metallic member is not readily plated by other means. Member 42 may be fabricated from metals like those described useful for the fabrication of member 35. Friction-reducing agents or coatings such as molybdenum disulfide may be used on the outer surface of the metallic members to further reduce wear.
It is believed that the metal-polymer shoe is capable of providing protection from breakage as a result of the ability of this composite to dissipate mechanical energy in the form of heat. Heat is generated by the physical distortion of a layer of viscoelastic material sandwiched between the vibrating structure and a thin metal constraining layer. While not bound by any theory, it is believed that needle breakage results from resonant vibration which is reduced or prevented by the presence of the metal-polymer composite.
Similarly, when the shoe is fabricated from a metal having excellent damping characteristics, it is believed that this same elimination or reduction of resonant vibration results. Thus, when the needle foot reaches the intersection between a horizontal and an inclined portion of the needle foot groove, a certain amount of energy or shock is believed to be absorbed by the metal-surfaced damping shoe and thus is not transmitted through the needle shaft to the needle hook. Thus, the particular choice of material for construction of the shoe is related to the needle size and oscillation frequency and it is not possible to describe a shoe composition which will be optimum under all conditions.
Although the shoes shown in the drawings are C-shaped, other shapes may also be used. For instance, the shoe can be in the shape of an elongated O. Alternatively, the shoe could merely surround the top and bottom surfaces of the needle foot and thus be in the shape of two U's. It is preferable that the outer surface of the composition be rounded in order to reduce wear both upon the composite itself and on the needle foot guide. Various coatings may be placed on the outer surface of the shoes in order to reduce corrosion, friction or wear. Such coatings are known to those skilled in the art and will not be described here in detail. One example is a chromium plating known by the trade name "Electrolized".
The polymer may be applied to the needle foot in any conventional manner such as the insertion of a premolded member over the needle foot prior to the placement of the metallic member. Alternatively, the polymer may be molded directly over the needle foot and a hole or plurality of openings or indentations may be provided in the needle foot to hold the polymer in place. Still further, the needle foot may be dipped in a liquid plastic which may then be cured or dried to form the polymeric member. Still further, the metal and polymer may be laminated or adhered to one another prior to placement over the needle foot. Also, the polymer could be provided in the form of a heat-shrinkable tube which could be placed over the needle foot and shrunk in place prior to the placing of the metallic member around the polymer. It is advantageous to provide a tight fit between the needle foot and the polymer in order to reduce the amount of impact exerted on the polymer by the needle foot.
The needle foot should, of course, be modified in exterior dimensions to permit the shoe to be placed over it without causing a binding of the shoe in the needle groove. The separation between the outer surface of the shoe and the needle groove should not be so great, however, as to cause an impact or slap between the shoe and the groove. Since wear can increase this tolerance a high wear surface such as tungsten-carbide is advantageous.
The present embodiments of this invention are thus to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims therefore are intended to be embraced therein.
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An improved needle for use in knitting machines is disclosed herein. The improved needle can operate at higher speeds than prior art needles without undue needle breakage. The needles are of the type which have a hook and latch at one end, a shaft extending from the hook and a needle foot protruding outwardly from the shaft. The foot is adapted to ride in a needle foot guide channel which causes the needle to move in an axial direction. The improved needle has a shoe covering at least a portion of the needle foot. The shoe is fabricated from a material which has a shear modulus of at least one million pounds per square inch and a loss tangent greater than 0.01. The shoe may be fabricated from a metal or a metal-elastomer composite.
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FIELD OF THE INVENTION
[0001] The present application relates to graft copolymers which are formed from free-radically polymerizable monomers and which, in addition to ethylenically unsaturated compounds substituted by long alkyl chains, especially acrylates or methacrylates, additionally also comprise monomers with hydrogen bond donor functions. According to the invention, the monomer with the hydrogen bond donor property is present both in the polymer backbone and in the grafted side branches. In addition to polymers which contain monomers with hydrogen bond donor function, also disclosed are those which contain monomers which simultaneously bear hydrogen bond donor and hydrogen bond acceptor functions. The polymers are particularly suitable as additives for lubricant oil formulations. It has been found that the hydrogen bond donor functions in the polymer, but in particular the simultaneous presence of hydrogen bond donor and acceptor functions, have positive effects on wear protection, detergency and dispersancy.
STATE OF THE ART
[0002] Polyalkyl acrylates are common polymeric additives for lubricant oil formulations. Long alkyl chains (typical chain length: C8-C18) in the ester functionalities of the acrylate monomers impart a good solubility in apolar solvents, for example mineral oil, to polyalkyl acrylates. Common fields of use of the additives are hydraulic, gearbox or motor oils. A viscosity index (VI)-optimizing action is attributed to the polymers, from where the name VI improvers originates. A high viscosity index means that an oil possesses a relatively high viscosity at high temperatures (for example in a typical range of 70-140° C.) and a relatively low viscosity at low temperatures (for example in a typical range of −60-20° C.). The improved lubricity of an oil at high temperatures compared to a non-polyacrylate-containing oil which has an otherwise identical kinematic viscosity at, for example, 40° C. is caused by a higher viscosity in the increased temperature range. At the same time, in the case of utilization of a VI improver at relatively low temperature, as is present, for example, during the cold-start phase of an engine, a lower viscosity is recorded in comparison to an oil which otherwise has an identical kinematic viscosity at 100° C. As a result of the lower viscosity of the oil during the start-up phase of an engine, a cold start is thus eased substantially.
[0003] In recent times, polyacrylate systems which, as well as VI optimization, provide additional properties, for example dispersancy, have become established in the lubricants industry. Either alone or together with dispersant-inhibitor (DI) additives used specifically for dispersion purposes, such polymers have the effect, inter alia, that the oxidation products occurring as a result of stress on the oil contribute less to a disadvantageous viscosity rise. By means of improved dispersibility, the lifetime of a lubricant oil can be extended. By virtue of their detergent action, such additives likewise have the effect that the engine cleanliness, for example expressed by the piston cleanliness or ring sticking, is influenced positively. Oxidation products are, for example, soot or sludge. In order to impart dispersancy to polyacrylates, nitrogen-containing functionalities may be incorporated into the side chains of the polymers. Common systems are polymers which bear partly amine-functionalized ester side chains. Often, dialkylamine-substituted meth-acrylates, their methacrylamide analogs or N-hetero-cyclic vinyl compounds are used as comonomers for improving the dispersion capacity. A further class of monomer types which should be mentioned owing to their dispersancy in lubricants is that of acrylates with ethoxylate- or propoxylate-containing functions in the ester substituents. The dispersible monomers may be present either randomly in the polymer, i.e. are incorporated into the polymer in a classical copolymerization, or else grafted onto a polyacrylate, which results in systems with a non-random structure.
[0004] There has to date been no targeted research for polyacrylates which, as well as the known advantages in relation to dispersancy detergency, also offer advantages in relation to wear reduction.
[0005] EP 164 807 (Agip Petroli S.p.A) describes a multi-functional VI improver with dispersancy, detergency and low-temperature action. The composition of the VI improvers corresponds to NVP-grafted polyacrylates which additionally contain difficult-to-prepare acrylates with amine-containing ethoxylate radicals.
[0006] DE-A 1 594 612 (Shell Int. Research Maatschappij N.V.) discloses lubricant oil mixtures which comprise oil-soluble polymers with carboxyl groups, hydroxyl groups and/or nitrogen-containing groups and a dispersed salt or hydroxide of an alkaline earth metal. As a result of the synergistic mode of action of these components, wear-reducing action is observed.
[0007] U.S. Pat. No. 3,153,640 (Shell Oil Comp.) includes copolymers consisting of long-chain esters of (meth)acrylic acid and N-vinyllactams, which exhibit an advantageous influence on wear in lubricant applications. The polymers described are random copolymers. Monomers having hydrogen bond donor function and graft copolymers are not mentioned.
[0008] In ASLE Transactions (1961, 4, 97-108), E. H. Okrent states that polyisobutylenes or polyacrylates used as VI improvers have influence on the wear behavior in the engine. No inferences are made on the chemistry used and the specific composition of the polymers. Wear-reducing action is accounted for merely with visco-elastic effects of polymer-containing oils. For example, no differences are detected between poly-acrylate and PIB-containing oils in influence on wear.
[0009] Literature publications by Neudörfl and Schödel (Schmierungstechnik 1976, 7, 240-243; SAE Paper 760269; SAE Paper 700054; Die Angew{dot over (a)}ndte Makromolekulare Chemie 1970, 2, 175-188) emphasize in particular the influence of the polymer concentration on the engine wear. Reference is made to the aforementioned article by E. H. Okrent and, in analogy to Okrent, no connection of a wear-improving action with the chemistry of the polymer is made. Generally, it is concluded that viscosity index improvers of low molecular weight bring improved wear results.
[0010] Like Neudörfl and Schödel, K. Yoshida (Tribology Transactions 1990, 33, 229-237) attributes effects of polymers on the wear behavior merely to viscometric aspects. Advantageous effects are explained with the preferred tendency to elastohydrodynamic film formation.
[0011] Almost without exception, the polymers known in the prior art are formed from monomers whose dispersing functionalities bear groups which are hydrogen bond acceptors (referred to hereinafter as H-bond acceptors), or, like dimethylaminopropylmethacrylamide, have both a functionality with hydrogen bond acceptor and a functionality with hydrogen bond donor (referred to hereinafter as H-bond donor). It is a further feature of such polymers useful for motor oil applications that the monomers bearing N-heterocycle have preferably been grafted onto the polymer backbone. Polymers containing dimethylaminopropylmethacrylamide are, in contrast, random copolymers and not graft copolymers.
[0012] It was therefore an object of the present invention to provide novel graft copolymers containing monomers with H-bond donor functions,
to provide multifunctional VI improvers which, in lubricant oil formulations, are notable not only for their VI action but also for their dispersancy and/or detergency, to provide multifunctional VI improvers which, in lubricant oil formulations, are notable not only for their VI action, but also for their positive influence on wear behavior, to provide a universally applicable process for preparing graft copolymers containing grafted monomers with H-bond donor functions. In particular it should be possible to prepare homogeneous polymer solutions of clear appearance by grafting monomers with H-bond donor functions. to provide lubricants comprising the inventive graft copolymers with improved properties in relation to wear protection, dispersancy and detergency, corrosion behavior and oxidation stability.
[0017] These objects, and also further objects which are not stated explicitly but which can be derived or discerned directly from the connections discussed by way of introduction herein are achieved by a graft copolymer containing, in the backbone, free-radically polymerized units of
a) from 0.01 to 15% by weight of a compound of the formula (I)
in which R 1 , R 2 and R 3 may each independently be hydrogen or an alkyl group having from 1 to 5 carbon atoms and R 4 is a group which has one or more structural units capable of forming hydrogen bonds and is a hydrogen donor, and
b) from 0 to 40% by weight of one or more (meth)acrylates of the formula (II)
in which R is hydrogen or methyl and R 5 is a linear or branched alkyl radical having from 1 to 5 carbon atoms,
c) from 35 to 99.99% by weight of one or more ethylenically unsaturated ester compounds of the formula (III)
in which R is hydrogen or methyl, R 8 is a linear, cyclic or branched alkyl radical having from 6 to 40 carbon atoms, R 6 and R 7 are each independently hydrogen or a group of the formula —COOR 8 where R 8 is hydrogen or a linear, cyclic or branched alkyl radical having from 6 to 40 carbon atoms, have, and
d) from 0 to 40% by weight of one or more comonomers,
where the percentage by weight of the above components is based on the total weight of the ethylenically unsaturated monomers of the backbone and where
a′) from 0.01 to 25% by weight, based on the total weight of the copolymer, of a compound of the formula (I)
in which R 1 , R 2 and R 3 may each independently be hydrogen or an alkyl group having from 1 to 5 carbon atoms and R 4 is a group which has one or more structural units capable of forming hydrogen bonds and is a hydrogen donor, and
b′) from 0 to 20% by weight, based on the total weight of the copolymer, of one or more compounds of the formula (IV)
in which R 9 , R 10 and R 11 may each independently be hydrogen or an alkyl group having from 1 to 5 carbon atoms and R 12 is either a C(O)OR 13 group and R 13 is a linear or branched alkyl radical which is substituted by at least one —NR 14 R 15 group and has from 2 to 20, preferably from 2 to 6 carbon atoms, where R 14 and R 15 are each independently hydrogen, an alkyl radical having from 1 to 20, preferably from 1 to 6, and where R 14 and R 15 , including the nitrogen atom and, if present, a further nitrogen or oxygen atom, form a 5- or 6-membered ring which may optionally be substituted by C 1 -C 6 -alkyl,
or R 12 is an NR 16 C(=o)R 17 group where R 16 and R 17 together form an alkylene group having from 2 to 6, preferably from 2 to 4 carbon atoms, where they form a 4- to 8-membered, preferably from 4- to 6-membered, saturated or unsaturated ring, if appropriate including a further nitrogen or oxygen atom, where this ring may also optionally be substituted by C 1 -C 6 -alkyl, are grafted onto the backbone of the copolymer.
[0033] Appropriate modifications of the inventive graft copolymers are protected in the subclaims dependent upon claim 1 . With regard to the process for preparing graft copolymers, claims 10 to 14 provide solutions to the underlying problems, while claims 15 to 17 protect a lubricant oil formulation using the graft copolymers prepared according to the present invention and also the preferred uses thereof.
ADVANTAGES OF THE INVENTION
[0034] The inventive polymers with hydrogen bond donor functions in the polymer, especially the polymers with simultaneous presence of hydrogen bond donor and acceptor functions, have positive effects on wear protection, detergency and dispersancy of the lubricant oil formulations produced with them. The polymers therefore constitute a wear-reducing alternative or supplement to the phosphorus and sulfur additives customary in industry, and help to avoid their known disadvantages.
[0035] In particular, the advantages achieved in wear behavior have a positive effect on the energy consumption, for example of a diesel or gasoline engine.
[0036] The formulations produced using the inventive graft copolymers feature good corrosion behavior and also good oxidation resistance.
[0037] The kinematic viscosity of polymer solutions which comprise methacrylic acid grafted in accordance with the invention has been lowered substantially compared to the comparable polymer which contains exclusively methacrylic acid in the polymer backbone.
[0038] The process disclosed for preparing graft copolymers leads to homogeneous polymer solutions of clear appearance and demonstrates that the synthesis principle presented herein is of universal character, i.e. can be applied not just to the grafting of carboxylic acids but also, for example, with carboxamides.
[0039] At the same time, the process according to the invention allows a series of further advantages to be achieved. These include:
With regard to pressure, temperature and solvent, the performance of the polymerization is relatively unproblematic; even at moderate temperatures, acceptable results are achieved under certain conditions. The process according to the invention is low in side reactions. The process can be performed inexpensively. With the aid of the process according to the invention, high yields can be achieved. With the aid of the process of the present invention, it is possible to prepare polymers with a predefined constitution and controlled structure.
[0045] The polymers which have VI and dispersing action and have been used to date in motor oils, as discussed above, comprise preferably monomer types with H-bond acceptor functionalities, which are especially N-heterocycles. It was therefore not directly foreseeable that the use of monomers with H-bond donor properties leads to polymers which possess the improved properties described.
[0046] Since it is known from the prior art that the grafting of monomers with H-bond donor functions onto polyalkyl acrylates is generally difficult, it was not immediately foreseeable that the grafting of this monomer type to polyacrylates can be achieved without any problems and with a wide range of application when, before the grafting, a small portion of one of these monomers has been incorporated into the backbone of the polyacrylate by polymerization. It was especially surprising that grafting performed more than once in succession was even possible, without there being the formation of unutilizable products. This is especially against the background that corresponding synthesis attempts according to the prior art afford inhomogeneous products having a cloudy appearance.
DETAILED DESCRIPTION OF THE INVENTION
[0047] The graft copolymers contain, as components, one or more compounds of the formula (I)
in which R 1 , R 2 and R 3 may each independently be hydrogen or an alkyl group having from 1 to 5 carbon atoms and R 4 is a group which has one or more structural units capable of forming hydrogen bonds and is a hydrogen donor.
[0049] The definition of a functionality as a group with hydrogen bond acceptor or hydrogen bond donor action can be taken from the current literature or known chemical reference works, for example “Römpp Lexikon Chemie, 10th edition, 1999, Verlag Thieme Stuttgart New York”.
[0050] According to this, a hydrogen bond (H-bond) is an important form of secondary valence bond which forms between a hydrogen atom bonded covalently to an atom of an electronegative element (hydrogen bond donor, proton donor, X) and the solitary electron pair of another electronegative atom (proton acceptor, Y). In general, such a system is formulated as RX—H . . . YR′, where the dotted line symbolizes the hydrogen bond. Possible X and Y are mainly O, N, S. and halogens. In some cases (e.g. HCN), C can also function as a proton donor. The polarity of the covalent bond of the donor causes a positive partial charge, δ + , of the hydrogen (proton), while the acceptor atom bears a corresponding negative partial charge, δ − .
[0051] Characteristic, structural and spectroscopic properties of a complex bonded via a hydrogen bond are:
a) The distance r HY is distinctly less than the sum of the van der Waals radii of the atoms H and Y. b) The XH equilibrium nucleus separation is enlarged compared to the free molecule RX—H. c) The XH stretching vibration (donor stretching vibration) experiences a shift to longer wavelengths (“red shift”). In addition, its intensity increases distinctly (in the case of relatively strong H-bonds, by more than one order of magnitude). d) Owing to mutual polarization, the dipole moment of the H-bond-bonded complex is greater than what corresponds to the vector sum of the dipole moments of the constituents. e) The electron density at the bond hydrogen atom is reduced in the case of formation of a hydrogen bond. This effect is expressed experimentally in the form of reduced NMR shifts (reduced shielding of the proton). At relatively short intermolecular distances, the electron shells of the monomers overlap. In this case, a chemical bond associated with a certain charge transfer of the 4-electron, 3-center bond type can form. In addition, exchange repulsion is present, since the Pauli principle keeps electrons with identical spins apart and prevents two monomers from coming too close. The dissociation energies D 0 =ΔH 0 (molar enthalpies of the reaction RX—H . . . YR′→RX—H+YR′ at the absolute zero point) are generally between 1 and 50 kJ mol −1 . For their experimental determination, thermochemical measurements (2 virial coefficients, thermal conductivities) or spectroscopic analyses are employed (more on this subject can be taken from “Chem. Rev. 88, Chem. Phys. 92, 6017-6029 (1990)).
[0057] For hydrogen atoms of structural units which are capable of forming H-bonds and are an H-donor, it is characteristic that they are bonded to relatively electronegative atoms, for example oxygen, nitrogen, phosphorus or sulfur. The terms “electronegative” or “electropositive” are familiar to those skilled in the art as a designation for the tendency of an atom in a covalent bond to pull the valence electron pair or pairs toward it in the sense of an asymmetric distribution of the electrons, which forms a dipole moment. A more detailed discussion of the terms “electronegativity” and “hydrogen bonds” can be found, for example, in “Advanced Organic Chemistry”, J. March, 4th edition, J. Wiley & Sons, 1992.
[0058] In some dimers, more than one hydrogen bond is formed, for example in dimers of carboxylic acids which form cyclic structures. Cyclic structures are frequently also favored energetically in higher oligomers, for example in oligomers of methanol above the trimers. The dissociation energy of the trimer into 3 monomers at 52 kJ·mol −1 is nearly four times as large as that of the dimer. Non-additivity in the dissociation energies per monomer is a typical property of complexes bonded via hydrogen bonds.
[0059] In the case of H-bond-forming functionalities, the present invention relates in particular to heteroatom-containing groups, where the heteroatom is preferably O, N, P or S. Even though a carbon-hydrogen bond can theoretically also function as an H-bond donor, such functions shall not fall within the scope of the claims made herein for functionalities with H-bond donor function.
[0060] Monomers with H-bond donor functions are, for example, the ethylenically unsaturated carboxylic acids and all of their derivatives which still have at least one free carboxyl group. Examples thereof are:
acrylic acid, methacrylic acid, 1-[2-(isopropenylcarbonyloxy)ethyl]maleate (monoester of 2-hydroxyethyl methacrylate (HEMA) and maleic acid), 1-[2-(vinylcarbonyloxy)ethyl]maleate (monoester of 2-hydroxyethyl acrylate (HEA) and maleic acid), 1-[2-(isopropenylcarbonyloxy)ethyl]succinate (monoester of HEMA and succinic acid), 1-[2-(vinylcarbonyloxy)ethyl]succinate (monoester of HEA and succinic acid), 1-[2-(isopropenylcarbonyloxy) -ethyl]phthalate (monoester of HEMA and phthalic acid), 1-[2-(vinylcarbonyloxy)ethyl]phthalate (monoester of HEA and phthalic acid), 1-[2-(isopropenylcarbonyloxy) -ethyl]hexahydrophthalate (monoester of HEMA and hexahydrophthalic acid), 1-[2-(vinylcarbonyloxy)ethyl]-hexahydrophthalate (monoester of HEA and hexahydro-phthalic acid), 1-[2-(isopropenylcarbonyloxy)butyl]-maleate (monoester of 2-hydroxybutyl methacrylate (HBMA) and maleic acid), 1-[2-(vinylcarbonyloxy)butyl]-maleate (monoester of 2-hydroxybutyl acrylate (HBA) and maleic acid), 1-[2-(isopropenylcarbonyloxy)butyl]-succinate (monoester of HBMA and succinic acid), 1-[2-(vinylcarbonyloxy)butyl]succinate (monoester of HBA and succinic acid), 1-[2-(isopropenylcarbonyloxy)butyl]-phthalate (monoester of HBMA and phthalic acid), 1-[2-(vinylcarbonyloxy)butyl]phthalate (monoester of HBA and phthalic acid), 1-[2-(isopropenylcarbonyloxy)butyl]-hexahydrophthalate (monoester of HBMA and hexahydro-phthalic acid), 1-[2-(vinylcarbonyloxy)butyl]hexahydro-phthalate (monoester of HBA and hexahydrophthalic acid), fumaric acid, methylfumaric acid, monoesters of fumaric acid or their derivatives, maleic acid, methylmaleic acid, monoesters of maleic acid or their derivatives, crotonic acid, itaconic acid, acrylamidoglycolic acid, methacrylamidobenzoic acid, cinnamic acid, vinylacetic acid, trichloroacrylic acid, 10-hydroxy-2-decenoic acid, 4-methacryloyloxyethyl-trimethyl acid, styrenecarboxylic acid.
[0062] Particular preference is given to acrylic acid and methacrylic acid.
[0063] Further suitable monomers with H-bond donor function are acetoacetate-functionalized (e.g. LONZAMON® AAEMA from Lonza) ethylenically unsaturated compounds, for example 2-acetoacetoxymethyl methacrylate or 2-acetoacetoxyethyl acrylate. These compounds may be present at least partly in the tautomeric enol form.
[0064] Also suitable as monomers with H-bond donor function are all ethylenically unsaturated monomers having at least one sulfonic acid group and/or at least one phosphonic acid group. These are all organic compounds which have both at least one ethylenic double bond and at least one sulfonic acid group and/or at least one phosphonic acid group. They include, for example:
2-(isopropenylcarbonyloxy)ethanesulfonic acid, 2-(vinylcarbonyloxy)ethanesulfonic acid, 2-(iso-propenylcarbonyloxy)propylsulfonic acid, 2-(vinyl-carbonyloxy)propylsulfonic acid, 2-acrylamido-2-methyl-propanesulfonic acid, acrylamidododecanesulfonic acid, 2-propene-1-sulfonic acid, methallylsulfonic acid, styrenesulfonic acid, styrenedisulfonic acid, meth-acrylamidoethanephosphonic acid, vinylphosphonic acid, 2-phosphatoethyl methacrylate, 2-sulfoethyl methacrylate, Ω-alkenecarboxylic acids such as 2-hydroxy-4-pentenoic acid, 2-methyl-4-pentenoic acid, 2-n-propyl-4-pentenoic acid, 2-isopropyl-4-pentenoic acid, 2-ethyl-4-pentenoic acid, 2,2-dimethyl-4-pentenoic acid, 4-pentenoic acid, 5-hexenoic acid, 6-heptenoic acid, 7-octenoic acid, 8-nonenoic acid, 9-decenoic acid, 10-undecenoic acid, 11-dodecenoic acid, 12-tridecenoic acid, 13-tetradecenoic acid, 14-pentadecenoic acid, 15-hexadecenoic acid, 16-hepta-decenoic acid, 17-octadecenoic acid, 22-tricosenoic acid, 3-butene-1,1-dicarboxylic acid.
[0067] Equally suitable as monomers are acid amides, which are known, just like the carboxylic acids, to be able to act simultaneously both as H-bond donors and as H-bond acceptors. The unsaturated carboxamides may either bear an unsubstituted amide moiety or an optionally mono-substituted carboxamide group. Suitable compounds are, for example:
amides of (meth)acrylic acid and N-alkyl-substituted (meth)acrylamides, such as N-(3-dimethylaminopropyl)methacrylamide, N-(diethylphosphono)methacrylamide, 1-methacryloyl-amido-2-methyl-2-propanol, N-(3-dibutylaminopropyl)-methacrylamide, N-t-butyl-N-(diethylphosphono)meth-acrylamide, N,N-bis(2-diethylaminoethyl)methacrylamide, 4-methacryloylamido-4-methyl-2-pentanol, N-(butoxy-methyl)methacrylamide, N-(methoxymethyl)methacrylamide, N-(2-hydroxyethyl)methacrylamide, N-acetylmethacryl-amide, N-(dimethylaminoethyl)methacrylamide, N-methyl-methacrylamide, N-methacrylamide, methacrylamide, acrylamide, N-isopropylmethacrylamide; aminoalkyl methacrylates, such as tris(2-methacryloxyethyl)amine, N-methylformamidoethyl methacrylate, N-phenyl-N′-methacryloylurea, N-methacryloylurea, 2-ureidoethyl methacrylate; N-(2-methacryloyloxyethyl)ethyleneurea, heterocyclic (meth)acrylates such as 2-(1-imidazolyl)-ethyl (meth)acrylate, 2-(4-morpholinyl)ethyl (meth)-acrylate, 1-(2-methacryloyloxyethyl)-2-pyrrolidone, furfuryl methacrylate.
[0069] Carboxylic esters likewise suitable as H-bond donors are:
2-tert-butylaminoethyl methacrylate, N-methylformamdio-ethyl methacrylate, 2-ureidoethyl methacrylate; heterocyclic (meth)acrylates such as 2-(1-imidazolyl)-ethyl (meth)acrylate, 1-(2-methacryloyloxyethyl)-2-pyrrolidone.
[0071] Hydroxyalkyl (meth)acrylates such as 3-hydroxypropyl methacrylate, 3,4-dihydroxybutyl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 2,5-dimethyl-1,6-hexanediol methacrylate, 1,10-decanediol (meth)acrylate, 1,2-propanediol (meth)acrylate; polyoxyethylene and polyoxypropylene derivatives of (meth)acrylic acid, such as triethylene glycol mono(meth)acrylate, tetraethylene glycol mono(meth)acrylate and tetrapropylene glycol mono(meth)acrylate. Methacryloylhydroxamic acid, acryloylhydroxamic acid, N-alkylmethacryloylhydroxamic acid, N-alkylacryloylhydroxamic acid, reaction product of methacrylic or acrylic acid with lactams, for example with caprolactam, reaction product of methacrylic or acrylic acid with lactones, for example with caprolactone; reaction product of methacrylic or acrylic acid with acid anhydrides; reaction product of methacrylamide or acrylamide with lactams, for example with caprolactam, reaction product of methacrylamide or acrylamide with lactones, for example with caprolactone; reaction product of methacrylamide or acrylamide with acid anhydrides.
[0072] The content of compounds which have one or more structural units capable of forming H-bonds and are H-donors is from 0.01 to 15% by weight, preferably from 0.1 to 10% by weight and more preferably from 0.5 to 8% by weight, based on the total weight of the ethylenically unsaturated monomers of the backbone of the graft copolymer.
[0073] The inventive graft copolymers containing, as a further component of the backbone, compounds of the formula II
where R is hydrogen or methyl and R 5 is a linear or branched alkyl radical having from 1 to 5 carbon atoms.
[0075] Examples of components of the formula II include (meth)acrylates which derive from saturated alcohols, such as
methyl (meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl (meth)acrylate, tert-butyl (meth)acrylate and pentyl. (meth)acrylate; cycloalkyl (meth)acrylates such as cyclopentyl (meth)acrylate; (meth)acrylates which derive from unsaturated alcohols, such as 2-propynyl (meth)acrylate and allyl (meth)acrylate, vinyl (meth)acrylate.
[0079] The content of (meth)acrylates of the formula (II) is from 0 to 40% by weight, from 0.1 to 30% by weight or from 1 to 20% by weight, based on the total weight of the ethylenically unsaturated monomers of the backbone of the graft copolymer.
[0080] The inventive graft copolymers comprise, as a further component of the backbone, one or more of the ethylenically unsaturated ester compounds of the formula III
where R is hydrogen or methyl, R 8 is a linear, cyclic or branched alkyl radical having from 6 to 40 carbon atoms, R 6 and R 7 are each independently hydrogen or a group of the formula —COOR 8 where R 8 is hydrogen or a linear, cyclic or branched alkyl radical having from 6 to 40 carbon atoms.
[0082] These compounds of the formula (III) include (meth)acrylates, maleates and fumarates, each of which have at least one alcohol radical having from 6 to 40 carbon atoms.
[0083] Preference is given here to (meth)acrylates of the formula (IIIa)
where
R is hydrogen or methyl and R 1 is a linear or branched alkyl radical having from 6 to 40 carbon atoms.
[0085] When the expression “(meth)acrylates” is used in the context of the present application, this term in each case encompasses methacrylates or acrylates alone or else mixtures of the two. These monomers are widely known. They include
(meth)acrylates which derive from saturated alcohols, such as hexyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, heptyl (meth)acrylate, 2-tert-butylheptyl (meth)acrylate, octyl (meth)acrylate, 3-isopropylheptyl (meth)acrylate, nonyl (meth)acrylate, decyl (meth)acrylate, undecyl (meth)acrylate, 5-methylundecyl (meth)acrylate, dodecyl (meth)acrylate, 2-methyldodecyl (meth)acrylate, tridecyl (meth)acrylate, 5-methyltridecyl (meth)acrylate, tetradecyl (meth)acrylate, pentadecyl (meth)acrylate, hexadecyl (meth)acrylate, 2-methylhexadecyl (meth)acrylate, heptadecyl (meth)acrylate, 5-isopropylheptadecyl (meth)acrylate, 4-tert-butyloctadecyl (meth)acrylate, 5-ethyloctadecyl (meth)acrylate, 3-isopropyloctadecyl (meth)acrylate, octadecyl (meth)acrylate, nonadecyl (meth)acrylate, eicosyl (meth)acrylate, cetyleicosyl (meth)acrylate, stearyleicosyl (meth)acrylate, docosyl (meth)acrylate and/or eicosyltetratriacontyl (meth)acrylate; (meth)acrylates which derive from unsaturated alcohols, for example oleyl (meth)acrylate; cycloalkyl (meth)acrylates such as 3-vinylcyclohexyl (meth)acrylate, cyclohexyl (meth)acrylate, bornyl (meth)acrylate.
[0088] The ester compounds with a long-chain alcohol radical can be obtained, for example, by reacting (meth)acrylates, fumarates, maleates and/or the corresponding acids with long-chain fatty alcohols, which generally forms a mixture of esters, for example. (meth)acrylates with various long-chain alcohol radicals. These fatty alcohols include Oxo Alcohol® 7911 and Oxo Alcohol® 7900, Oxo Alcohol® 1100 from Monsanto; Alphanol® 79 from ICI; Nafol® 1620, Alfol® 610 and Alfol® 810 from Sasol; Epal® 610 and Epal® 810 from Ethyl Corporation; Linevol® 79, Linevol® 911 and Dobanol® 25 L from Shell; Lial 125® from Sasol; Dehydad® and Lorol® types from Henkel KGaA, and Linopol® 7-11 and Acropol® 91.
[0089] The long-chain alkyl radical of the (meth)acrylates of the formula III has generally from 6 to 40 carbon atoms, preferably from 6 to 24 carbon atoms, more preferably from 8 to 18 carbon atoms, and may be linear, branched, mixed linear/branched or have cyclic fractions. The preferred embodiment is to use a mixture of methyl methacrylate and C8-C18-alkyl methacrylates as the methacrylates.
[0090] The alcohols with long-chain alkyl radicals which are used to prepare the (meth)acrylic esters are commercially available and consist generally of more or less broad mixtures of different chain lengths. In these cases, the specification of the number of carbon atoms is generally based on the mean carbon number. When an alcohol or a long-chain (meth)acrylic ester prepared using this alcohol is referred to as “C-12” alcohol or as “C-12” ester in the context of the present application, the alkyl radical of these compounds will generally comprise, in addition to alkyl radicals having 12 carbon atoms, also possibly those having 8, 10, 14 or 16 carbon atoms in smaller fractions, the mean carbon number being 12. When, in the context of the present application, for example, a compound is designated as C12-C18-alkyl acrylate, this means a mixture of esters of acrylic acid which is characterized in that linear and/or branched alkyl. substituents are present and that the alkyl substituents contain between 12 and 18 carbon atoms.
[0091] The content of the (meth)acrylates of the formula (III) or (IIIa) is from 35 to 99.99% by weight, from 40 to 99% by weight or from 50 to 80% by weight, based on the total weight of the ethylenically unsaturated monomers of the backbone of the graft copolymer.
[0092] To form the backbone of the graft copolymer, it is also possible for from 0 to 40% by weight, in particular from 0.5 to 20% by weight, based on the total weight of the ethylenically unsaturated monomers of the backbone of the graft copolymer, of one or more free-radically polymerizable further monomers to be involved. Examples thereof are
nitriles of (meth)acrylic acid and other nitrogen-containing methacrylates, such as methacryloylamidoacetonitrile, 2-methacryloyloxyethyl-methylcyanamide, cyanomethyl methacrylate; aryl (meth)acrylates, such as benzyl methacrylate or phenyl methacrylate, where the aryl radicals may each be unsubstituted or up to tetrasubstituted; carbonyl-containing methacrylates such as oxazolidinylethyl methacrylate, N-(methacryloyloxy)formamide, acetonyl methacrylate, N-methacryloylmorpholine, N-methacryloyl-2-pyrrolidinone; glycol dimethacrylates such as 1,4-butanediol methacrylate, 2-butoxyethyl methacrylate, 2-ethoxyethoxymethyl methacrylate, 2-ethoxyethyl methacrylate, methacrylates of ether alcohols, such as tetrahydrofurfuryl methacrylate, vinyloxyethoxyethyl methacrylate, methoxyethoxyethyl methacrylate, 1-butoxypropyl methacrylate, 1-methyl-(2-vinyloxy)ethyl methacrylate, cyclohexyloxymethyl methacrylate, methoxymethoxyethyl methacrylate, benzyloxymethyl methacrylate, furfuryl methacrylate, 2-butoxyethyl methacrylate, 2-ethoxyethoxymethyl methacrylate, 2-ethoxyethyl methacrylate, allyloxymethyl methacrylate, 1-ethoxybutyl methacrylate, methoxymethyl methacrylate, 1-ethoxyethyl methacrylate, ethoxymethyl methacrylate; methacrylates of halogenated alcohols, such as 2,3-dibromopropyl methacrylate, 4-bromophenyl methacrylate, 1,3-dichloro-2-propyl methacrylate, 2-bromoethyl methacrylate, 2-iodoethyl methacrylate, chloromethyl methacrylate; oxiranyl methacrylates such as 2,3-epoxybutyl methacrylate, 3,4-epoxybutyl methacrylate, glycidyl methacrylate; phosphorus-, boron- and/or silicon-containing methacrylates such as 2-(dimethylphosphato)propyl methacrylate, 2-(ethylene-phosphito)propyl methacrylate, dimethylphosphinomethyl methacrylate, dimethylphosphonoethyl methacrylate, diethylmethacryloyl phosphonate, dipropylmethacryloyl phosphate; sulfur-containing methacrylates, such as ethylsulfinylethyl methacrylate, 4-thiocyanatobutyl methacrylate, ethylsulfonylethyl methacrylate, thio-cyanatomethyl methacrylate, methylsulfinylmethyl methacrylate, bis(methacryloyloxyethyl) sulfide; trimethacrylates such as trimethylolpropane trimethacrylate; vinyl halides, for example vinyl chloride, vinyl fluoride, vinylidene chloride and vinylidene fluoride; α, vinyl esters such as vinyl acetate; styrene, substituted styrenes having an alkyl substituent in the side chain, for example α-methylstyrene and α-ethylstyrene, substituted styrenes with an alkyl substituent on the ring, such as vinyltoluene and p-methylstyrene, halogenated styrenes, for example 3.5 monochlorostyrenes, dichlorostyrenes, tribromostyrenes and tetrabromostyrenes; heterocyclic vinyl compounds such as 2-vinylpyridine, 3-vinylpyridine, 2-methyl-5-vinylpyridine, 3-ethyl-4-vinylpyridine, 2,3-dimethyl-5-vinylpyridine, vinylpyrimidine, vinylpiperidine, 9-vinylcarbazole, 3-vinylcarbazole, 4-vinylcarbazole, 1-vinylimidazole, 2-methyl-1-vinylimidazole, N-vinyl-pyrrolidone, 2-vinylpyrrolidone, N-vinylpyrrolidine, 3-vinylpyrrolidine, N-vinylcaprolactam, N-vinylbutyro-lactam, vinyloxolane, vinylfuran, vinylthiophene, vinylthiolane, vinylthiazoles and hydrogenated vinylthiazoles, vinyloxazoles and hydrogenated vinyloxazoles; vinyl and isoprenyl ethers; maleic acid derivatives, for example diesters of maleic acid, where the alcohol radicals have from 1 to 9 carbon atoms, maleic anhydride, methylmaleic anhydride, maleimide, methylmaleimide; fumaric acid derivatives, for example diesters of fumaric acid, where the alcohol radicals have from 1 to 9 carbon atoms; dienes, for example divinylbenzene.
[0100] Free-radically polymerizable α-olefins having 4-40 carbon atoms.
[0101] Representative examples include:
butene-1, pentene-1, hexene-1, heptene-1, octene-1, nonene-1, decene-1, undecene-1, dodecene-1, tri-decene-1, tetradecene-1, pentadecene-1, hexadecene-1, heptadecene-1, octadecene-1, nonadecene-1, eicosene-1, heneicosene-1, docosene-1, trocosene-1, tetracosene-1, pentacosene-1, hexacosene-1, heptacosene-1, octa-cosene-1, nonacosene-1, triacontene-1, hentria-contene-1, dotriacontene-1, or the like. Also suitable are branched-chain alkenes, for example vinylcyclo-hexane, 3,3-dimethylbutene-1, 3-methylbutene-1, diiso-butylene-4-methylpentene-1 or the like.
[0103] Also suitable are alkenes-1 having from 10 to 32 carbon atoms which are obtained in the polymerization of ethylene, propylene or mixtures, these materials in turn being obtained from hydrocracked materials.
[0104] From 0.01 to 25% by weight, based on the total weight of the copolymer, are grafted onto the backbone of the copolymer
where R 1 , R 2 and R 3 may each independently be hydrogen or an alkyl group having from 1 to 5 carbon atoms, and R 4 is a group which has one or more structural units capable of forming H-bonds and is an H-donor. In particular embodiments, the fraction of grafted compounds of the formula (I) may also be from 0.1 to 20% by weight, from 1 to 15% by weight or from 1 to 10% by weight, based in each case on the total weight of the copolymer. The maximum possible amount of monomer which can be used for the grafting depends upon the chemical nature of the monomer in a manner understandable to the person skilled in the art. For example, it will be more easily possible to incorporate an amount corresponding to the upper limiting range of the amount added into the graft copolymer when a dialkylaminoalkyl(meth)acrylamide is used, while the amount added of more strongly polar monomers such as methacrylic acid or acrylic acid will appropriately vary within the region of less than 10% by weight or less than 5% by weight.
[0105] The structure of the compounds of the formula (I) and specific examples thereof have already been described in detail for the components of the backbone and reference is made here explicitly thereto.
[0106] The grafting to the backbone may optionally additionally be carried out with from 0 to 20% by weight or with from 0 to 10% by weight, based on the total weight of the copolymer, of one or more compounds of the formula (IV)
in which R 9 , R 10 , R 11 and R 12 are each as already defined.
[0107] Examples of compounds of the formula (IV) include N,N-dimethylacrylamide and N,N-dimethylmethacrylamide, N,N-diethylacrylamide and N,N-diethylmethacylamide, aminoalkyl methacrylates such as tris(2-methacryloyloxyethyl)amine, N-methylformamidoethyl methacrylate, 2-ureidoethyl methacrylate;
heterocyclic (meth)acrylates such as 2-(1-imidazolyl)-ethyl (meth)acrylate, 2-(4-morpholinyl)ethyl (meth)acrylate and 1-(2-methacryloylethyl)-2-pyrrolidone, heterocyclic compounds such as 2-vinylpyridine, 3-vinylpyridine, 2-methyl-5-vinylpyridine, 3-ethyl-4-vinylpyridine, 2,3-dimethyl-5-vinylpyridine, vinyl-pyrimidine, vinylpiperidine, 9-vinylcarbazole, 3-vinyl-carbazole, 4-vinylcarbazole, 1-vinylimidazole, 2-methyl-1-vinylimidazole, N-vinylpyrrolidone, 2-vinyl-pyrrolidone, N-vinylpyrrolidine, 3-vinylpyrrolidine, N-vinylcaprolactam, N-vinylbutyrolactam, vinyloxolane, vinylfuran, vinylthiophene, vinylthiolane, vinyl-thiazoles and hydrogenated vinylthiazoles, vinyl-oxazoles and hydrogenated vinyloxazoles.
Preparation of the Polymers
[0110] The aforementioned ethylenically unsaturated monomers may be used individually or as mixtures. It is additionally possible to vary the monomer composition during the polymerization.
[0111] Basic polymerization techniques for the preparation of the polymers are known per se. For instance, these polymers can be effected especially by free-radical polymerization, and also related processes, for example ATRP (=atom transfer radical polymerization) or RAFT (=reversible addition fragmentation chain transfer).
[0112] The customary free-radical polymerization is explained, inter alia, in Ullmanns's Encylopedia of Industrial Chemistry, Sixth Edition. In general, a polymerization initiator is used for this purpose.
[0113] These include the azo initiators well known in the technical field, such as AIBN and 1,1-azo-biscyclohexanecarbonitrile, and also peroxy compounds such as methyl ethyl ketone peroxide, acetylacetone peroxide, dilauryl peroxide, tert-butyl per-2-ethyl-hexanoate, ketone peroxide, tert-butyl peroctoate, methyl isobutyl ketone peroxide, cyclohexanone peroxide, dibenzoyl peroxide, tert-butyl peroxy-benzoate, tert-butyl peroxyisopropylcarbonate, 2,5-bis-(2-ethylhexanoylperoxy)-2,5-dimethylhexane, tert-butyl peroxy-2-ethylhexanoate, tert-butyl peroxy-3,5,5-trimethylhexanoate, dicumyl peroxide, l,1-bis(tert-butylperoxy)cyclohexane, 1,1-bis(tert-butylperoxy)-3,3,5-trimethylcyclohexane, cumyl hydroperoxide, tert-butyl hydroperoxide, bis(4-tert-butylcyclohexyl) peroxydicarbonate, mixtures of two or more of the aforementioned compounds with one another, and also mixtures of the aforementioned compounds with compounds which have not been mentioned and can likewise form free radicals.
[0114] The ATRP process is known per se. It is assumed that it is a “living” free-radical polymerization, without any intention that this should restrict the description of the mechanism. In these processes, a transition metal compound is reacted with a compound which has a transferable atom group. This transfers the transferable atom group to the transition metal compound, which oxidizes the metal. This reaction forms a radical which adds onto ethylenic groups. However, the transfer of the atom group to the transition metal compound is reversible, so that the atom group is transferred back to the growing polymer chain, which forms a controlled polymerization system. The structure of the polymer, the molecular weight and the molecular weight distribution can be controlled correspondingly.
[0115] This reaction is described, for example, by J-S. Wang, et al., J. Am. Chem. Soc., vol. 117, p. 5614-5615 (1995), by Matyjaszewski, Macromolecules, vol. 28, p. 7901-7910 (1995). In addition, the patent applications WO 96/30421, WO 97/47661, WO 97/18247, ATRP explained above.
[0116] In addition, the inventive polymers may be obtained, for example, also via RAFT methods. This process is presented in detail, for example, in WO 98/01478, to which reference is made explicitly for the purposes of disclosure.
[0117] The polymerization may be carried out at standard pressure, reduced pressure or elevated pressure. The polymerization temperature too is uncritical. However, it is generally in the range of −20°-200° C., preferably 0°-130° C. and more preferably 60°-120° C.
[0118] The polymerization may be carried out with or without solvent. The term solvent is to be understood here in a broad sense.
[0119] The polymerization is preferably carried out in a nonpolar solvent. These include hydrocarbon solvents, for example aromatic solvents such as toluene, benzene and xylene, saturated hydrocarbons, for example cyclohexane, heptane, octane, nonane, decane, dodecane, which may also be present in branched form. These solvents may be used individually and as a mixture. Particularly preferred solvents are mineral oils, natural oils and synthetic oils, and also mixtures thereof. Among these, very particular preference is given to mineral oils.
[0120] Mineral oils are known per se and commercially available. They are generally obtained from mineral oil or crude oil by distillation and/or refining and optionally further purification and finishing processes, the term mineral oil including in particular the higher-boiling fractions of crude or mineral oil. In general, the boiling point of mineral oil is higher than 200° C., preferably higher than 300° C., at 5000 Pa. The production by low-temperature carbonization of shale oil, coking of bituminous coal, distillation of brown coal with exclusion of air, and also hydrogenation of bituminous or brown coal is likewise possible. Mineral oils are also produced in a smaller proportion from raw materials of vegetable (for example from jojoba, rapeseed) or animal (for example neatsfoot oil) origin. Accordingly, mineral oils have, depending on their origin, different proportions of aromatic, cyclic, branched and linear hydrocarbons.
[0121] In general, a distinction is drawn between paraffin-base, naphthenic and aromatic fractions in crude oils or mineral oils, in which the term paraffin-base fraction represents longer-chain or highly branched isoalkanes, and naphthenic fraction represents cyclo-alkanes. In addition, mineral oils, depending on their origin and finishing, have different fractions of n-alkanes, isoalkanes having a low degree of branching, known as mono-methyl-branched paraffins, and compounds having heteroatoms, in particular O, N and/or S, to which a degree of polar properties are attributed. The fraction of n-alkanes in preferred mineral oils is less than 3% by weight, the proportion of O—, N— and/or S-containing compounds less than 6% by weight. The proportion of the aromatics and of the mono-methyl-branched paraffins is generally in each case in the range from 0 to 30% by weight. In one interesting aspect, mineral oil comprises mainly naphthenic and paraffin-base alkanes which have generally more than 13, preferably more than 18 and most preferably more than 20 carbon atoms. The fraction of these compounds is generally ≧60% by weight, preferably ≧80% by weight, without any intention that this should impose a restriction. An analysis of particularly preferred mineral oils, which was effected by means of conventional processes such as urea separation and liquid chromatography on silica gel shows, for example, the following constituents, the percentages relating to the total weight of the particular mineral oil used:
n-alkanes having from approx. 18 to 31 carbon atoms; 0.7-1.0%, slightly branched alkanes having from 18 to 31 carbon atoms: 1.0-8.0%, aromatics having from 14 to 32 carbon atoms: 0.4-10.7%, iso- and cycloalkanes having from 20 to 32 carbon atoms: 60.7-82.4%, polar compounds: 0.1-0.8%, loss: 6.9-19.4%.
[0134] Valuable information with regard to the analysis of mineral oils and a list of mineral oils which have a different composition can be found, for example, in Ullmanns's Encyclopedia of Industrial Chemistry, 5th Edition on CD-ROM, 1997, under “lubricants and related products”.
[0135] Synthetic oils include organic esters, organic ethers such as silicone oils, and synthetic hydrocarbons, especially polyolefins. They are usually somewhat more expensive than the mineral oils, but have advantages with regard to their performance.
[0136] Natural oils are animal or vegetable oils, for example neatsfoot oils or jojoba oils.
[0137] These oils may also be used as mixtures and are in many cases commercially available.
[0138] These solvents are used preferably in an amount of from 1 to 99% by weight, more preferably from 5 to 95% by weight and most preferably from 10 to 60% by weight, based on the total weight of the mixture. The composition may also have polar solvents, although their amount is restricted by the fact that these solvents must not exert any unacceptably disadvantageous action on the solubility of the polymers.
[0139] The molecular weights Mw of the polymers are from 5000 to 4 000 000 g/mol, in particular 10 000-2 000 000 g/mol and more preferably 20 000-500 000 g/mol. The polydispersities (Mw/Mn) are preferably in a range of 1.2-7.0. The molecular weights may be determined by known methods. For example, gel permeation chromatography, also known as “size exclusion chromatography” (SEC), may be used. Equally useful for determining the molecular weights is an osmometric process, for example vapor phase osmometry. The processes mentioned are described, for example, in: P. J. Flory, “Principles of Polymer Chemistry” Cornell University Press (1953), Chapter VII, 266-316 and “Macromolecules, an Introduction to Polymer Science”, F. A. Bovey and F. H. Winslow, Editors, Academic Press (1979), 296-312 and W. W. Yau, J. J. Kirkland and D. D. Bly, “Modern Size Exclusion Liquid Chromatography”, John Wiley and Sons, New York, 1979. To determine the molecular weights of the polymers presented herein, preference is given to using gel permeation chromatography. It should preferably be measured against polymethyl acrylate or polyacrylate standards.
[0140] The residual monomer contents (for example C8-C18-alkyl acrylate, MMA, methacrylic acid, NVP) were determined by customary HPLC analysis processes. They are stated either in ppm or % by weight in relation to the total weight of the polymer solutions prepared. It should be mentioned by way of example for acrylates having long-chain alkyl substitution that the residual monomer content stated for C8-C18-alkyl acrylates for example includes all acrylate monomers used which bear alkyl substitutions in the ester side chains, which are characterized in that they contain between 8 and 18 carbon atoms.
[0141] The syntheses described in the present invention comprise the preparation of polymer solutions, by prescribing that the syntheses described cannot be undertaken without solvent. The kinematic viscosities specified relate accordingly to the polymer solutions and not the pure, isolated polymers. The term “thickening action” relates to the kinematic viscosity of a polymer solution, which is measured by diluting a certain amount of the polymer solution with a further solvent at a certain temperature. Typically, 10-15% by weight of the polymer solution prepared in each case are diluted in a 150N oil and the kinematic viscosities of the resulting solution are determined at 40° C. and 100° C. The kinematic viscosities are determined by customary processes, for example in an Ubbelohde viscometer or in automatic test apparatus from Herzog. The kinematic viscosity is always specified in mm 2 /s.
[0142] The process for preparing the graft copolymers of the present invention is characterized in that the backbone is prepared in the first step by free-radical polymerization of the monomers a), c) and optionally b) and/or d), and in that a further amount of one or more of the monomers of the formula (I) is then grafted onto the backbone in the second step.
[0143] The graft copolymers are thus prepared by using the monomers which possess one or more structural units capable of forming H-bonds and which are H-donors not just in the grafting process but also, in a small fraction, to form the backbone of the graft copolymer, which is often referred to as the polymer backbone. An advantageous procedure may consist, for example, in incorporating 1, 2, 3 or 5% by weight, based on the total weight of the ethylenically unsaturated monomers of the backbone, of a monomer having a group which possesses one or more structural units capable of forming H-bonds and is an H-donor by free-radical polymerization into an acrylate copolymer, and then being followed by a grafting with, for example, a further 1, 2, 3 or 5% by weight of the same monomer or of another compound of the formula (I).
[0144] A particularly suitable monomer for use according to the procedure described above is methacrylic acid.
[0145] The monomers with H-bond donor functionalities used for grafting, and also the monomers with H-bond donor functionalities already used to form the main polymer chain, need not necessarily correspond. Thus, in accordance with the present invention, polymers can be obtained in which it is optionally also possible to use different monomers with H-bond donor functionalities to form the polymer backbone and/or for the grafting step.
[0146] In an advantageous embodiment of the process for preparing graft copolymers, after the grafting of one or more monomers of the formula (I), a further grafting process is carried out with one or more monomers of the formula (IV) which may also optionally be a monomer which need not have structural units capable of forming H-bonds.
[0147] It is likewise possible to reverse the above-described sequence of the grafting steps. In this embodiment of the process for preparing graft copolymers, after the polymerization of the backbone, a grafting process is first carried out with one or more monomers of the formula (IV), followed by a further grafting process with one or more monomers of the formula (I).
[0148] The present process for preparing the graft copolymers can also be carried out advantageously by carrying out a grafting process using a mixture of in each case one or more monomers of the formulae (I) and (IV).
[0149] In a further advantageous embodiment of the present process for preparing graft copolymers, the grafting process is carried out up to 5 times in succession. In this case, a plurality of graftings with in each case a small amount of monomer, for example in each case 1% by weight of a monomer which can act as an H-bond donor, are carried out successively. When, for example, a total of 2% by weight of such a monomer is used for grafting, preference is given to carrying out two successive grafting steps with, for example, in each case 1% by weight of the monomer in question. It is clear to those skilled in the art that, depending on the individual case, it is also possible here to use a number of other values for the amounts of monomer used and for the number of grafting steps, so that they do not have to be listed individually here. It is self-evident that the multiple, up to 5-fold repetition of the grafting step can also be effected with mixtures of the monomers of the formulae (I) and (IV).
[0150] The monomer in formula (IV) may be an N-functionalized monomer, preferably an N-vinyl-substituted monomer, for example N-vinylpyrrolidone, N-vinylcaprolactam, N-vinyltriazole, N-vinylbenzotriazole or N-vinylimidazole. In another embodiment, it may also be a vinylpyridine, for example 2-vinylpyridine. It may equally be a methacrylate or acrylate which contains an N-heterocycle in its ester function. In addition, the N-containing monomer may be an N,N-dialkylamino acrylate or its methacrylate analog, where the aminoalkyl groups contain 1-8 carbon atoms. With regard to the further possible compounds, reference is made at this point to the comprehensive list in the definition of the monomers of the formula (IV).
[0151] It is possible to use the inventive graft copolymers to produce a concentrate as a lubricant oil additive. The concentrate contains from 15 to 85% by weight of one or more of the graft copolymers. In addition, it is also possible for organic solvents, especially a mineral oil and/or a synthetic oil, to be present in the concentrate.
[0152] The inventive graft copolymers are particularly suitable for producing lubricant oil compositions. In this case, the graft copolymers are generally used in an amount in the range from 0.2 to 30% by weight. The lubricant oil compositions may also comprise from 5 to 90% by weight of mineral and/or synthetic base oil and, all together, from 0.2 to 20% by weight of further customary additives, for example pour point depressants, VI improvers, aging stabilizers, detergents, dispersing assistants or wear-reducing components.
[0153] In practice, acid-functionalized polymers are often neutralized in polymer-like reactions with amines, polyamines or alcohols; methods for this purpose are disclosed, for example, by DE-A 2519197 (ExxonMobil) and U.S. Pat. No. 3,994,958 (Rohm & Haas Company). Just as in these two applications, the inventive polymers of the present application may subsequently be neutralized or esterified in a polymer-like reaction with primary or secondary amine compounds or alcohols. In this case, a partial or full neutralization of the polymers can be carried out. A full neutralization includes both an esterification of the acid functions present in the backbone and an esterification of the acid functions present in the grafted portion.
[0154] In addition to VI, dispersancy and properties not discussed herein, for example oxidation stability, the influence of a lubricant oil on the wear behavior of a machine element is also of particular interest. Wear-reducing additives intended specifically for this purpose are generally added to lubricant oils. Such additives are usually phosphorus- and/or sulfur-containing. In the lubricants industry, there is a drive to reduce the phosphorus and sulfur input into modern lubricant oil formulations. This has both technical (prevention of exhaust gas catalytic converter poisoning) and environmental politics reasons. The search for phosphorus- and sulfur-free lubricant additives has thus become, specifically in the recent past, an intensive research activity of many additives manufacturers.
[0155] Advantages in the wear behavior can have a positive effect on the energy consumption, for example of a diesel or gasoline engine. The polymers of the present invention have to date not yet been connected with a positive effect on wear behavior.
[0156] The polymers of the present invention are superior to known, commercial polymers with N-functionalities in relation to wear protection.
[0157] According to the current state of the art, crankshaft drive, piston group, cylinder bore and the valve control system of an internal combustion engine are lubricated with a motor oil. This is done by conveying the motor oil which collects in the oil sump of the engine to the individual lubrication points by means of conveying pump through an oil filter (pressure circulation lubrication in conjunction with injection and oil-mist lubrication).
[0158] In this system, the motor oil has the functions of: transferring forces, reducing friction, reducing wear, cooling components, and gas sealing of the piston.
[0159] The oil is fed under pressure to the bearing points (crankshaft, connection rod and camshaft bearings). The lubrication points of the valve drive, the piston group, gearwheels and chains are supplied with injected oil, spin-off oil or oil mist.
[0160] At the individual lubrication points, forces to be transferred, contact geometry, lubrication rate and temperature vary within wide ranges in operation.
[0161] The increase in the power density of the engines (kW/capacity; torque/capacity) lead to higher component temperatures and surface pressures of the lubrication points.
[0162] To ensure the motor oil functions under these conditions, the performance of a motor oil is tested in standardized test methods and engine tests (for example API classification in the USA or ACEA test sequences in Europe). In addition, test methods self-defined by individual manufacturers are used before a motor oil is approved for use.
[0163] Among the abovementioned lubricant oil properties, the wear protection of the motor oil is of particular significance. As an example, the requirement list of the ACEA Test Sequences 2002 shows that, in each category (A for passenger vehicle gasoline engines, B for passenger vehicle diesel engines and E for heavy goods vehicle engines) with a separate engine test, the confirmation of sufficient wear protection for the valve drive is to be conducted.
[0164] The oil is exposed to the following stresses in operation:
Contact with hot components (up to above 300° C.) Presence of air (oxidation), nitrogen oxides (nitration), fuel and its combustion residues (wall condensation, input in liquid form) and soot particles from combustion (input of solid extraneous substances). At the time of combustion, the oil film on the cylinder is exposed to high radiative heat. The turbulence generated by the crankshaft drive of the engine creates a large active surface area of the oil in the form of drops in the gas space of the crankshaft drive and gas bubbles in the oil sump.
[0169] The listed stresses of evaporation, oxidation, nitration, dilution with fuel and input of particles, owing to the engine operation, change the motor oil itself and components of the engine which are wetted with motor oil in operation. As a consequence, the following undesired effects for the trouble-free operation of the engine arise:
Change in the viscosity (determined in the low-temperature range and at 400 and 100° C.) Pumpability of the oil at low external temperatures Deposit formation on hot and cold components of the engine: this is understood to mean the formation of lacquer-like layers (brown to black in color) up to and including the formation of carbon. These deposits impair the function of individual components such as: free passage of the piston rings and narrowing of air-conducting components of the turbocharger (diffuser and spirals). The result may be serious engine damage or power loss and increase in the exhaust gas emissions. In addition, a sludge-like deposit layer forms, preferentially on the horizontal surfaces of the oil space, and in the extreme case can even block oil filters and oil channels of the engine, which can likewise cause engine damage.
[0173] The reduction in the deposit formation and the provision of high detergency and dispersancy and also anti-wear action over a long utilization time are of central significance in current clearance procedures, as can be seen by the following example of ACEA test sequences from 1998:
Category A (gasoline engines): In 6 engine test methods, oil deposition is determined 10 times, wear 4 times and viscosity 2 times. In the determination of deposition behavior, piston cleanliness is assessed 3 times, piston ring sticking 3 times and sludge formation 3 times. Category B (light diesel engines): In 5 engine test methods, oil deposition is determined 7 times, wear 3 times and viscosity 2 times. In the determination of the deposition behavior, piston cleanliness is assessed 4 times, piston ring sticking 2 times and sludge formation once. Category E (heavy diesel engines heavy duty diesel): In 5 engine test methods, oil deposition is determined 7 times, wear 6 times and viscosity once. In the determination of the deposition behavior, piston cleanliness is assessed 3 times, sludge formation 2 times and turbo deposition once.
[0177] For the present invention, the influence of the lubricant used on wear was measured by test method CEC-L-51-A-98. This test method is suitable both for the investigation of the wear behavior in a passenger vehicle diesel engine (ACEA category B) and in a heavy goods vehicle diesel engine (ACEA category E). In these test methods, the circumference profile of each cam is determined in 1° steps on a 2- or 3-D test machine before and after test, and compared. The profile deviation formed in the test corresponds to the cam wear. To assess the tested motor oil, the wear results of the individual cams are averaged and compared with the limiting value of the corresponding ACEA categories.
[0178] In a departure from the CEC test method, the test time was shortened from 200 h to 100 h. The investigations performed showed that clear differentiations can be made between the oils used even after 100 h, since significant differences in the wear were detected already after this time.
[0179] Oil A (see tables 1 and 2) of the present invention served as the first comparative example for the wear experiment. It was a heavy-duty diesel motor oil formulation of the category SAE 5W-30. As usual in practice, this oil was mixed up from a commercial base oil, in the present case Nexbase 3043 from Fortum, and also further typical additives. The first of these additives is Oloa 4549 from Oronite. The latter component is a typical DI additive for motor oils. In addition to ashless dispersants, the product also comprises components for improving the wear behavior. The latter components in Oloa 4549 are zinc and phosphorus compounds. Zinc and phosphorus compounds can be regarded as the currently most commonly used additives for improving the wear behavior. As a further additive, for the purpose of thickener or VI improver action, an ethylene-propylene copolymer (Paratone 8002 from Oronite) was used. As usual in practice, Paratone 8002 was used as a solution in a mineral oil. Even though their VI action is limited, ethylene-propylene copolymers are currently the most common VI improvers in passenger vehicle and heavy goods vehicle motor oils owing to their good thickening action. A noticeable wear-improving action has not been described to date for such systems. A polyacrylate was not used as an additive component for oil A. In summary, oil A was composed of 75.3% by weight of Nexbase 3043, 13.2% by weight of Oloa 4594 and 11.5% by weight of a solution of Paratone 8002.
TABLE 1 Wear results to CEC-L-51-A-98, obtained with oils A-C Polyacrylate CEC-L-51-A-98, mean Content of in each case cam wear Oil Paratone 8002 3% by wt. after 100 h [μm] A 11.5% by wt. — 47.4 B 8.5% by wt. Example 1 23.9 C 8.5% by wt. Example 3 3.9
[0180]
TABLE 2
Rheological data and TBN values of the
formulations used for the wear tests
Content of
Paratone
Polyacrylate
8002
in each case
Oil
[% by wt.]
3% by wt.
KV40° C.
KV100° C.
VI
TBN
CCS
HTHS
A
11.5
—
11.38
B
8.5
Example 1
67.07
11.91
176
9.1
4621
3.41
C
8.5
Example 3
62.88
11.46
180
9.3
4406
3.35
[0181] As is evident from table 2, all formulations used for the wear experiments essentially do not differ with regard to their kinematic viscosity data. This can be seen with reference to the kinematic viscosities measured at 40 and 100° C. (denoted in table 2 as KV40° C. and KV100° C. respectively). Table 2 likewise shows that the formulations used do not differ markedly with regard to viscosity index (VI), total base number (TBN), cold-start behavior expressed by crank case simulator data (CCS), and temporary shear losses at high temperatures expressed by high-temperature high-shear d data (HTHS). The KV40° C., KV100° C., VI, TBN, CCS and HTHS data were determined by the ASTM methods known to those skilled in the art.
[0182] With regard to corrosion behavior and oxidation resistance, no noticeable differences of the inventive formulations compared to the comparative examples were recognizable. By way of example, the inventive formulations B and C were examined with regard to their corrosion behavior in direct comparison with oil A (see table 3). These examinations were carried out to ASTM D 5968 for lead, copper and tin, and to ASTM D 130 for copper.
TABLE 3 Corrosion behavior of formulations used for wear tests Corrosion ASTM D ASTM D 5968 130 Oil Polyacrylate Pb Cu Sn Cu A — 109.5 4 0 1b B Example 1 130.0 4 0 1b C Example 3 77.0 4.5 0 1b
[0183] The oxidation behavior was determined using the PDSC method known to those skilled in the art (CEC L-85-T-99).
[0184] It was common to oils B and C that 3% by weight of the Paratone 8002 solution in each case was replaced by 3% by weight of the particular polyacrylate solution. Oils B and C are the inventive formulations with regard to wear behavior. It is clear that, in particular, a formulation which comprises a polymer from example 3 is to be considered as particularly advantageous with regards to wear protection (see table 1). The mean cam wear at 3.9 μm was particularly low here compared to the comparative formulations. The polymer from example 1 which is simple to prepare was found to be improved over the prior art, indicated by a comparison in the cam wear compared to values determined for oil A.
[0185] Suitable base oils for the preparation of an inventive lubricant oil formulation are in principle any compound which ensures a sufficient lubricant film which does not break even at elevated temperatures. To determine this property, it is possible, for example, to use the viscosities, as laid down, for example, in the SAE specifications.
[0186] Particularly suitable compounds include those which have a viscosity which is in the range from 15 Saybolt seconds (SUS, Saybolt Universal Seconds) to 250 SUS, preferably in the range from 15 to 100 SUS, in each case determined at 100° C.
[0187] The compounds suitable for this purpose include natural oils, mineral oils and synthetic oils, and also mixtures thereof.
[0188] Natural oils are animal or vegetable oils, for example neatsfoot oils or jojoba oils. Mineral oils are obtained mainly by distillation of crude oil. They are advantageous especially with regard to their favorable cost. Synthetic oils include organic esters, synthetic hydrocarbons, especially polyolefins, which satisfy the abovementioned requirements. They are usually somewhat more expensive than the mineral oils, but have advantages with regard to their performance.
[0189] These base oils may also be used in the form of mixtures and are in many cases commercially available.
[0190] In addition to the base oil and the polymers mentioned herein, which already make contributions to the dispersion behavior and to the wear protection, lubricant oils generally comprise further additives. This is the case especially for motor oils, gearbox oils and hydraulic oils. The additives suspend solids (detergent-dispersant behavior), neutralize acidic reaction products and form a protective film on the cylinder surface (EP additive, “extreme pressure”). In addition, friction-reducing additives such as friction modifiers, aging protectants, pour point depressants, corrosion protectants, dyes, demulsifiers and odorants are used. Further valuable information can be found by those skilled in the art in Ullmanns's Encyclopedia of Industrial Chemistry, Fifth Edition on CD-ROM, 1998 edition. The inventive polymers of the present invention may, owing to their contribution to wear protection, ensure sufficient wear protection even in the absence of a friction modifier or of an EP additive. The wear-improving action is then contributed by the inventive polymer, to which friction modifier action could therefore be attributed.
[0191] The amounts in which abovementioned additives are used are dependent upon the field of use of the lubricant. In general, the proportion of the base oil is between 25 to 90% by weight, preferably from 50 to 75% by weight. The additives may also be used in the form of DI packages (detergent-inhibitor) which are widely known and can be obtained commercially.
[0192] Particularly preferred motor oils comprise, in addition to the base oil, for example,
0.1-1% by weight of pour point depressants, 0.5-15% by weight of VI improvers, 0 . 4 -2% by weight of aging protectants, 2-10% by weight of detergents, 1-10% by weight of lubricity improvers, 0.0002-0.07% by weight of antifoams, 0.1-1% by weight of corrosion protectants from 1 to 10% by weight of dispersing components.
[0200] The inventive lubricant oil may, as well as the base oil described above, additionally, preferably in a concentration of 0.05-10.0 percent by weight, comprise an alkyl alkoxylate of the formula (V). The alkyl alkoxylate may be added to the lubricant oil composition directly, as a constituent of the VI improver, as a constituent of the DI package, as a constituent of a lubricant concentrate or subsequently to the oil. The oil used here may also be processed used oils.
R 1 —[(CR 2 R 3 ) n ] z -L-A-R 4 (V),
in which
[0201] R 1 , R 2 and R 3 are each independently hydrogen or a hydrocarbon radical having up to 40 carbon atoms,
R 4 is hydrogen, a methyl or ethyl radical, L is a linking group, n is an integer in the range from 4 to 40, A is an alkoxy group having from 2 to 25 repeat units which are derived from ethylene oxide, propylene oxide and/or butylene oxide, where A includes homopolymers and also random copolymers of at least two of the aforementioned compounds, and z is 1 or 2, where the nonpolar part of the compound (V) of the formula (VI)
R 1 —[(CR 2 R 3 ) n ] z -L- (VI)
contains at least 9 carbon atoms. These compounds are referred to in the context of the invention as alkyl alkoxylates. These compounds may be used either individually or as a mixture.
[0208] Hydrocarbon radicals having up to 40 carbon atoms shall be understood to mean, for example, saturated and unsaturated alkyl radicals which may be linear, branched or cyclic, and also aryl radicals which may also comprise heteroatoms and alkyl substituents, which may optionally be provided with substituents, for example halogens.
[0209] Among these radicals, preference is given to (C 1 -C 20 )-alkyl, in particular (C 1 -C 8 )-alkyl and very particularly (C 1 -C 4 )-alkyl radicals.
[0210] The term “(C 1 -C 4 )-alkyl” is understood to mean an unbranched or branched hydrocarbon radical having from 1 to 4 carbon atoms, for example the methyl, ethyl, propyl, isopropyl, 1-butyl, 2-butyl, 2-methylpropyl or tert-butyl radical;
the term “(C 1 -C 8 )-alkyl” the aforementioned alkyl radicals, and also, for example, the pentyl, 2-methylbutyl, hexyl, heptyl, octyl, or the 1,1,3,3-tetramethylbutyl radical; the term “(C 1 -C 20 )-alkyl” the aforementioned alkyl radicals, and also, for example, the nonyl, 1-decyl, 2-decyl, undecyl, dodecyl, pentadecyl or eicosyl radical.
[0213] In addition, (C 3 -C 8 )-cycloalkyl radicals are preferred as the hydrocarbon radical. These include the cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl or cyclooctyl group.
[0214] In addition, the radical may also be unsaturated. Among these radicals, preference is given to “(C 2 -C 20 )-alkenyl”, “(C 2 -C 20 )-alkynyl” and in particular to “(C 2 -C 4 )-alkenyl” and “(C 2 -C 4 )-alkynyl”. The term “(C 2 -C 4 )-alkenyl” is understood to mean, for example, the vinyl, allyl, 2-methyl-2-propenyl or 2-butenyl group;
the term “(C 2 -C 20 )-alkenyl” the aforementioned radicals and also, for example, the 2-pentenyl, 2-decenyl or the 2-eicosenyl group; the term “(C 2 -C 4 )-alkynyl”, for example, the ethynyl, propargyl, 2-methyl-2-propynyl or 2-butynyl group; the term “(C 2 -C 20 )-alkenyl” the aforementioned radicals, and also, for example, the 2-pentynyl or the 2-decynyl group.
[0218] In addition, preference is given to aromatic radicals such as “aryl” or “heteroaromatic ring systems”. The term “aryl” is understood to mean an isocyclic aromatic radical having preferably from 6 to 14, in particular from 6 to 12 carbon atoms, for example phenyl, naphthyl or biphenylyl, preferably phenyl;
the term “heteroaromatic ring system” is understood to mean an aryl radical in which at least one CH group has been replaced by N and/or at least two adjacent CH groups have been replaced by S, NH or O, for example a radical of thiophene, furan, pyrrole, thiazole, oxazole, imidazole, isothiazole, isoxazole, pyrazole, 1,3,4-oxadiazole, 1,3,4-thiadiazole, 1,3,4-triazole, 1,2,4-oxadiazole, 1,2,4-thiadiazole, 1,2,4-triazole, 1,2,3-triazole, 1,2,3,4-tetrazole, benzo[b]thiophene, benzo [b]furan, indole, benzo[c]thiophene, benzo[c]-furan, isoindole, benzoxazole, benzothiazole, benzi-midazole, benzisoxazole, benzisothiazole, benzo-pyrazole, benzothiadiazole, benzotriazole, dibenzo-furan, dibenzothiophene, carbazole, pyridine, pyrazine, pyrimidine, pyridazine, 1,3,5-triazine, 1,2,4-triazine, 1,2,4,5-triazine, quinoline, isoquinoline, quinoxaline, cinnoline, 1,8-naphthyridine, 1,5-naphthyridine, 1,6-naphthyridine, 1,7-naphthyridine, phthalazine, pyridopyrimidine, purine, pteridine or 4H-quinolizine.
[0220] The R 2 or R 3 radicals which may occur repeatedly in the hydrophobic moiety of the molecule may each be the same or different.
[0221] The linking L group serves to join the polar alkoxide moiety to the nonpolar alkyl radical. Suitable groups include, for example, aromatic radicals such as phenoxy (L=—C 6 H 4 —O—), radicals derived from acids, for example ester groups (L=—CO—O—), carbamate groups (L=—NH—CO—O—) and amide groups (L=—CO—NH—), ether groups (L=—O—) and keto groups (L=—CO—). Preference is given here to particularly stable groups, for example the ether, keto and aromatic groups.
[0222] As mentioned above, n is an integer in the range from 4 to 40, in particular in the range from 10 to 30. If n is greater than 40, the viscosity which is generated by the inventive additive generally becomes too great. If n is less than 4, the lipophilicity of the molecular moiety is generally insufficient to keep the compound of the formula (V) in solution. Accordingly, the nonpolar moiety of the compound (V) of the formula (VI) contains preferably a total of from 10 to 100 carbon atoms and most preferably a total of from 10 to 35 carbon atoms.
[0223] The polar moiety of the alkyl alkoxylate is illustrated by A in formula (V). It is assumed that this moiety of the alkyl alkoxylate can be illustrated by the formula (VII)
in which the R 5 radical is hydrogen, a methyl radical and/or ethyl radical, and m is an integer in the range form 2 to 40, preferably from 2 to 25, in particular 2 and 15, and most preferably from 2 to 5. In the context of the present invention, the aforementioned numerical values are to be understood as mean values, since this moiety of the alkyl alkoxylate is generally obtained by polymerization. If m is greater than 40, the solubility of the compound in the hydrophobic environment is too low, so that there is opacity in the oil, in some cases precipitation. When the number is less than 2, the desired effect cannot be ensured.
[0224] The polar moiety may have units which are derived from ethylene oxide, from propylene oxide and/or from butylene oxide, preference being given to ethylene oxide. In this context, the polar moiety may have only one of these units. These units may also occur together randomly in the polar radical.
[0225] The number z results from the selection of the connecting group, and from the starting compounds used. It is 1 or 2.
[0226] The number of carbon atoms of a nonpolar moiety of the alkyl alkoxylate of the formula (VI) is preferably greater than the number of carbon atoms of the polar moiety A, probably of the formula (VII), of this molecule. The nonpolar moiety preferably comprises at least twice as many carbon atoms as the polar moiety, more preferably three times the number or more. Alkyl alkoxylates are commercially available. These include, for example, the ®Marlipal and ®Marlophen types from Sasol and the ®Lutensol types from BASF.
[0227] These include, for example, ®Marlophen NP 3 (nonylphenol polyethylene glycol ether (3EO)), ®Marlophen NP 4 (nonylphenol polyethylene glycol ether (4EO)), ®Marlophen NP 5 (nonylphenol polyethylene glycol ether (5EO)), ®Marlophen NP 6 (nonylphenol polyethylene glycol ether (6EO));
®Marlipal 1012/6 (C 10 -C 12 fatty alcohol polyethylene glycol ether (6EO)), ®Marlipal MG (C 12 fatty alcohol polyethylene glycol ether), ®Marlipal 013/30 (C 13 oxo alcohol polyethylene glycol ether (3EO)), ®Marlipal 013/40 (C 13 oxo alcohol polyethylene glycol ether (4EO)); ®Lutensol TO 3 (i-C 13 fatty alcohol with 3 EO units), ®Lutensol TO 5 (i-C 13 fatty alcohol with 5 EO units), ®Lutensol TO 7 (i-C 13 fatty alcohol with 7 EO units), Lutensol TO 8 (i-C 13 fatty alcohol with 8 EO units) and Lutensol TO 12 (i-C 13 fatty alcohol with 12 EO units)
EXAMPLES
[0230] Comparative examples 1-3 of the present invention, which are intended to be representative of those synthesis attempts which failed, lead to reaction products which are characterized in that a portion of the polymers formed precipitates out of the polymer solution actually in solid form.
[0231] The preparation according to example 1) provides a homogeneous polymer solution with clear appearance. When the grafting process is carried out analogously, i.e. with 2% by weight of methacrylic acid under the same process conditions but without having used a small amount of methacrylic acid beforehand to form the polymer backbone, an inhomogeneous polymer solution with cloudy appearance is obtained (see comparative example 3). Even in the case of grafting with only 1% by weight of methacrylic acid, an inhomogeneous reaction product is obtained (see comparative example 1). It is therefore no surprise that grafting with 3% by weight of methacrylic acid without having incorporated a certain fraction of this species into the polymer backbone beforehand likewise leads to a highly cloudy product, which is characterized in that solid constituents precipitate actually out of the solution (see comparative example 2). This is also the case when attempts are made to react the 3% by weight of methacrylic acid in a grafting process not all at once but rather gradually, for example in portions of 1% by weight each. Interestingly, it is conveniently possible to prepare a copolymer with 3% by weight of methacrylic acid which have been polymerized randomly into the polymer and not by means of a grafting step.
[0232] Just like carboxylic acids, acid amides are known for their simultaneous possible action as both H-bond donors and H-bond acceptors. In analogy to example 1, in which methacrylic acid was selected as the monomer type with H-bond donor function, example 4 of the present invention describes a polymer in which dimethylaminopropylmethacrylamide (DMAPMAM) is present both in the polymer backbone and in the grafted fraction. The process detailed in example 4 leads to a homogeneous polymer solution of clear appearance and demonstrates that the synthesis principle presented herein is of universal character, i.e. can be applied not just to carboxylic acid derivatives but also, for example, to acid amides.
[0233] The monomers with H-bond donor functionalities used for grafting and the monomers with H-bond donor functionalities already used to form the main polymer chain need not necessarily correspond. Thus, the present invention includes polymers in which mixtures of different monomers with H-bond donor functionalities are used to form the polymer backbone and/or for the grafting step. Example 2 describes a polymer synthesis in which 1% by weight of methacrylic acid is incorporated into the polymer backbone and a further 2% by weight of the same species, followed by 3% by weight of DMAPMAM, are present in the grafted fraction.
[0234] In addition to a grafting with a monomer having H-bond donor function, it is possible to carry out further graftings with other monomer types. To this end, the N- or O-containing monomer types with dispersing action mentioned at the outset are used with preference. The latter monomers are characterized in that their N- or O-containing functionality is generally an H-bond acceptor function. An additional grafting with such a monomer may either follow the grafting process with the monomer which possesses H-bond donor function or precede it. It is equally possible to perform graftings with monomer mixtures which, as well as monomers with H-bond donor functionalities, additionally contain the abovementioned monomers by the inventive polymerization process. Example 3 of the present invention encompasses a polymer synthesis in which 1% by weight of methacrylic acid has been used to form the backbone by the process according to the invention, then grafted twice with a further 1% by weight of methacrylic acid in each case by the process according to the invention and then finally followed by a grafting step with 3% by weight of N-vinylpyrrolidone. In this case too, a homogeneous reaction product, characterized by a clear solution, is contained.
[0235] It is clear that, in particular, a formulation which comprises a polymer from example 3 is to be considered as particularly advantageous in relation to wear protection. The mean cam wear at 3.9 μm was particularly low here compared to the comparative formulations. The copolymers from example 1 which are simple to prepare were found to be improved over the prior art, indicated by a comparison in the cam wear compared to values determined with oil A.
[0000] Products and Starting Materials Used:
[0236] The starting materials such as initiators or chain transferrers used for the polymer syntheses described herein were entirely commercial products, as obtainable, for example, from Aldrich or Akzo Nobel. Monomers, for example MMA (Degussa), NVP (BASF), DMAPMAM (Degussa), 10-undecenoic acid (Atofina) or methacrylic acid (Degussa) were likewise obtained from commercial sources. Plex 6844-0 was a methacrylate containing urea in the ester radical from Degussa.
[0237] For other monomers used herein, for example C8-C18-alkyl methacrylates or ethoxylated methacrylates, reference is made to the description of the present application. This is equally true for the more precise description of the solvents used, for example oils or alkyl alkoxylates.
[0000] Explanations of Terms, Test Methods
[0238] When an acrylate or, for example, an acrylate polymer or polyacrylate is discussed in the present invention, this is understood to mean not only acrylates, i.e. derivatives of acrylic acid, but also methacrylates, i.e. derivatives of methacrylic acid, or else mixtures of systems based on acrylate and methacrylate.
[0239] When a polymer is referred to as a random polymer in the present application, this means a copolymer in which the monomer types used are distributed randomly in the polymer chain. Graft copolymers, block copolymers or systems with a concentration gradient of the monomer types used along the polymer chain are referred to in this context as non-random polymers or non-randomly structured polymers.
[0240] The term “grafted fraction” relates to the fraction of the polymer which is attached subsequently, i.e. after completion of polymerization of the polymer backbone, covalently to this finished polymer backbone. It should be pointed out that this does not give any information about the structure of the end products, expressed by the number, size and the precise covalent attachment points of the grafted fractions. However, the statement that all polymers described herein with grafted fractions have a non-random structure does apply.
[0000] Polymer Syntheses
Comparative Example 1
(Failed Grafting of 1% by Weight of Methacrylic Acid onto a Polyacrylate)
[0241] A 2 liter four-neck flask equipped with saber stirrer (operated at 150 revolutions per minute), thermometer and reflux condenser is initially charged with 430 g of a 150N oil and 47.8 g of a monomer mixture consisting of C12-C18-alkyl methacrylate and methyl methacrylate in a weight ratio of 85.0/15.0. The temperature is adjusted to 100° C. After 100° C. has been attained, 0.38 g of tert-butyl peroctoate is added and, at the same time, a feed of 522.2 g of a mixture consisting of C12-C18-alkyl methacrylate and methyl methacrylate in a weight ratio of 85.0/15.0 together with 2.09 g of tert-butyl peroctoate is started. The feed time is 3.5 hours and the feed rate is uniform. Two hours after the feeding has ended, another 1.14 g of tert-butyl peroctoate are added. The total reaction time is 8 hours. Thereafter, 4.3 g of 150N oil, 5.7 g of methacrylic acid and 1.45 g of tert-butyl peroctoate are added at 100° C. One hour after this addition, 0.72 g of tert-butyl peroctoate is then added once again three times at a separation of one hour each time. The total reaction time after addition of the methacrylic acid is 8 hours. A cloudy reaction product of inhomogeneous appearance, which is characterized in that polymeric fractions have already precipitated out of the liquid phase in solid form, is obtained.
Comparative Example 2
(Failed Grafting of 3% by Weight of Methacrylic Acid onto a Polyacrylate)
[0242] A 2 liter four-neck flask equipped with saber stirrer (operated at 150 revolutions per minute), thermometer and reflux condenser is initially charged with 430 g of a 150N oil and 47.8 g of a monomer mixture consisting of C12-C18-alkyl methacrylate and methyl methacrylate in a weight ratio of 85.0/15.0. The temperature is adjusted to 100° C. After 100° C. has been attained, 0.38 g of tert-butyl peroctoate is added and, at the same time, a feed of 522.2 g of a mixture consisting of C12-C18-alkyl methacrylate and methyl methacrylate in a weight ratio of 85.0/15.0 together with 2.09 g of tert-butyl peroctoate is started. The feed time is 3.5 hours and the feed rate is uniform. Two hours after the feeding has ended, another 1.14 g of tert-butyl peroctoate are added. The total reaction time is 8 hours. Thereafter, 13.17 g of 150N oil, 17.45 g of methacrylic acid and 1.45 g of tert-butyl peroctoate are added at 100° C. One hour after this addition, 0.73 g of tert-butyl peroctoate each time is then added once again three times at a separation of one hour each time. The total reaction time after addition of the methacrylic acid is 8 hours. A very cloudy reaction product of inhomogeneous appearance, which is characterized in that polymeric fractions have already precipitated out of the liquid phase in solid form, is obtained.
Comparative Example 3
(Failed Grafting of 2% by Weight of Methacrylic Acid onto a Polyacrylate)
[0243] A 2 liter four-neck flask equipped with saber stirrer (operated at 150 revolutions per minute), thermometer and reflux condenser is initially charged with 430 g of a 150N oil and 47.8 g of a monomer mixture consisting of C12-C18-alkyl methacrylate and methyl methacrylate in a weight ratio of 85.0/15.0. The temperature is adjusted to 100° C. After 100° C. has been attained, 0.38 g of tert-butyl peroctoate is added and, at the same time, a feed of 522.2 g of a mixture consisting of C12-C18-alkyl methacrylate and methyl methacrylate in a weight ratio of 85.0/15.0 together with 2.09 g of tert-butyl peroctoate is started. The feed time is 3.5 hours. The feed rate is uniform. Two hours after the feeding has ended, another 1.14 g of tert-butyl peroctoate are added. The total reaction time is 8 hours. Thereafter, 8.68 g of 150N oil, 11.52 g of methacrylic acid and 1.45 g of tert-butyl peroctoate are added at 100° C. One hour after this addition, 0.72 g of tert-butyl peroctoate each time is then added once again three times at a separation of one hour each time. The total reaction time after addition of the methacrylic acid is 8 hours. An opaque reaction product of inhomogeneous appearance, which is characterized in that polymeric fractions have already precipitated out of the liquid phase in solid form, is obtained.
Example 1
(Polyacrylate with 1% by Weight of Methacrylic Acid in the Polymer Backbone and 2% by Weight of Methacrylic Acid in the Grafted Fraction)
[0244] A 2 liter four-neck flask equipped with saber stirrer (operated at 150 revolutions per minute), thermometer and reflux condenser was initially charged with 430 g of 150N oil and 47.8 g of a monomer mixture of C12-C18-alkyl methacrylate, methyl methacrylate and methacrylic acid in a weight ratio of 84.0/15.0/1.0. The temperature is adjusted to 100° C. After the 100° C. has been attained, 0.80 g of tert-butyl peroctoate is added and, at the same time, a feed of 522.2 g of a monomer mixture consisting of C12-C18-alkyl methmethacrylate, methyl methacrylate, methacrylic acid in a weight ratio of 84.0/15.0/1.0 together with 4.44 g of tert-butyl peroctoate is started. The feed time is 3.5 hours and the feed rate is uniform. Two hours after the feeding has ended, another 1.14 g of tert-butyl peroctoate are added. The total reaction time is 8 hours. Thereafter, 8.69 g of 150N oil, 5.76 g of methacrylic acid and 0.72 g of tert-butyl peroctoate are added at 100° C. One hour thereafter, another 5.76 g of methacrylic acid and 0.72 g of tert-butyl peroctoate are added. The total reaction time is 8 hours. A reaction product of homogeneous appearance is obtained.
Kinematic viscosity at 100° C.: 3764 mm 2 /s Thickening action at 100° C. (10% in a 150N oil): 11.14 mm 2 /s Thickening action at 40° C. (10% in a 150N oil): 59.6.0 mm 2 /s C12-C18-Alkyl methacrylate residual monomer content: 0.51% MMA residual monomer content: 0.036% Methacrylic acid residual monomer content: 0.072%
Example 2
(Polyacrylate with 1% by Weight of Methacrylic Acid in the Polymer Backbone and 2% by Weight of Methacrylic Acid and 3% by Weight of DMAPMAM in the Grafted Fraction)
[0253] A 2 liter four-neck flask equipped with saber stirrer (operated at 150 revolutions per minute), thermometer and reflux condenser is initially charged with 430 g of a 150N oil and 47.8 g of a monomer mixture consisting of C12-C18-alkyl methacrylate, methyl methacrylate and methacrylic acid in a weight ratio of 84.0/15.0/1.0. The temperature is adjusted to 100° C. After the 100° C. has been attained, 0.75 g of tert-butyl peroctoate is added and, at the same time, a feed of 522.2 g of a mixture consisting of C12-C18-alkyl methacrylate, methyl methacrylate and methacrylic acid in a weight ratio of 84.0/15.0/1.0 together with 4.17 g of tert-butyl peroctoate is started. The feed time is 3.5 hours and the feed rate is uniform. Two hours after the feeding has ended, another 1.14 g of tert-butyl peroctoate are added. The total reaction time is 8 hours. Thereafter, 8.69 g of 150N oil, 5.76 g of methacrylic acid and 0.72 g of tert-butyl peroctoate are added at 100° C. One hour thereafter, 5.76 g of methacrylic acid and 0.72 g of tert-butyl peroctoate are added. After a further hour, 13.43 g of 150N oil, 17.81 g of dimethylaminopropylmethacrylamide (DMAPMAM) and 1.48 g of tert-butyl peroctoate are added. One hour and 2 hours thereafter, another 0.74 g of tert-butyl peroctoate each time is added. The total reaction time is 8 hours. A reaction product of homogeneous appearance is obtained.
Kinematic viscosity of the polymer solution at 100° C.: 3634 mm2/s Thickening action at 100° C. (10% in a 150N oil): 11.21 mm 2 /s Thickening action at 40° C. (10% in a 150N oil): 60.63 mm 2 /s C12-C18-Alkyl methacrylate residual monomer content: 0.444% MMA residual monomer content: 0.035% Methacrylic acid residual monomer content: 98 ppm
Example 3
(Polyacrylate with 1% by Weight of Methacrylic Acid in the Polymer Backbone and 2% by Weight of Methacrylic Acid and 3% by Weight of NVP in the Grafted Fraction)
[0264] A 2 liter four-neck flask equipped with saber stirrer (operated at 150 revolutions per minute), thermometer and reflux condenser is initially charged with 430 g of 150N oil and 47.8 g of a monomer mixture of C12-C18-alkyl methacrylate, methyl methacrylate and methacrylic acid in a weight ratio of 84.0/15.0/1.0. The temperature is adjusted to 100° C. After the 100° C. has been attained, 0.94 g of tert-butyl peroctoate is added and, at the same time, a feed of 522.2 g of a mixture of C12-C18-alkyl methacrylate, methyl methacrylate and methacrylic acid in a weight ratio of 84.0/15.0/1.0 together with 5.22 g of tert-butyl peroctoate is started. The feed time is 3.5 hours and the feed rate is uniform. Two hours after the feeding has ended, another 1.14 g of tert-butyl peroctoate are added. The total reaction time is 8 hours.
[0265] Thereafter, 8.69 g of 150N oil, 5.76 g of methacrylic acid and 0.72 g of tert-butyl peroctoate are added at 100° C. One hour thereafter, another 5.76 g of methacrylic acid and 0.72 g of tert-butyl peroctoate are added. After a further hour, the mixture is heated to 130° C. Once 130° C. has been attained, 13.43 g of 150N oil, 17.81 g of N-vinylpyrrolidone (NVP) and 1.48 g of tert-butyl perbenzoate are added. One hour and 2 hours thereafter, another 0.74 g of tert-butyl perbenzoate each time is added. The total reaction time of the 3 grafting steps overall is 8 hours. A clear reaction product of homogeneous appearance is obtained.
Specific viscosity (20° C. in chloroform): 36.5 ml/g Kinematic viscosity at 100° C.: 3584 mm 2 /S Thickening action at 100° C. (10% in a 150N oil): 11.02 mm 2 /s Thickening action at 40° C. (10% in a 150N oil): 59.60 mm 2 /s C12-C18-Alkyl methacrylate residual monomer content: 0.064% MMA residual monomer content: 45 ppm Methacrylic acid residual monomer content: 9.5 ppm N-Vinylpyrrolidone residual monomer content: 0.045%
Example 4
(Polyacrylate with 1% by Weight of DMAPMAM in the Polymer Backbone and 2% by Weight of DMAPMAM in the Grafted Fraction)
[0276] A 2 liter four-neck flask equipped with saber stirrer (operated at 150 revolutions per minute), thermometer and reflux condenser is initially charged with 430 g of 150N oil and 47.8 g of a monomer mixture of C12-C18-alkyl methacrylate, methyl methacrylate and DMAPMAM in a weight ratio of 84.0/15.0/1.0. The temperature is adjusted to 100° C. After the 100° C. had been attained, 0.80 g of tert-butyl peroctoate are added and, at the same time, a feed of 522.2 g of a monomer mixture of C12-C18-alkyl methmethacrylate, methyl methacrylate and DMAPMAM in a weight ratio of 84.0/15.0/1.0, together with 4.44 g of tert-butyl peroctoate is started. The feed time is 3.5 hours and the feed rate is uniform. Two hours after the feeding has ended, a further 1.14 g of tert-butyl peroctoate are added. The total reaction time is 8 hours. Thereafter, 8.69 g of 150N oil, 5.76 g of DMAPMAM and 0.72 g of tert-butyl peroctoate are added at 100° C. One hour thereafter, another 5.76 g of DMAPMAM and 0.72 g of tert-butyl peroctoate are added. The total reaction time is 8 hours. A reaction product of homogeneous appearance is obtained.
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The invention relates to graft copolymers produced by radically polymerizing polymerisable monomers and, in addition comprising long-chain ethylenically unsaturated compounds which contain alkyl substitutes, in particular acrylates or methacrylates and monomers with hydrogen bridge donator functions. According to said invention, said hydrogen bridge donator monomer is introduced into a polymer backbone and into graft side branches. The inventive polymers are particularly usable for lubricating oil formulations.
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This application is a continuation of application Ser. No. 09/815,966,filed Mar. 23, 2001,now U.S. Pat. No. 6,524,481, which is a continuation under 35 U.S.C. §120 of International Patent Application No. PCT/AU99/00817 filed on Sep. 24, 1999 under the Patent Cooperation Treaty (PCT), which was published by the International Bureau in English on Apr. 6, 2000, which designates the U.S. and claims the benefit of Australian Provisional Patent Application No. PP 6217 filed on Sep. 25, 1998, Australian Provisional Patent Application No. PP 6218 filed on Sep. 25, 1998, and Australian Provisional Patent Application No. PQ 1112 filed on Jun. 21, 1999.
TECHNICAL FIELD
The present invention relates to an apparatus and the related method to effectively clean membrane modules by means of a mixture of gas and liquid formed by a venturi, jet or the like. For membrane modules to be applied to an environment of high concentration of suspended solids, for example, in bioreactors, several improved module configurations are described to reduce solid accumulation within a module.
BACKGROUND OF THE INVENTION
The importance of membrane for treatment of waste water is growing rapidly. It is now well known that membrane processes can be used as an effective tertiary treatment of sewage and provide quality effluent. However, the capital and operating cost can be prohibitive. With the arrival of submerged membrane processes where the membrane modules are immersed in a large feed tank and filtrate is collected through suction applied to the filtrate side of the membrane, membrane bioreactors combining biological and physical processes in one stage promise to be more compact, efficient and economic. Due to their versatility, the size of membrane bioreactors can range from household (such as septic tank systems) to the community and large-scale sewage treatment.
The success of a membrane filtration process largely depends on employing an effective and efficient membrane cleaning method. Commonly used physical cleaning methods include backwash (backpulse, backflush) using a liquid permeate or a gas, membrane surface scrubbing or scouring using a gas in the form of bubbles in a liquid. Examples of the second type of method is illustrated in U.S. Pat. No. 5,192,456 to Ishida et al, U.S. Pat. No. 5,248,424 to Cote et al, U.S. Pat. No. 5,639,373 to Henshaw et al, U.S. Pat. No. 5,783,083 to Henshaw et al and our PCT Application No. WO98/28066.
In the examples referred to above, a gas is injected, usually by means of a pressurised blower, into a liquid system where a membrane module is submerged to form gas bubbles. The bubbles so formed then travel upwards to scrub the membrane surface to remove the fouling substances formed on the membrane surface. The shear force produced largely relies on the initial gas bubble velocity, bubble size and the resultant of forces applied to the bubbles. The fluid transfer in this approach is limited to the effectiveness of the gas lifting mechanism. To enhance the scrubbing effect, more gas has to be supplied. However, this method has several disadvantages: it consumes large amounts of energy, possibly forms mist or froth flow reducing effective membrane filtration area, and may be destructive to membranes. Moreover, in an environment of high concentration of solids, the gas distribution system may gradually become blocked by dehydrated solids or simply be blocked when the gas flow accidentally ceases.
For most tubular membrane modules, the membranes are flexible in the middle (longitudinal direction) of the modules but tend to be tighter and less flexible towards to both potted heads. When such modules are used in an environment containing high concentrations of suspended solids, solids are easily trapped within the membrane bundle, especially in the proximity of two potted heads. The methods to reduce the accumulation of solids include the improvement of module configurations and flow distribution when gas scrubbing is used to clean the membranes.
In the design of a membrane module, the packing density of the tubular membranes in a module is an important factor. The packing density of the fibre membranes in a membrane module as used herein is defined as the cross-sectional potted area taken up by the fibre membranes divided by the total potted area and is normally expressed as a percentage. From the economical viewpoint it is desirable that the packing density be as high as possible to reduce the cost of making membrane modules. In practice solid packing is reduced in a less densely packed membrane module. However, if the packing density is too low, the rubbing effect between membranes could also be lessened, resulting in less efficient scrubbing/scouring of the membrane surfaces. It is thus desirable to provide a membrane configuration which assists removal of accumulated solids while maximising packing density of the membranes.
SUMMARY OF THE INVENTION
The present invention, at least in its embodiments, seeks to overcome or least ameliorate some of the disadvantages of the prior art or at least provide the public with a useful alternative.
According to one aspect, the present invention provides a method of scrubbing a membrane surface using a liquid medium with gas bubbles entrained therein, including the steps of entraining said gas bubbles into said liquid medium by flow of said liquid medium past a source of said gas, and flowing said gas bubbles and liquid medium along said membrane surface to dislodge fouling materials therefrom.
Preferably, the gas bubbles are entrained into said liquid stream by means of a venturi device. For further preference, the gas bubbles are entrained or injected into said liquid stream by means of devices which forcibly mix gas into a liquid flow to produce a mixture of liquid and bubbles, such devices including a jet, nozzle, ejector, eductor, injector or the like. Optionally, an additional source of bubbles may be provided in said liquid medium by means of a blower or like device. The gas used may include air, oxygen, gaseous chlorine or ozone. Air is the most economical for the purposes of scrubbing and/or aeration. Gaseous chlorine may be used for scrubbing, disinfection and enhancing the cleaning efficiency by chemical reaction at the membrane surface. The use of ozone, besides the similar effects mentioned for gaseous chlorine, has additional features, such as oxidising DBP precursors and converting non-biodegradable NOM's to biodegradable dissolved organic carbon.
According to a second aspect, the present invention provides a membrane module comprising a plurality of porous membranes, said membranes being arranged in close proximity to one another and mounted to prevent excessive movement therebetween, and means for providing, from within the module, by means other than gas passing through the pores of said membranes, gas bubbles entrained in a liquid flow such that, in use, said liquid and bubbles entrained therein move past the surfaces of said membranes to dislodge fouling materials therefrom, said gas bubbles being entrained in said liquid by flowing said liquid past a source of gas to draw the gas into said liquid flow.
Preferably, said liquid and bubbles are mixed and then flowed past membranes to dislodge the fouling materials.
According to one preferred form, the present invention provides a method of removing fouling materials from the surface of a plurality of porous hollow fibre membranes mounted and extending longitudinally in an array to form a membrane module, said membranes being arranged in close proximity to one another and mounted to prevent excessive movement therebetween, the method comprising the steps of providing, from within said array, by means other than gas passing through the pores of said membranes, uniformly distributed gas bubbles entrained in a liquid flow, said gas bubbles being entrained in said liquid flow by flowing said liquid past a source of gas so as to cause said gas to be drawn and/or mixed into said liquid, said distribution being such that said bubbles pass substantially uniformly between each membrane in said array to, in combination with said liquid flow, scour the surface of said membranes and remove accumulated solids from within the membrane module. Preferably, said bubbles are injected and mixed into said liquid flow.
For preference, the membranes comprise porous hollow fibres, the fibres being fixed at each end in a header, the lower header having one or more holes formed therein through which gas/liquid flow is introduced. The holes can be circular, elliptical or in the form of a slot. The fibres are normally sealed at the lower end and open at their upper end to allow removal of filtrate, however, in some arrangements, the fibres may be open at both ends to allow removal of filtrate from one or both ends. The fibres are preferably arranged in cylindrical arrays or bundles. It will be appreciated that the cleaning process described is equally applicable to other forms of membrane such flat or plate membranes.
According to a further aspect the present invention provides a membrane module comprising a plurality of porous hollow fibre membranes, said fibre membranes being arranged in close proximity to one another and mounted to prevent excessive movement therebetween, the fibre membranes being fixed at each end in a header, one header having one or more of holes formed therein through which gas/liquid flow is introduced, and partition means extending at least part way between said headers to partition said membrane fibres into groups. Preferably, the partition means are formed by a spacing between respective fibre groups. The partitions may be parallel to each other or, in the case of cylindrical arrays of fibre membranes, the partitions may extend radially from the centre of the array or be positioned concentrically within the cylindrical array. In an alternative form, the fibre bundle may be provided with a central longitudinal passage extending the length of the bundle between the headers.
According to yet a further aspect, the present invention provides a membrane module for use in a membrane bioreactor including a plurality of porous hollow membrane fibres extending longitudinally between and mounted at each end to a respective potting head, said membrane fibres being arranged in close proximity to one another and mounted to prevent excessive movement therebetween, said fibres being partitioned into a number of bundles at least at or adjacent to their respective potting head so as to form a space therebetween, one of said potting heads having an array of aeration openings formed therein for providing gas bubbles within said module such that, in use, said bubbles move past the surfaces of said membrane fibres to dislodge fouling materials therefrom.
The fibre bundle is protected and fibre movement is limited by a module support screen which has both vertical and horizontal elements appropriately spaced to provide unrestricted fluid and gas flow through the fibres and to restrict the amplitude of fibre motion reducing energy concentration at the potted ends of the fibres.
Preferably, said aeration openings are positioned to coincide with the spaces formed between said partitioned bundles. For preference, said openings comprise a slot, slots or a row of holes. Preferably, the fibre bundles are located in the potting head between the slots or rows of holes.
For further preference, the gas bubbles are entrained or mixed with a liquid flow before being fed through said holes or slots, though it will be appreciated that gas only may be used in some configurations. The liquid used may be the feed to the membrane module. The fibres and/or fibre bundles may cross over one another between the potting heads though it is desirable that they do not.
Preferably, the fibres within the module have a packing density (as defined above) of between about 5 to about 70% and, more preferably, between about 8 to about 55%.
For preference, said holes have a diameter in the range of about 1 to 40 mm and more preferably in the range of about 1.5 to about 25 mm. In the case of a slot or row of holes, the open area is chosen to be equivalent to that of the above holes.
Typically, the fibre inner diameter ranges from about 0.1 mm to about 5 mm and is preferably in the range of about 0.25 mm to about 2 mm. The fibres wall thickness is dependent on materials used and strength required versus filtration efficiency. Typically wall thickness is between 0.05 to 2 mm and more often between 0.1 mm to 1 mm.
According to another aspect, the present invention provides a membrane bioreactor including a tank having means for the introduction of feed thereto, means for forming activated sludge within said tank, a membrane module according to the first aspect positioned within said tank so as to be immersed in said sludge and said membrane module provided with means for withdrawing filtrate from at least one end of said fibre membranes.
According to yet another aspect, the present invention provides a method of operating a membrane bioreactor of the type described in the second aspect comprising introducing feed to said tank, applying a vacuum to said fibres to withdraw filtrate therefrom while periodically or continuously supplying gas bubbles through said aeration openings to within said module such that, in use, said bubbles move past the surfaces of said membrane fibres to dislodge fouling materials therefrom. Preferably, the gas bubbles are entrained or mixed with a liquid flow when fed through said holes or slots.
If required, a further source of aeration may be provided within the tank to assist microorganism activity. For preference, the membrane module is suspended vertically within the tank and said further source of aeration may be provided beneath the suspended module. Preferably, the further source of aeration comprises a group of air permeable tubes. The membrane module may be operated with or without backwash depending on the flux. A high mixed liquor of suspended solids (5,000 to 20,000 ppm) in the bioreactor has been shown to significantly reduce residence time and improve filtrate quality. The combined use of aeration for both degradation of organic substances and membrane cleaning has been shown to enable constant filtrate flow without significant increases in transmembrane pressure while establishing high concentration of MLSS. The use of partitioned fibre bundles enables higher packing densities to be achieved without significantly compromising the gas scouring process. This provides for higher filtration efficiencies to be gained.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:
FIG. 1 shows a schematic side elevation of one embodiment of a membrane module and illustrates the method of cleaning according to the invention;
FIG. 2 shows an enlarged schematic side elevation of one form of the jet type arrangement used to form entrained gas bubbles;
FIG. 3 a shows a schematic side elevation of a partitioned membrane module according to one embodiment of the present invention;
FIG. 3 b shows a section through the membrane bundle of FIG. 3 a;
FIG. 4 a shows a schematic side elevation of a partitioned membrane module according to a further embodiment of the present invention;
FIG. 4 b shows a section through the membrane bundle of FIG. 4 a;
FIG. 5 a shows a schematic side elevation of a partitioned membrane module according to another embodiment of the present invention;
FIG. 5 b shows a section through the membrane bundle of FIG. 5 a;
FIG. 6 a shows a schematic side elevation of a partitioned membrane module according to another embodiment of the present invention;
FIG. 6 b shows a section through the membrane bundle of FIG. 6 a;
FIG. 7 shows a similar view to FIG. 2 of a further embodiment of the invention;
FIG. 8 shows a similar view to FIG. 2 of yet a further embodiment of the invention;
FIG. 9 shows a sectioned perspective pictorial view of the lower end of another preferred embodiment of the membrane module according to the invention; and
FIG. 10 shows a sectioned perspective pictorial view of the upper end of the membrane module of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the embodiments of the invention will be described in relation to a membrane module of the type disclosed in our earlier PCT application No. WO98/28066 which is incorporated herein by cross-reference, however, it will be appreciated that the invention is equally applicable to other forms of membrane module. The membrane module 5 typically comprises fibre, tubular or flat sheet form membranes 6 potted at two ends 7 and 8 and encased in a support structure, in this case a screen 9 . Either one or both ends of the membranes may be used for the permeate collection. The bottom of the membrane module has a number of through apertures 10 in the pot 11 to distribute a mixture of gas and liquid feed past the membrane surfaces.
Referring to the embodiment shown in FIG. 1, a venturi device 12 or the like is connected to the base of the module. The venturi device 12 intakes gas through inlet 13 , mixes or entrains the gas with liquid flowing through feed inlet 14 , forms gas bubbles and diffuses the liquid/gas mix into the module apertures 10 . After passing through the distribution apertures 10 , the entrained gas bubbles scrub membrane surfaces while travelling upwards along with the liquid flow. Either the liquid feed or the gas can be a continuous or intermittent injection depending on the system requirements. With a venturi device it is possible to create gas bubbles and aerate the system without a blower. The venturi device 12 can be a venturi tube, jet, nozzle, ejector, eductor, injector or the like.
Referring to FIG. 2, an enlarged view of jet or nozzle type device 15 is shown. In this embodiment, liquid is forced through a jet 16 having a surrounding air passage 17 to produce a gas entrained liquid flow 18 . Such a device allows the independent control of gas and liquid medium by adjusting respective supply valves.
The liquid commonly used to entrain the gas is the feed water, wastewater or mixed liquor to be filtered. Pumping such an operating liquid through a venturi or the like creates a vacuum to suck the gas into the liquid, or reduces the gas discharge pressure when a blower is used. By providing the gas in a flow of the liquid, the possibility of blockage of the distribution apertures 10 is substantially reduced.
The present invention at least in its preferred embodiments may provide a number of advantages which may be summarised as follows:
1. By using a venturi device or the like it is possible to generate gas bubbles to scrub membrane surfaces without the need for a pressurised gas supply such as a blower. When a motive fluid passes through a venturi it generates a vacuum to draw the gas into the liquid flow and generate gas bubbles therein. Even if a blower is still required, the use of the above process reduces the discharge pressure of the blower and therefore lowers the cost of operation.
2. The liquid and gas phases are well mixed in the venturi and then diffuse into the membrane module to scrub the membranes. Where a jet type device is used to forcibly mix the gas into the liquid medium, an additional advantage is provided in that a higher velocity of bubble stream is produced. In treatment of wastewater, such thorough mixing provides excellent oxygen transfer when the gas used is air or oxygen. If the gas is directly injected into a pipe filled with a liquid, it is possible that the gas will form a stagnant gas layer on the pipe wall and therefore gas and liquid will bypass into different parts of a module, resulting in poor cleaning efficiency.
3. The flow of gas bubbles is enhanced by the liquid flow along the membrane resulting in a large scrubbing shear force being generated. This method of delivery of gas/liquid provides a positive fluid transfer and aeration with the ability to independently adjust flow rates of gas and liquid.
4. The injection of a mixture of two-phase fluid (gas/liquid) into the holes of the air distribution device can eliminate the formation of dehydrated solids and therefore prevent the gradual blockage of the holes by such dehydrated solids.
5. The injection arrangement further provides an efficient cleaning mechanism for introducing cleaning chemicals effectively into the depths of the module while providing scouring energy to enhance chemical cleaning. This arrangement, in combination with the high packing density obtainable with the module configuration described, enables the fibres to be effectively cleaned with a minimal amount of chemicals.
6. The module configuration described allows a higher fibre packing density in a module without significantly increasing solid packing. This adds an additional flexibility that the membrane modules can be either integrated into the aerobic basin or arranged in a separate tank. In the latter arrangement, the advantage is a significant saving on chemical usage due to the small chemical holding in the tank and in labor costs because the chemical cleaning process can be automated. The reduction in chemicals used is also important because the chemicals, which may be fed back to the bio process, are still aggressive oxidisers and therefore can have a deleterious effect on bio process. Accordingly, any reduction in the chemical load present in the bio-process provides significant advantages.
7. The positive injection of a mixture of gas and liquid feed to each membrane module provides a uniform distribution of process fluid around membranes and therefore minimises the feed concentration polarisation during filtration. The concentration polarisation is greater in a large-scale system and for the process feed containing large amounts of suspended solids. The prior art systems have poor uniformity because the process fluid often enters one end of the tank and concentrates as it moves across the modules. The result is that some modules deal with much higher concentrations than others resulting in inefficient operation.
8. The filtration efficiency is enhanced due to a reduced filtration resistance. The feed side resistance is decreased due to a reduced transverse flow passage to the membrane surfaces and the turbulence generated by the gas bubbles and the two-phase flow.
9. Such a cleaning method can be used to the treatment of drinking water, wastewater and the related processes by membranes. The filtration process can be driven by suction or pressurisation.
Referring to FIGS. 3 to 5 , embodiments of various partitioning arrangements are shown. Again these embodiments are illustrated with respect to cylindrical tubular or fibre membrane bundles 20 , however, it will be appreciated that the invention is not limited to such applications.
FIG. 3 shows a bundle of tubular membranes 20 partitioned vertically into several thin slices 21 by a number of parallel partition spaces 22 . This partitioning of the bundle enables accumulated solids to be removed more easily without significant loss of packing density. Such partitioning can be achieved during the potting process to form complete partitions or partial partitions. Another method of forming a partitioned module is to pot several small tubular membrane bundles 23 into each module as shown in FIG. 4 .
Another improved configuration of membrane module is illustrated in FIG. 5 . The central membrane-free zone forms a passage 24 to allow for more air and liquid injection. The gas bubbles and liquid then travel along the tubular membranes 20 and pass out through arrays of fibres at the top potted head 8 , scouring and removing solids from membrane walls. A single gas or a mixture of gas/liquid can be injected into the module.
FIG. 6 illustrates yet a further embodiment similar to FIG. 5 but with single central hole 30 in the lower pot 7 for admission of the cleaning liquid/gas mixture to the fibre membranes 20 . In this embodiment, the fibres are spread adjacent the hole 30 and converge in discrete bundles 23 toward the top pot 8 . The large central hole 30 has been found to provide greater liquid flow around the fibres and thus improved cleaning efficiency.
FIGS. 7 and 8 show further embodiments of the invention having a similar membrane configuration to that of FIG. 6 and jet mixing system similar to that of the embodiment of FIG. 2 . The use of a single central hole 30 allows filtrate to drawn off from the fibres 20 at both ends as shown in FIG. 8 .
Referring to FIGS. 9 and 10 of the drawings, the module 45 comprises a plurality of hollow fibre membrane bundles 46 mounted in and extending between an upper 47 and lower potting head 8 . The potting heads 47 and 48 are mounted in respective potting sleeves 49 and 50 for attachment to appropriate manifolding (not shown). The fibre bundles 46 are surrounded by a screen 51 to prevent excessive movement between the fibres.
As shown in FIG. 9, the lower potting head 48 is provided with a number of parallel arranged slot type aeration holes 52 . The fibre membranes 53 are potted in bundles 46 to form a partitioned arrangement having spaces 54 extending transverse of the fibre bundles. The aeration holes 52 are positioned to generally coincide with the partition spaces, though there is generally a number of aeration holes associated with each space.
The lower potting sleeve 50 forms a cavity 55 below the lower pot 48 . A gas or a mixture of liquid and gas is injected into this cavity 55 by a jet assembly 57 (described earlier) before passing through the holes 52 into the membrane array.
In use, the use of partitioning enables a high energy flow of scouring gas and liquid mixture, particularly near the pot ends of the fibre bundles, which assist with removal of buildup of accumulated solids around the membrane fibres.
Air is preferably introduced into the module continuously to provide oxygen for microorganism activities and to continuously scour the membranes. Alternatively, in some applications, pure oxygen or other gas mixtures may be used instead of air. The clean filtrate is drawn out of the membranes by a suction pump attached to the membrane lumens which pass through the upper pot as described in our earlier aforementioned application.
Preferably, the membrane module is operated under low transmembrane pressure (TMP) conditions because of the high concentration of suspended solids (MLSS) present in the reactor.
The membrane bioreactor is preferably combined with an anaerobic process which assists with further removal of nutrients from the feed sewage.
It has been found that the module system employed is more tolerant of high MLSS than many present systems and the efficient air scrub and back wash (when used) assists efficient operation and performance of the bioreactor module.
It will be appreciated that, although the invention and embodiments have been described in relation to an application to bioreactors and like systems, the invention may be equally applicable to other types of application.
It will be appreciated that the invention is not limited to the specific embodiments described and other embodiments and exemplifications of the invention are possible without departing from the sprit or scope of the invention.
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A method and apparatus for cleaning a membrane module, the membrane module having a plurality of porous membranes, the membranes being arranged in close proximity to one another and mounted to prevent excessive movement therebetween and means for providing, from within the module, by means other than gas passing through the pores of the membranes, gas bubbles entrained in a liquid flow such that, in use, the liquid and bubbles entrained therein move past the surfaces of the membranes to dislodge fouling materials therefrom, the gas bubbles being entrained in the liquid by flowing the liquid past a source of gas to draw the gas into the liquid flow. The gas bubbles are preferably entrained into the liquid using a venturi type device. The membranes are preferably partitioned into discrete groups to assist cleaning while maintaining high packing density.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/402,615 filed Nov. 20, 2014, which is a U.S. national stage application filed under 35 U.S.C. §371 of International Patent Application No. PCT/US2013/042693 filed May 24, 2013, now expired, which claims priority to and the benefit of U.S. Provisional Patent Application No. 61/651,870 filed May 25, 2012; U.S. Provisional Patent Application No. 61/697,104 filed Sep. 5, 2012; and U.S. Provisional Application No. 61/780,445 filed Mar. 13, 2013, the entire disclosures of each of which are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The invention relates to new methods of modulating cholesterol in a subject by inhibiting proprotein convertase subtilisin/kexin type 9 (PCSK9) protein with fatty acid derivatives; and new methods for treating or preventing a metabolic disease comprising the administration of an effective amount of a fatty acid derivative. The present invention is also directed to fatty acid bioative derivatives and their use in the treatment of metabolic diseases.
BACKGROUND OF THE INVENTION
[0003] Recent studies have demonstrated that proprotein convertase subtilisin/kexin type 9 (PCSK9) could be an attractive therapeutic target for lowering low-density lipoprotein-cholesterol (LDL-C). In terms of validation, gain or loss-of-function PCSK9 variants in humans have been shown to result in hypercholesterolemia or hypocholesterolemia respectively. For instance, gain-of-function mutations in the PCSK9 gene are associated with elevated serum LDL-C levels of >300 mg/dL and premature cardiovascular heart disease (Abifadel et al Nat. Gent. 2003, 34, p. 154-156). On the other hand, loss-of-function mutations in the PCSK9 gene are associated with low serum LDL-C of ≦100 mg/dL and a reduction in cardiovascular heart disease (Cohen et al Nat. Gent. 2005, 37, p. 161-165). PCSK9 is a serine protease, made primarily by the liver and intestine, and consists of a signal peptide, a prodomain, a catalytic domain, and the histidine-rich C terminal domain (Piper et al Structure 2007, 15, p. 545-552). Data has shown that PCSK9 can exert its effects on LDL-C by binding to hepatocyte LDL receptor and preventing it from recycling to the cell surface after endocytosis. This sequence of events results in reduced LDL receptor levels, decreased cellular uptake of LDL-C, and higher LDL-C levels in blood (Horton et al J. Lip. Res. 2009, 50 ( Suppl .), p. S172-S177). Neutralizing antibodies to PCSK9 have now been shown to significantly reduce serum LDL-C in mice and nonhuman primates (Chan et al PNAS 2009, 106, p. 9820-9825; Liang et al Pharmacology and Experimental Therapeutics 2012, 340, p. 228-236). REGN727, AMG 145, RN316, and LGT209 are some monoclonal antibodies that are currently being evaluated in human clinical trials for hypercholesterolemia.
[0004] The statin drug class has been used extensively in the clinic to lower cholesterol. However, statin treatment has been shown to significantly increase the expression of PCSK9 (Dubuc et al Arterioscler. Thromb. Vasc. 2004, p. 1453-1459). The increased level of PCSK9 essentially counteracts some of the beneficial effects of statins since PCSK9 enhances the degradation of LDL receptors, leading to higher plasma levels of LDC-C.
[0005] Oily cold water fish, such as salmon, trout, herring, and tuna are the source of dietary marine omega-3 fatty acids, eicosapentaenoic acid (EPA) and docosahexaenoic acid (DHA) being the key marine derived omega-3 fatty acids. Both niacin and marine omega-3 fatty acids (EPA and DHA) have been shown to reduce cardiovascular disease, coronary heart disease, atherosclerosis and reduce mortality in patients with dyslipidemia, hypercholesterolemia, or Type 2 diabetes, and metabolic disease. Niacin at high dose (1.5 to 4 grams per day) has been shown to improve very low-density lipoprotein (“VLDL”) levels through lowering Apolipoprotein B (“ApoB”) and raising high density lipoprotein (“HDL”) through increasing Apolipoprotein A1 (“ApoA1”) in the liver. Niacin can also inhibit diacylglycerol acyltransferase-2, a key enzyme for TG synthesis (Kamanna, V. S.; Kashyap, M. L. Am. J. Cardiol. 2008, 101 (8A), 20B-26B). Unfortunately, niacin has many actions outside of the liver that detract from its therapeutic utility. The most common side effect of niacin is flushing, which can limit the dose a patient can tolerate. Flushing is thought to occur through the GPR109 receptor in the vasculature.
[0006] Omega-3 fatty acids have previously been shown to improve insulin sensitivity and glucose tolerance in normoglycemic men and in obese individuals. Omega-3 fatty acids have also been shown to improve insulin resistance in obese and non-obese patients with an inflammatory phenotype. Lipid, glucose, and insulin metabolism have been shown to improve in overweight hypertensive subjects through treatment with omega-3 fatty acids. Omega-3 fatty acids (EPA/DHA) have also been shown to decrease triglycerides and to reduce the risk for sudden death caused by cardiac arrhythmias in addition to improve mortality in patients at risk of a cardiovascular event. Omega-3 fatty acids have also been taken as dietary supplements part of therapy used to treat dyslipidemia, and anti-inflammatory properties. A higher intake of omega-3 fatty acids lower levels of circulating TNF-α and IL-6, two of the cytokines that are markedly increased during inflammation processes (Chapkin et al, Prostaglandins, Leukot Essent Fatty Acids 2009, 81, p. 187-191; Duda et al, Cardiovasc Res 2009, 84, p. 33-41). In addition, a higher intake of omega-3 fatty acids has also been shown to increase levels of the well-characterized anti-inflammatory cytokine IL-10 (Bradley et al, Obesity (Silver Spring) 2008, 16, p. 938-944). More recently, DHA has been shown to attenuate kidney disease and prolong the lifespan of autoimmune lupus-prone mice (Halade et al, J. Immunology 2010, 184, p. 5280-6). Studies have shown that DHA could potentially suppress glomerulonephritis because of its ability to lower LPS-mediated increase in serum IL-18 as well as its ability to dampen LPS-mediated PI3K, Akt and NF-κB activation in the kidney.
[0007] Hyperlipidemia are classified according to which types of lipids are elevated, that is hypercholesterolemia, hypertriglyceridemia, or both in combined hyperlipidemia. Elevated levels of lipoprotein may also be classified as a form of hyperlipidemia. There are five types of hyperlipoproteinemia (types I through V) and these are further classified according to the Fredrikson classification, based on the pattern of lipoproteins on electrophoresis or ultracentrifugation. Type I hyperlipoproteinemia has three subtypes: Type Ia (also called Buerger-Gruetz syndrome or familial hyperchylomicronemia), Type Ib (also called familial apoprotein CII deficiency) and Type Ic. Due to defects in either decreased in lipoprotein lipase (LPL), altered ApoC2 or LPL inhibitor in blood, all three subtypes of Type I hyperlipoproteinemia share the same characteristic increase in chylomicrons. The frequency of occurrence for Type I hyperlipoproteinemia is 1 in 1,000,000 and thus far no drug therapy is available and treatment has consisted only of diet. Type II hyperlipoproteinemia has two subtypes: Type IIa (also called familial hypercholesterolemia) is characterized by an elevated level of low-density lipoprotein (LDL); and Type IIb (also called familial combined hyperlipidemia) is characterized by an elevated level of LDL and very-low density lipoprotein (VLDL). Type III hyperlipoproteinemia (also called familial dysbetalipoproteinemia) is characterized by an elevated level of intermediate-density lipoprotein (IDL). Type IV hyperlipoproteinemia (also called familial hypertriglyceridemia) is characterized by an elevated level of VLDL. Type V hyperlipoproteinemia is characterized by an elevated level of VLDL and chylomicrons. Treatment for Type V hyperlipoproteinemia thus far has not been adequate with using just niacin or fibrate.
[0008] The present invention is directed to overcome the above-described deficiencies in the treatment of metabolic diseases.
SUMMARY OF THE INVENTION
[0009] The invention is based in part on the discovery of fatty acid derivatives and their demonstrated effects in achieving improved treatment that cannot be achieved by administering the omega-3 fatty acid EPA or DHA alone or in combination with other bioactives. These omega-3 fatty acid derivatives are designed to be stable in the plasma and absorbed by cells where they inhibit the production or secretion of PCSK9. Inhibiting the production or secretion of PCSK9 has the effect of reducing plasma cholesterol levels in animals and humans. In addition, since omega-3 fatty acid derivatives are inhibitors of PCSK9, they can enhance the efficacy of statins when administered in combination.
[0010] Accordingly in one aspect, the present invention relates to a method of treating metabolic diseases. The method involves inhibiting the production or lowering serum levels of PCSK9 by administering to a patient in need thereof an effective amount of a fatty acid bioactive derivative. In one embodiment, the fatty acid bioactive derivative comprises a fatty acid covalently linked to a bioactive molecule, wherein the fatty acid is selected from the group consisting of omega-3 fatty acids and fatty acids that are metabolized in vivo to omega-3 fatty acids.
[0011] In another aspect, a method of inhibiting the production of PCSK9 or lowering serum levels of PCSK9 is provided. The method involves administering to a patient in need thereof a compound of the Formula I:
[0000]
[0000] or a pharmaceutically acceptable salt, hydrate, solvate, prodrug, enantiomer or a stereoisomer thereof;
[0012] wherein
[0013] W 1 and W 2 are each independently null, O, S, NH, NR, or W 1 and W 2 can be taken together can form an imidazolidine or piperazine group, with the proviso that W 1 and W 2 can not be O simultaneously;
[0014] each a, b, c and d is independently —H, -D, —CH 3 , —OCH 3 , —OCH 2 CH 3 , —C(O)OR, or —O—Z, or benzyl, or two of a, b, c, and d can be taken together, along with the single carbon to which they are bound, to form a cycloalkyl or heterocycle;
[0015] each n, o, p, and q is independently 0, 1 or 2;
[0016] each L is independently null, —O—, —S—, —S(O)—, —S(O) 2 —, —S—S—, —(C 1 -C 6 alkyl)-, —(C 3 -C 6 cycloalkyl)-, a heterocycle, a heteroaryl,
[0000]
[0017] wherein the representation of L is not limited directionally left to right as is depicted, rather either the left side or the right side of L can be bound to the W 1 side of the compound of Formula I;
[0018] R 6 is independently —H, -D, —C 1 -C 4 alkyl, -halogen, cyano, oxo, thiooxo, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, —C 1 -C 3 alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl;
[0019] R 5 is each independently selected from the group consisting of —H, -D, —Cl, —F, —CN, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —C(O)H, —C(O)C 1 -C 3 alkyl, —C(O)OC 1 -C 3 alkyl, —C(O)NH 2 , —C(O)NH(C 1 -C 3 alkyl), —C(O)N(C 1 -C 3 alkyl) 2 , —C 1 -C 3 alkyl, —O—C 1 -C 3 alkyl, —S(O)C 1 -C 3 alkyl and —S(O) 2 C 1 -C 3 alkyl;
[0020] each g is independently 2, 3 or 4;
[0021] each h is independently 1, 2, 3 or 4;
[0022] m is 0, 1, 2, or 3; if m is more than 1, then L can be the same or different;
[0023] m1 is 0, 1, 2 or 3;
[0024] k is 0, 1, 2, or 3;
[0025] z is 1, 2, or 3;
[0026] each R 3 is independently H or C 1 -C 6 alkyl, or both R 3 groups, when taken together with the nitrogen to which they are attached, can form a heterocycle;
[0027] each R 4 is independently e, H or straight or branched C 1 -C 10 alkyl which can be optionally substituted with OH, NH 2 , CO 2 R, CONH 2 , phenyl, C 6 H 4 OH, imidazole or arginine;
[0028] each e is independently H or any one of the side chains of the naturally occurring amino acids;
[0029] each Z is independently —H,
[0000]
[0030] with the proviso that there is at least one
[0000]
[0031] in the compound;
[0032] each r is independently 2, 3, or 7;
[0033] each s is independently 3, 5, or 6;
[0034] each t is independently 0 or 1;
[0035] each v is independently 1, 2, or 6;
[0036] R 1 and R 2 are each independently hydrogen, deuterium, —C 1 -C 4 alkyl, -halogen, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl; and
[0037] each R is independently —H, —C 1 -C 3 alkyl, phenyl or straight or branched C 1 -C 4 alkyl optionally substituted with OH, or halogen.
[0038] Another aspect relates to a method of inhibiting the production or lowering serum levels of PCSK9 which comprises administering to a patient in need thereof a compound of the Formula II:
[0000]
[0000] or a pharmaceutically acceptable salt, hydrate, solvate, prodrug, enantiomer or a stereoisomer thereof
[0039] wherein
[0040] R n is a phenyl, naphthyl, heteroaryl, heterocycle,
[0000]
[0041] W 1 and W 2 are each independently null, O, S, NH, NR, or W 1 and W 2 can be taken together can form an imidazolidine or piperazine group, with the proviso that W 1 and W 2 can not be O simultaneously;
[0042] each a, b, c and d is independently —H, -D, —CH 3 , —OCH 3 , —OCH 2 CH 3 , —C(O)OR, or —O—Z, or benzyl, or two of a, b, c, and d can be taken together, along with the single carbon to which they are bound, to form a cycloalkyl or heterocycle;
[0043] each n, o, p, and q is independently 0, 1 or 2;
[0044] each L is independently null, —O—, —S—, —S(O)—, —S(O) 2 —, —S—S—, —(C 1 -C 6 alkyl)-, —(C 3 -C 6 cycloalkyl)-, a heterocycle, a heteroaryl,
[0000]
[0045] wherein the representation of L is not limited directionally left to right as is depicted, rather either the left side or the right side of L can be bound to the W 1 side of the compound of Formula II;
[0046] R 6 is independently —H, -D, —C 1 -C 4 alkyl, -halogen, cyano, oxo, thiooxo, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, —C 1 -C 3 alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl;
[0047] R 5 is each independently selected from the group consisting of —H, -D, —Cl, —F, —CN, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —C(O)H, —C(O)C 1 -C 3 alkyl, —C(O)OC 1 -C 3 alkyl, —C(O)NH 2 , —C(O)NH(C 1 -C 3 alkyl), —C(O)N(C 1 -C 3 alkyl) 2 , —C 1 -C 3 alkyl, —O—C 1 -C 3 alkyl, —S(O)C 1 -C 3 alkyl and —S(O) 2 C 1 -C 3 alkyl;
[0048] each g is independently 2, 3 or 4;
[0049] each h is independently 1, 2, 3 or 4;
[0050] m is 0, 1, 2, or 3; if m is more than 1, then L can be the same or different;
[0051] m1 is 0, 1, 2 or 3;
[0052] m2 is 0, 1, 2, 3, 4 or 5;
[0053] k is 0, 1, 2, or 3;
[0054] z is 1, 2, or 3;
[0055] each R 3 is independently H or C 1 -C 6 alkyl, or both R 3 groups, when taken together with the nitrogen to which they are attached, can form a heterocycle;
[0056] each R 4 is independently e, H or straight or branched C 1 -C 10 alkyl which can be optionally substituted with OH, NH 2 , CO 2 R, CONH 2 , phenyl, C 6 H 4 OH, imidazole or arginine;
[0057] each e is independently H or any one of the side chains of the naturally occurring amino acids;
[0058] each Z is independently —H,
[0000]
[0059] with the proviso that there is at least one
[0000]
[0060] in the compound;
[0061] each r is independently 2, 3, or 7;
[0062] each s is independently 3, 5, or 6;
[0063] each t is independently 0 or 1;
[0064] each v is independently 1, 2, or 6;
[0065] R 1 and R 2 are each independently hydrogen, deuterium, —C 1 -C 4 alkyl, -halogen, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, —C 1 -C 3 alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl; and
[0066] each R is independently —H, —C 1 -C 3 alkyl, phenyl or straight or branched alkyl optionally substituted with OH, or halogen;
[0067] In another aspect, a method of inhibiting the production of PCSK9 or lowering serum levels of PCSK9 is provided. The method involves administering to a patient in need thereof a compound of the Formula III:
[0000]
[0000] or a pharmaceutically acceptable salt, hydrate, solvate, enantiomer or a stereoisomer thereof;
[0068] wherein
[0000]
[0069] each r is independently 2, 3, or 7;
[0070] each s is independently 3, 5, or 6;
[0071] each t is independently 0 or 1;
[0072] each v is independently 1, 2, or 6;
[0073] R 1 and R 2 are independently —H, -D, alkyl, -halogen, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, —C 1 -C 3 alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl;
[0074] R 7 and R 8 are independently
[0000]
[0000] H, D, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, aryl, heteroaryl, and heterocycle;
[0075] each e is independently H or any one of the side chains of the naturally occurring amino acids;
[0076] each m is independently 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12;
[0077] each R 9 is independently —H, —C 1 -C 3 alkyl, or straight or branched C alkyl optionally substituted with OH, or halogen; and
[0078] each R 10 is independently —H, straight or branched —C 1 -C 6 alkyl, —C 1 -C 6 cycloalkyl, aryl, heteroaryl or heterocyclic that is optionally substituted with one, two, three, four or five groups selected from OH, CN, halogen, CO 2 R 9 , CONHR 9 , CONR 9 R 9 , S(O) 2 NR 9 R 9 , NR 9 R 9 , NR 9 COR 9 , —(OCH 2 CH 2 ) m —OCH 3 .
[0079] In another aspect, a method of inhibiting the production or lowering serum levels of PCSK9 is provided. The method comprises administering to a patient in need thereof a compound of the Formula IV:
[0000]
[0000] or a pharmaceutically acceptable salt, hydrate, solvate, prodrug, enantiomer or a stereoisomer thereof
[0080] R 1 and R 2 are each independently hydrogen, deuterium, —C 1 -C 4 alkyl, -halogen, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, —C 1 -C 3 alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl;
[0081] R 5 is independently selected from the group consisting of H, -D, —Cl, —F, —CN, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —C(O)H, —C(O)C 1 -C 3 alkyl, —C(O)OC 1 -C 3 alkyl, —C(O)NH 2 , —C(O)NH(C 1 -C 3 alkyl), —C(O)N(C 1 -C 3 alkyl) 2 , —C 1 -C 6 alkyl, —O—C 1 -C 3 alkyl, —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl, an aryl, a cycloalkyl, a heterocycle and
[0000]
[0082] R 3 is independently H or C 1 -C 6 alkyl, or both R 3 groups, when taken together with the nitrogen to which they are attached, can form
[0000]
[0083] f1=1, 2, 3 or 4;
[0084] f2=1, 2 or 3;
[0085] W 1 and W 2 are each independently null, O, S, NH, NR, or W 1 and W 2 can be taken together can form an imidazolidine or piperazine group, with the proviso that W 1 and W 2 can not be O simultaneously;
[0086] each a, b, c, and d is independently —H, -D, —CH 3 , —OCH 3 , —OCH 2 CH 3 , —C(O)OR, —O—Z, or benzyl, or two of a, b, c, and d can be taken together, along with the single carbon to which they are bound, to form a cycloalkyl or heterocycle;
[0087] each n, o, p, and q is independently 0, 1 or 2;
[0088] each L is independently —O—, —S—, —S(O)—, —S(O) 2 —, —S—S—, —(C 1 -C 6 alkyl)-, —(C 3 -C 6 cycloalkyl)-, a heterocycle, a heteroaryl,
[0000]
[0089] wherein the representation of L is not limited directionally left to right as is depicted, rather either the left side or the right side of L can be bound to the W 1 side of the compound of Formula IV;
[0090] R 6 is independently —H, -D, —C 1 -C 4 alkyl, -halogen, cyano, oxo, thiooxo, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, —C 1 -C 3 alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl;
[0091] each g is independently 2, 3 or 4;
[0092] each h is independently 1, 2, 3 or 4;
[0093] m is 0, 1, 2, 3, 4 or 5; if m is more than 1, then L can be the same or different;
[0094] m1 is 0, 1, 2 or 3;
[0095] k is 0, 1, 2, or 3;
[0096] z is 1, 2, or 3;
[0097] each R 4 independently e, H or straight or branched C 1 -C 10 alkyl which can be optionally substituted with OH, NH 2 , CO 2 R, CONH 2 , phenyl, C 6 H 4 OH, imidazole or arginine;
[0098] each e is independently H or any one of the side chains of the naturally occurring amino acids;
[0099] each Z is independently —H, or
[0000]
[0100] with the proviso that there is at least one
[0000]
[0101] in the compound;
[0102] each r is independently 2, 3, or 7;
[0103] each s is independently 3, 5, or 6;
[0104] each t is independently 0 or 1;
[0105] each v is independently 1, 2, or 6;
[0106] each R is independently —H, —C 1 -C 3 alkyl, or straight or branched C 1 -C 4 alkyl optionally substituted with OH, or halogen;
[0107] provided that
when m, n, o, p, and q are each 0, W 1 and W 2 are each null, and Z is
[0000]
then t must be 0; and
when m, n, o, p, and q are each 0, and W 1 and W 2 are each null, then Z must not be
[0000]
[0111] Another aspect relates to a method of inhibiting the production of or lowering serum levels of PCSK9; the method comprising administering to a patient in need thereof a compound of the Formula V:
[0000]
[0000] or a pharmaceutically acceptable salt, hydrate, solvate, prodrug, enantiomer or stereoisomer thereof;
[0112] wherein
[0113] R 1 and R 2 are each independently hydrogen, deuterium, —C 1 -C 4 alkyl, -halogen, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, —C 1 -C 3 alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl;
[0114] R 3 is independently H or C 1 -C 6 alkyl, or both R 3 groups, when taken together with the nitrogen to which they are attached, can form
[0000]
[0115] f1=1, 2, 3 or 4;
[0116] W 1 and W 2 are each independently null, O, S, NH, NR, or W 1 and W 2 can be taken together can form an imidazolidine or piperazine group, with the proviso that W 1 and W 2 can not be O simultaneously;
[0117] each a, b, c, and d is independently —H, -D, —CH 3 , —OCH 3 , —OCH 2 CH 3 , —C(O)OR, —O—Z, or benzyl, or two of a, b, c, and d can be taken together, along with the single carbon to which they are bound, to form a cycloalkyl or heterocycle;
[0118] each n, o, p, and q is independently 0, 1 or 2;
[0119] each L is independently —O—, —S—, —S(O)—, —S(O) 2 —, —S—S—, —(C 1 -C 6 alkyl)-, —(C 3 -C 6 cycloalkyl)-, a heterocycle, a heteroaryl,
[0000]
[0120] wherein the representation of L is not limited directionally left to right as is depicted, rather either the left side or the right side of L can be bound to the W 1 side of the compound of Formula V;
[0121] R 6 is independently —H, -D, —C 1 -C 4 alkyl, -halogen, cyano, oxo, thiooxo, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, —C 1 -C 3 alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl;
[0122] each g is independently 2, 3 or 4;
[0123] each h is independently 1, 2, 3 or 4;
[0124] m is 0, 1, 2, 3, 4 or 5; if m is more than 1, then L can be the same or different;
[0125] m1 is 0, 1, 2 or 3;
[0126] k is 0, 1, 2, or 3;
[0127] z is 1, 2, or 3;
[0128] each R 4 independently e, H or straight or branched C 1 -C 10 alkyl which can be optionally substituted with OH, NH 2 , CO 2 R, CONH 2 , phenyl, C 6 H 4 OH, imidazole or arginine;
[0129] each e is independently H or any one of the side chains of the naturally occurring amino acids;
[0130] each Z is independently —H, or
[0000]
[0131] with the proviso that there is at least one
[0000]
[0132] in the compound;
[0133] each r is independently 2, 3, or 7;
[0134] each s is independently 3, 5, or 6;
[0135] each t is independently 0 or 1;
[0136] each v is independently 1, 2, or 6;
[0137] each R is independently —H, —C 1 -C 3 alkyl, or straight or branched C 1 -C 4 alkyl optionally substituted with OH, or halogen;
[0138] provided that
when m, n, o, p, and q are each 0, W 1 and W 2 are each null, and Z is
[0000]
then t must be 0; and
when m, n, o, p, and q are each 0, and W 1 and W 2 are each null, then Z must not be
[0000]
[0142] Yet another aspect of the invention relates to compounds of Formula II′:
[0000]
[0000] and pharmaceutically acceptable salts, hydrates, solvates, prodrugs, enantiomers and stereoisomers thereof
[0143] wherein
[0144] R n is phenyl, naphthyl, heteroaryl, or a heterocycle;
[0145] W 1 and W 2 are each independently null, O, S, NH, NR, or W 1 and W 2 can be taken together can form an imidazolidine or piperazine group, with the proviso that W 1 and W 2 can not be O simultaneously;
[0146] W 3 is independently 0 or null;
[0147] R 12 is independently H, OH, OR″, R″, or OC(O)R″ where R″ is independently C 1 -C 6 alkyl;
[0148] each m1 is independently 0, 1, 2 or 3;
[0149] each a, b, c and d is independently —H, -D, —CH 3 , —OCH 3 , —OCH 2 CH 3 , —C(O)OR, or —O—Z, or benzyl, or two of a, b, c, and d can be taken together, along with the single carbon to which they are bound, to form a cycloalkyl or heterocycle;
[0150] each n, o, p, and q is independently 0, 1 or 2;
[0151] each L is independently null, —O—, —S—, —S(O)—, —S(O) 2 —, —S—S—, —(C 1 -C 6 alkyl)-, —(C 3 -C 6 cycloalkyl)-, a heterocycle, a heteroaryl,
[0000]
[0152] wherein the representation of L is not limited directionally left to right as is depicted, rather either the left side or the right side of L can be bound to the W 1 side of the compound of Formula II′;
[0153] with the proviso that when L is independently —O—, —S—, —S(O)—, —S(O) 2 —, —S—S—,
[0000]
[0000] then Rn is not
[0000]
[0000] and in which g, h, k, R, R 3 , R 5 and Z are as defined below;
[0154] and with the further proviso that Rn is not:
[0000]
[0155] R 6 is independently —H, -D, —C 1 -C 4 alkyl, -halogen, cyano, oxo, thiooxo, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, —C 1 -C 3 alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl;
[0156] R 5 is each independently selected from the group consisting of —H, -D, —Cl, —F, —CN, OH, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —C(O)H, —C(O)C 1 -C 3 alkyl, —C(O)OC 1 -C 3 alkyl, —C(O)NH 2 , —C(O)NH(C 1 -C 3 alkyl), —C(O)N(C 1 -C 3 alkyl) 2 , —C 1 -C 3 alkyl, —O—C 1 -C 3 alkyl, —S(O)C 1 -C 3 alkyl and —S(O) 2 C 1 -C 3 alkyl;
[0157] each g is independently 2, 3 or 4;
[0158] each h is independently 1, 2, 3 or 4;
[0159] m is 0, 1, 2, or 3; if m is more than 1, then L can be the same or different;
[0160] m1 is 0, 1, 2 or 3;
[0161] m2 is 0, 1, 2, 3, 4 or 5;
[0162] k is 0, 1, 2, or 3;
[0163] z is 1, 2, or 3;
[0164] each R 3 is independently H or C 1 -C 6 alkyl, or both R 3 groups, when taken together with the nitrogen to which they are attached, can form a heterocycle;
[0165] each R 4 is independently e, H or straight or branched C 1 -C 10 alkyl which can be optionally substituted with OH, NH 2 , CO 2 R, CONH 2 , phenyl, C 6 H 4 OH, imidazole or arginine;
[0166] each e is independently H or any one of the side chains of the naturally occurring amino acids;
[0167] each Z is independently —H,
[0000]
[0168] with the proviso that there is at least one
[0000]
[0169] in the compound;
[0170] each r is independently 2, 3, or 7;
[0171] each s is independently 3, 5, or 6;
[0172] each t is independently 0 or 1;
[0173] each v is independently 1, 2, or 6;
[0174] R 1 and R 2 are each independently hydrogen, deuterium, —C 1 -C 4 alkyl, -halogen, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, —C 1 -C 3 alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl; and
[0175] each R is independently —H, —C 1 -C 3 alkyl, phenyl or straight or branched C 1 -C 4 alkyl optionally substituted with OH, or halogen;
[0176] In another aspect, compounds of Formula VI are described:
[0000]
[0000] and pharmaceutically acceptable salts, hydrates, solvates, prodrugs, enantiomers and stereoisomers thereof;
[0177] wherein
[0178] W 1 and W 2 are each independently null, O, S, NH, NR, or W 1 and W 2 can be taken together can form an imidazolidine or piperazine group, with the proviso that W 1 and W 2 can not be O simultaneously;
[0179] R 11 is independently H, —OH, —OC(O)—R, —O-aryl, -aryl, -heteroaryl, or -heterocyclic;
[0180] R 13 is independently H, C 1 -C 3 alkyl, —OH, —OC(O)—R, or halogen;
[0181] each a, b, c and d is independently —H, -D, —CH 3 , —OCH 3 , —OCH 2 CH 3 , —C(O)OR, or —O—Z, or benzyl, or two of a, b, c, and d can be taken together, along with the single carbon to which they are bound, to form a cycloalkyl or heterocycle;
[0182] each n, o, p, and q is independently 0, 1 or 2;
[0183] each L is independently null, —O—, —S—, —S(O)—, —S(O) 2 —, —S—S—, —(C 1 -C 6 alkyl)-, —(C 3 -C 6 cycloalkyl)-, a heterocycle, a heteroaryl,
[0000]
[0184] wherein the representation of L is not limited directionally left to right as is depicted, rather either the left side or the right side of L can be bound to the W 1 side of the compound of Formula I;
[0185] R 6 is independently —H, -D, —C 1 -C 4 alkyl, -halogen, cyano, oxo, thiooxo, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, —C 1 -C 3 alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl;
[0186] R 5 is each independently selected from the group consisting of —H, -D, —Cl, —F, —CN, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —C(O)H, —C(O)C 1 -C 3 alkyl, —C(O)OC 1 -C 3 alkyl, —C(O)NH 2 , —C(O)NH(C 1 -C 3 alkyl), —C(O)N(C 1 -C 3 alkyl) 2 , —C 1 -C 3 alkyl, —O—C 1 -C 3 alkyl, —S(O)C 1 -C 3 alkyl and —S(O) 2 C 1 -C 3 alkyl;
[0187] each g is independently 2, 3 or 4;
[0188] each h is independently 1, 2, 3 or 4;
[0189] m is 0, 1, 2, or 3; if m is more than 1, then L can be the same or different;
[0190] m1 is 0, 1, 2 or 3;
[0191] k is 0, 1, 2, or 3;
[0192] z is 1, 2, or 3;
[0193] each R 3 is independently H or C 1 -C 6 alkyl, or both R 3 groups, when taken together with the nitrogen to which they are attached, can form a heterocycle;
[0194] each R 4 is independently e, H or straight or branched C 1 -C 10 alkyl which can be optionally substituted with OH, NH 2 , CO 2 R, CONH 2 , phenyl, C 6 H 4 OH, imidazole or arginine;
[0195] each e is independently H or any one of the side chains of the naturally occurring amino acids;
[0196] each Z is independently —H,
[0000]
[0197] with the proviso that there is at least one
[0000]
[0198] in the compound;
[0199] each r is independently 2, 3, or 7;
[0200] each s is independently 3, 5, or 6;
[0201] each t is independently 0 or 1;
[0202] each v is independently 1, 2, or 6;
[0203] R 1 and R 2 are each independently hydrogen, deuterium, —C 1 -C 4 alkyl, -halogen, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, —C 1 -C 3 alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl; and
[0204] each R is independently —H, —C 1 -C 3 alkyl, phenyl or straight or branched C 1 -C 4 alkyl optionally substituted with OH, or halogen.
[0205] Another aspect relates to compounds of Formula VII:
[0000]
[0000] and pharmaceutically acceptable salts, hydrates, solvates, prodrugs, enantiomers and stereoisomers thereof;
[0206] wherein
[0207] R x is independently
[0000]
[0208] W 1 and W 2 are each independently null, O, S, NH, NR, or W 1 and W 2 can be taken together can form an imidazolidine or piperazine group, with the proviso that W 1 and W 2 can not be O simultaneously;
[0209] each a, b, c and d is independently —H, -D, —CH 3 , —OCH 3 , —OCH 2 CH 3 , —C(O)OR, or —O—Z, or benzyl, or two of a, b, c, and d can be taken together, along with the single carbon to which they are bound, to form a cycloalkyl or heterocycle;
[0210] each n, o, p, and q is independently 0, 1 or 2;
[0211] each L is independently null, —(C 1 -C 6 alkyl)-, —(C 3 -C 6 cycloalkyl)-, a heterocycle, a heteroaryl,
[0000]
[0212] wherein the representation of L is not limited directionally left to right as is depicted, rather either the left side or the right side of L can be bound to the W 1 side of the compound of Formula I;
[0213] R 6 is independently —H, -D, —C 1 -C 4 alkyl, -halogen, cyano, oxo, thiooxo, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, —C 1 -C 3 alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl;
[0214] R 5 is each independently selected from the group consisting of —H, -D, —Cl, —F, —CN, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —C(O)H, —C(O)C 1 -C 3 alkyl, —C(O)OC 1 -C 3 alkyl, —C(O)NH 2 , —C(O)NH(C 1 -C 3 alkyl), —C(O)N(C 1 -C 3 alkyl) 2 , —C 1 -C 3 alkyl, —O—C 1 -C 3 alkyl, —S(O)C 1 -C 3 alkyl and —S(O) 2 C 1 -C 3 alkyl;
[0215] each g is independently 2, 3 or 4;
[0216] each h is independently 1, 2, 3 or 4;
[0217] m is 0, 1, 2, or 3; if m is more than 1, then L can be the same or different;
[0218] m1 is 0, 1, 2 or 3;
[0219] k is 0, 1, 2, or 3;
[0220] z is 1, 2, or 3;
[0221] each R 3 is independently H or C 1 -C 6 alkyl, or both R 3 groups, when taken together with the nitrogen to which they are attached, can form a heterocycle;
[0222] each R 4 is independently e, H or straight or branched C 1 -C 10 alkyl which can be optionally substituted with OH, NH 2 , CO 2 R, CONH 2 , phenyl, C 6 H 4 OH, imidazole or arginine;
[0223] each e is independently H or any one of the side chains of the naturally occurring amino acids;
[0224] each Z is independently —H,
[0000]
[0225] with the proviso that there is at least one
[0000]
[0226] in the compound;
[0227] each r is independently 2, 3, or 7;
[0228] each s is independently 3, 5, or 6;
[0229] each t is independently 0 or 1;
[0230] each v is independently 1, 2, or 6;
[0231] R 1 and R 2 are each independently hydrogen, deuterium, —C 1 -C 4 alkyl, -halogen, —OH, —C(O)C 1 -C 4 alkyl, —O-aryl, —O-benzyl, —OC(O)C 1 -C 4 alkyl, —C 1 -C 3 alkene, alkyne, —C(O)C 1 -C 4 alkyl, —NH 2 , —NH(C 1 -C 3 alkyl), —N(C 1 -C 3 alkyl) 2 , —NH(C(O)C 1 -C 3 alkyl), —N(C(O)C 1 -C 3 alkyl) 2 , —SH, —S(C 1 -C 3 alkyl), —S(O)C 1 -C 3 alkyl, —S(O) 2 C 1 -C 3 alkyl; and
[0232] each R is independently —H, —C 1 -C 3 alkyl, phenyl or straight or branched C 1 -C 4 alkyl optionally substituted with OH, or halogen.
[0233] In Formula I, II, II′, III, IV, V, VI and VII, any one or more of H may be substituted with a deuterium. It is also understood in Formula I, II, II′, III, IV, V, VI and VII that a methyl substituent can be substituted with a C 1 -C 6 alkyl.
[0234] Also described are pharmaceutical formulations comprising at least one fatty acid derivative.
[0235] Also described herein are methods of treating a disease susceptible to treatment with a fatty acid derivative in a patient in need thereof by administering to the patient an effective amount of a fatty acid derivative.
[0236] Also described herein are methods of treating metabolic diseases by administering to a patient in need thereof an effective amount of a fatty acid derivative.
[0237] The invention also includes pharmaceutical compositions that comprise an effective amount of a fatty acid derivative and a pharmaceutically acceptable carrier. The compositions are useful for treating or preventing a metabolic disease. The invention includes a fatty acid derivative provided as a pharmaceutically acceptable prodrug, a hydrate, a salt, such as a pharmaceutically acceptable salt, enantiomer, stereoisomer, or mixtures thereof
[0238] The details of the invention are set forth in the accompanying description below. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, illustrative methods and materials are now described. Other features, objects, and advantages of the invention will be apparent from the description and from the claims. In the specification and the appended claims, the singular forms also include the plural unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. All patents and publications cited in this specification are incorporated herein by reference in their entireties.
BRIEF DESCRIPTION OF THE FIGURES
[0239] FIG. 1 is a graphic representation of the data showing the comparative effects of compounds I-8, II-1, and compound A on PCSK9.
[0240] FIG. 2 is a graphic representation of the data showing the effects of compound I-8 and a combination of EPA and niacin on PCSK9 in HepG2 assay incubated with atorvastatin.
[0241] FIG. 3 is a graphic representation of the data showing the effects of compound I-8 on the plasma triglyceride level of the Zucker fa/fa Rat model of Dyslipidemia.
[0242] FIG. 4 is a graphic representation of the data showing the effects of a combination of compound I-8 and atorvastatin on plasma cholesterol and other lipids in ApoE3Leiden mice after 2 weeks of treatment.
[0243] FIG. 5 is a graphic representation of the data showing the effects of a combination of compound I-8 and atorvastatin on plasma cholesterol and other lipids in ApoE3Leiden mice after 4 weeks of treatment.
[0244] FIG. 6 is a graphic representation of the data showing the effects of a combination of compound I-8 and atorvastatin on plasma triglycerides and other lipids in ApoE3Leiden mice after 4 weeks of treatment.
[0245] FIG. 7 is a graphic representation of the data showing the effects of administering compound I-8 on ApoE3Leiden mice liver weight
DETAILED DESCRIPTION OF THE INVENTION
[0246] Metabolic diseases are a wide variety of medical disorders that interfere with a subject's metabolism. Metabolism is the process a subject's body uses to transform food into energy. Metabolism in a subject with a metabolic disease is disrupted in some way. The fatty acid derivatives possess the ability to treat or prevent metabolic diseases. The fatty acid derivatives have been designed to bring together omega-3 fatty acids and an aryl, a heteroaryl or a heterocycle into a single fatty acid bioactive derivative. In some instances, the heteroaryl group can also be niacin or any other derivatives thereof. The activity of the fatty acid derivatives is substantially greater than the sum of the individual components of the fatty acid bioactive derivative, suggesting that the activity induced by the fatty acid derivatives is synergistic. Based on this information, it was conceived that the present fatty acid derivatives could be effective in lowering the production of PCSK9 in in vitro cell assays. In addition, these fatty acid derivatives could also lower the serum PCSK9 level when dosed in vivo. As a result of these activities, fatty acid derivatives can be used as a monotherapy or as a combination therapy with a statin or other cholesterol lowering agent to effectively treat hypercholesterolemia, dyslipidemia or metabolic disease.
DEFINITIONS
[0247] The following definitions are used in connection with the fatty acid derivatives:
[0248] The term “fatty acid derivatives” includes any and all possible isomers, stereoisomers, enantiomers, diastereomers, tautomers, pharmaceutically acceptable salts, hydrates, solvates, and prodrugs of the fatty acid derivatives described herein.
[0249] The articles “a” and “an” are used in this disclosure to refer to one or more than one (i.e., to at least one) of the grammatical object of the article. By way of example, “an element” means one element or more than one element.
[0250] The term “and/or” is used in this disclosure to mean either “and” or “or” unless indicated otherwise.
[0251] Unless otherwise specifically defined, the term “aryl” refers to cyclic, aromatic hydrocarbon groups that have 1 to 2 aromatic rings, including monocyclic or bicyclic groups such as phenyl, biphenyl or naphthyl. Where containing two aromatic rings (bicyclic, etc.), the aromatic rings of the aryl group may be joined at a single point (e.g., biphenyl), or fused (e.g., naphthyl). The aryl group may be optionally substituted by one or more substituents, e.g., 1 to 5 substituents, at any point of attachment. The substituents can themselves be optionally substituted.
[0252] “C 1 -C 3 alkyl” refers to a straight or branched chain saturated hydrocarbon containing 1-3 carbon atoms. Examples of a C 1 -C 3 alkyl group include, but are not limited to, methyl, ethyl, propyl and isopropyl.
[0253] “C 1 -C 4 alkyl” refers to a straight or branched chain saturated hydrocarbon containing 1-4 carbon atoms. Examples of a C 1 -C 4 alkyl group include, but are not limited to, methyl, ethyl, propyl, butyl, isopropyl, isobutyl, sec-butyl and tert-butyl.
[0254] “C 1 -C 5 alkyl” refers to a straight or branched chain saturated hydrocarbon containing 1-5 carbon atoms. Examples of a C 1 -C 5 alkyl group include, but are not limited to, methyl, ethyl, propyl, butyl, pentyl, isopropyl, isobutyl, sec-butyl and tert-butyl, isopentyl and neopentyl.
[0255] “C 1 -C 6 alkyl” refers to a straight or branched chain saturated hydrocarbon containing 1-6 carbon atoms. Examples of a C 1 -C 6 alkyl group include, but are not limited to, methyl, ethyl, propyl, butyl, pentyl, hexyl, isopropyl, isobutyl, sec-butyl, tert-butyl, isopentyl, and neopentyl.
[0256] The term “cycloalkyl” refers to a cyclic hydrocarbon containing 3-6 carbon atoms. Examples of a cycloalkyl group include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl. It is understood that any of the substitutable hydrogens on a cycloalkyl can be substituted with halogen, C 1 -C 3 alkyl, hydroxyl, alkoxy and cyano groups.
[0257] The term “heterocycle” as used herein refers to a cyclic hydrocarbon containing 3-6 atoms wherein at least one of the atoms is an O, N, or S. Examples of heterocycles include, but are not limited to, aziridine, oxirane, thiirane, azetidine, oxetane, thietane, pyrrolidine, tetrahydrofuran, tetrahydrothiophene, piperidine, tetrahydropyran, thiane, imidazolidine, oxazolidine, thiazolidine, dioxolane, dithiolane, piperazine, oxazine, dithiane, and dioxane.
[0258] The term “heteroaryl” as used herein refers to a monocyclic or bicyclic ring structure having 5 to 12 ring atoms wherein one or more of the ring atoms is a heteroatom, e.g. N, O or S and wherein one or more rings of the bicyclic ring structure is aromatic. Some examples of heteroaryl are pyridyl, furyl, pyrrolyl, thienyl, thiazolyl, oxazolyl, imidazolyl, indolyl, tetrazolyl, benzofuryl, xanthenes and dihydroindole. It is understood that any of the substitutable hydrogens on a heteroaryl can be substituted with halogen, C 1 -C 3 alkyl, hydroxyl, alkoxy and cyano groups.
[0259] The term “any one of the side chains of the naturally occurring amino acids” as used herein means a side chain of any one of the following amino acids: Isoleucine, Alanine, Leucine, Asparagine, Lysine, Aspartate, Methionine, Cysteine, Phenylalanine, Glutamate, Threonine, Glutamine, Tryptophan, Glycine, Valine, Proline, Arginine, Serine, Histidine, and Tyrosine.
[0260] The term “fatty acid” as used herein means an omega-3 fatty acid and fatty acids that are metabolized in vivo to omega-3 fatty acids. Non-limiting examples of fatty acids are all-cis-7,10,13-hexadecatrienoic acid, α-linolenic acid (ALA or all-cis-9,12,15-octadecatrienoic acid), stearidonic acid (STD or all-cis-6,9,12,15-octadecatetraenoic acid), eicosatrienoic acid (ETE or all-cis-11,14,17-eicosatrienoic acid), eicosatetraenoic acid (ETA or all-cis-8,11,14,17-eicosatetraenoic acid), eicosapentaenoic acid (EPA or all-cis-5,8,11,14,17-eicosapentaenoic acid), docosapentaenoic acid (DPA, clupanodonic acid or all-cis-7,10,13,16,19-docosapentaenoic acid), docosahexaenoic acid (DHA or all-cis-4,7,10,13,16,19-docosahexaenoic acid), tetracosapentaenoic acid (all-cis-9,12,15,18,21-docosahexaenoic acid), or tetracosahexaenoic acid (nisinic acid or all-cis-6,9,12,15,18,21-tetracosenoic acid).
[0261] The term “niacin” as used herein means the molecule known as niacin and any derivative thereof
[0262] The term “bioactive” or “bioactive molecule” as used herein means an aryl, including phenylor naphthyl, heteroaryl, or a heterocycle derivative which possesses biological activity.
[0263] A “subject” is a mammal, e.g., a human, mouse, rat, guinea pig, dog, cat, horse, cow, pig, or non-human primate, such as a monkey, chimpanzee, baboon or rhesus, and the terms “subject” and “patient” are used interchangeably herein.
[0264] The invention also includes pharmaceutical compositions comprising an effective amount of a fatty acid derivative of Formula II′, VI, or VII as described above and a pharmaceutically acceptable carrier. The invention includes a fatty acid niacin derivative provided as a pharmaceutically acceptable prodrug, hydrate, salt, such as a pharmaceutically acceptable salt, enantiomers, stereoisomers, or mixtures thereof
[0265] Representative “pharmaceutically acceptable salts” include, e.g., water-soluble and water-insoluble salts, such as the acetate, amsonate (4,4-diaminostilbene-2,2-disulfonate), benzenesulfonate, benzonate, bicarbonate, bisulfate, bitartrate, borate, bromide, butyrate, calcium, calcium edetate, camsylate, carbonate, chloride, citrate, clavulariate, dihydrochloride, edetate, edisylate, estolate, esylate, fiunarate, gluceptate, gluconate, glutamate, glycollylarsanilate, hexafluorophosphate, hexylresorcinate, hydrabamine, hydrobromide, hydrochloride, hydroxynaphthoate, iodide, isothionate, lactate, lactobionate, laurate, magnesium, malate, maleate, mandelate, mesylate, methylbromide, methylnitrate, methylsulfate, mucate, napsylate, nitrate, N-methylglucamine ammonium salt, 3-hydroxy-2-naphthoate, oleate, oxalate, palmitate, pamoate (1,1-methene-bis-2-hydroxy-3-naphthoate, einbonate), pantothenate, phosphate/diphosphate, picrate, polygalacturonate, propionate, p-toluenesulfonate, salicylate, stearate, subacetate, succinate, sulfate, sulfosalicylate, suramate, tannate, tartrate, teoclate, tosylate, triethiodide, and valerate salts.
[0266] The term “metabolic disease” as used herein refers to disorders, diseases and syndromes involving dyslipidemia, and the terms metabolic disorder, metabolic disease, and metabolic syndrome are used interchangeably herein.
[0267] An “effective amount” when used in connection with a fatty acid derivative is an amount effective for treating or preventing a metabolic disease.
[0268] The term “carrier”, as used in this disclosure, encompasses carriers, excipients, and diluents and means a material, composition or vehicle, such as a liquid or solid filler, diluent, excipient, solvent or encapsulating material, involved in carrying or transporting a pharmaceutical agent from one organ, or portion of the body, to another organ, or portion of the body.
[0269] The term “treating”, with regard to a subject, refers to improving at least one symptom of the subject's disorder. Treating can be curing, improving, or at least partially ameliorating the disorder.
[0270] The term “disorder” is used in this disclosure to mean, and is used interchangeably with, the terms disease, condition, or illness, unless otherwise indicated.
[0271] The term “administer”, “administering”, or “administration” as used in this disclosure refers to either directly administering a compound or pharmaceutically acceptable salt of the compound or a composition to a subject, or administering a prodrug derivative or analog of the compound or pharmaceutically acceptable salt of the compound or composition to the subject, which can form an equivalent amount of active compound within the subject's body.
[0272] The term “prodrug,” as used in this disclosure, means a compound which is convertible in vivo by metabolic means (e.g., by hydrolysis) to a fatty acid derivative.
[0273] The following abbreviations are used herein and have the indicated definitions: Boc and BOC are tert-butoxycarbonyl, Boc 2 O is di-tert-butyl dicarbonate, BSA is bovine serum albumin, CDI is 1,1′-carbonyldiimidazole, DCC is N,N′-dicyclohexylcarbodiimide, DIEA is N,N-diisopropylethylamine, DMAP is 4-dimethylaminopyridine, DMEM is Dulbecco's Modified Eagle Medium, DMF is N,N-dimethylformamide, DOSS is sodium dioctyl sulfosuccinate, EDC and EDCI are 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride, ELISA is enzyme-linked immunosorbent assay, EtOAc is ethyl acetate, FBS is fetal bovine serum, h is hour, HATU is 2-(7-aza-1H-benzotriazole-1-yl)-1,1,3,3-tetramethyluronium hexafluorophosphate, HIV is human immunodeficiency virus, HPMC is hydroxypropyl methylcellulose, oxone is potassium peroxymonosulfate, Pd/C is palladium on carbon, TFA is trifluoroacetic acid, TGPS is tocopherol propylene glycol succinate, and THF is tetrahydrofuran.
Compounds
[0274] Accordingly in one aspect, the present invention provides a method of using a fatty acid bioactive derivative which comprises a fatty acid and an aryl, a heteroaryl or a heterocycle covalently linked, wherein the fatty acid is selected from the group consisting of omega-3 fatty acids and fatty acids that are metabolized in vivo to omega-3 fatty acids, and the derivative is capable of hydrolysis to produce free fatty acid and free aryl, heteroaryl or heterocycle.
[0275] In some embodiments, the fatty acid is selected from the group consisting of all-cis-7,10,13-hexadecatrienoic acid, α-linolenic acid, stearidonic acid, eicosatrienoic acid, eicosatetraenoic acid, eicosapentaenoic acid (EPA), docosapentaenoic acid, docosahexaenoic acid (DHA), tetracosapentaenoic acid and tetracosahexaenoic acid. In other embodiments, the fatty acid is selected from eicosapentaenoic acid and docosahexaenoic acid. In some embodiments, the hydrolysis is enzymatic.
[0276] In another aspect, the present invention also provides fatty acid bioactive derivatives according to Formulae:
[0000]
[0000] and pharmaceutically acceptable salts, hydrates, solvates, prodrugs, enantiomers, and stereoisomers thereof;
[0277] wherein
[0278] R n , R x , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 11 , R, W 1 , W 2 , L, a, c, b, d, e, g, h, m, m1, m2, n, o, p, q, Z, r, s, t, and v are as defined above for formulae II′, VI, and VII.
[0279] with the proviso that there is at least one
[0000]
[0280] in the compound.
[0281] In some embodiments, R x is
[0000]
[0282] In some embodiments, R x is
[0000]
[0283] In some embodiments, R x is
[0000]
[0284] In some embodiments, R x is
[0000]
[0285] In some embodiments, R x is
[0000]
[0286] In some embodiments, R x is
[0000]
[0287] In some embodiments, R n is phenyl.
[0288] In some embodiments, one Z is
[0000]
[0000] and r is 2.
[0289] In some embodiments, one Z is
[0000]
[0000] and r is 3.
[0290] In some embodiments, one Z is
[0000]
[0000] and r is 7.
[0291] In other embodiments, one Z is
[0000]
[0000] and s is 3.
[0292] In some embodiments, one Z is
[0000]
[0000] and s is 5.
[0293] In some embodiments, one Z is
[0000]
[0000] and s is 6.
[0294] In some embodiments, one Z is
[0000]
[0000] and v is 1.
[0295] In other embodiments, one Z is
[0000]
[0000] and v is 2.
[0296] In some embodiments, one Z is
[0000]
[0000] and v is 6.
[0297] In some embodiments, one Z is
[0000]
[0000] and s is 3.
[0298] In some embodiments, one Z is
[0000]
[0000] and s is 5.
[0299] In other embodiments, one Z is
[0000]
[0000] and s is 6.
[0300] In some embodiments, W 1 is NH.
[0301] In some embodiments, W 2 is NH.
[0302] In some embodiments, W 1 is O.
[0303] In some embodiments, W 2 is O.
[0304] In some embodiments, W 1 is null.
[0305] In some embodiments, W 2 is null.
[0306] In some embodiments, W 1 and W 2 are each NH.
[0307] In some embodiments, W 1 and W 2 are each null.
[0308] In some embodiments, W 1 is 0 and W 2 is NH.
[0309] In some embodiments, W 1 and W 2 are each NR, and R is CH 3 .
[0310] In some embodiments, m is 0.
[0311] In other embodiments, m is 1.
[0312] In other embodiments, m is 2.
[0313] In some embodiments, L is —S— or —S—S—.
[0314] In some embodiments, L is —O—.
[0315] In some embodiments, L is —C(O)—.
[0316] In some embodiments, L is heteroaryl.
[0317] In some embodiments, L is heterocycle.
[0318] In some embodiments, L is
[0000]
[0319] In some embodiments, L is
[0000]
[0320] In some embodiments, L is
[0000]
[0321] In some embodiments, L is
[0000]
[0322] In some embodiments, L is
[0000]
[0323] In some embodiments, L is
[0000]
[0324] In some embodiments, L is
[0000]
[0000] wherein m is 2.
[0325] In some embodiments, L is
[0000]
[0000] wherein m is 3.
[0326] In some embodiments, L is
[0000]
[0327] In some embodiments, L is
[0000]
[0328] In some embodiments, L is
[0000]
[0329] In some embodiments, L is
[0000]
[0330] In some embodiments, L is
[0000]
[0331] In some embodiments, L is
[0000]
[0332] In some embodiments, L is
[0000]
[0333] In other embodiments, one of n, o, p, and q is 1.
[0334] In some embodiments, two of n, o, p, and q are each 1.
[0335] In other embodiments, three of n, o, p, and q are each 1.
[0336] In some embodiments n, o, p, and q are each 1.
[0337] In some embodiments, one d is C(O)OR.
[0338] In some embodiments, r is 2 and s is 6.
[0339] In some embodiments, r is 3 and s is 5.
[0340] In some embodiments, t is 1.
[0341] In some embodiments, W 1 and W 2 are each NH, m is 0, n, and o are each 1, and p and q are each 0.
[0342] In some embodiments, W 1 and W 2 are each NH, m is 1, n, o, p, and q are each 1, and L is O.
[0343] In some embodiments, W 1 and W 2 are each NH, m is 1, n, o, p, and q are each 1, and L is
[0000]
[0344] In some embodiments, W 1 and W 2 are each NH, m is 1, n, o, p, and q are each 1, and L is —S—S—.
[0345] In some embodiments, W 1 and W 2 are each NH, m is 1, n and o are each 0, p and q are each 1, and L is
[0000]
[0346] In some embodiments, W 1 and W 2 are each NH, m is 1, k is 0, n and o are each 0, p and q are each 1, and L is
[0000]
[0347] In some embodiments, W 1 and W 2 are each NH, m is 1, n and o are each 1, p and q are each 0, and L is
[0000]
[0348] In some embodiments, W 1 and W 2 are each NH, m is 1, k is 0, n is 1, o, p and q are each 0, and L is
[0000]
[0349] In some embodiments, W 1 and W 2 are each NH, m is 1, n, o, and p are each 0, and q is 1, and L is
[0000]
[0350] In some embodiments, W 1 and W 2 are each NH, m is 1, k is 1, n, o, and p are each 0, and q is 1, and L is
[0000]
[0351] In some embodiments, W 1 and W 2 are each NH, m is 1, n is 1, and o, p, and q are each 0, and L is
[0000]
[0352] In some embodiments, W 1 and W 2 are each NH, m is 1, k is 1, o, p, and q are each 0, and L is
[0000]
[0353] In some embodiments, W 1 and W 2 are each NH, m is 1, n, o, p, and q are each 1, and L is
[0000]
[0354] In some embodiments, W 1 and W 2 are each NH, m is 1, n, o, p, and q are each 1, and L is
[0000]
[0355] In some embodiments, W 1 and W 2 are each NH, m is 0, k is 1, o and p are each 1, and q is 0.
[0356] In some embodiments, W 1 and W 2 are each NH, m is 0, n, o, p, and q are each 1.
[0357] In some embodiments, W 1 and W 2 are each NH, m is 0, n and o are each 1, p and q are each 0, and each a is CH 3 .
[0358] In some embodiments, W 1 and W 2 are each NH, m is 0, n and o are each 1, p and q are each 0, and each b is CH 3 .
[0359] In some embodiments, W 1 and W 2 are each NH, m is 1, n, o, p, and q are each 1, R 3 is H, and L is
[0000]
[0360] In some embodiments, W 1 and W 2 are each NH, m is 1, n, p and q are each 1, and o is 2, R 3 is H, and L is
[0000]
[0361] In some embodiments, W 1 and W 2 are each NH, m is 1, n, o, p are each 1, and q is 2, and L is
[0000]
[0362] In some embodiments, W 1 and W 2 are each NH, m is 1, n, o, p, and q are each 1, and L is
[0000]
[0363] In some embodiments, W 1 and W 2 are each NH, m is 1, n and p are each 1, and o and q are each 0, and L is —C(O)—.
[0364] In some embodiments, W 1 and W 2 are each NH, m is 1, n and p are each 1, and o, and q are each 0, and L is
[0000]
[0365] In some embodiments, W 1 and W 2 are each NH, m is 1, n, o, p, q are each 1, and L is
[0000]
[0366] In some embodiments, W 1 and W 2 are each NH, m is 1, n, o, p, and q are each 1, h is 1, and L is
[0000]
[0367] In some embodiments, W 1 and W 2 are each NH, m is 1, n, o, p, and q are each 1, and L is —S—.
[0368] In some embodiments, W 1 and W 2 are each NH, m is 1, n, o, p are each 0, q is 1, one d is —CH 3 , and L is
[0000]
[0369] In some embodiments, W 1 and W 2 are each NH, m is 2, n, o, p, and q are each 0, one L is
[0000]
[0000] and
one L is
[0000]
[0371] In some embodiments, m is 0, n, o, p, and q are each 0, and W 1 and W 2 are taken together to form an optionally substituted piperazine group.
[0372] In some embodiments, m is 1, n, o, p, and q are each 0, W 1 and W 2 are each null, and L is
[0000]
[0373] In some embodiments, m is 1, n and p are each 1, o and q are each 0, W 1 and W 2 are each NH, and L is C 3 -C 6 cycloalkyl.
[0374] In some embodiments, m is 1, n is 1, o, p, and q are each 0, W 1 and W 2 are each NH, and L is C 3 -C 6 cycloalkyl.
[0375] In some embodiments, m is 1, n, o, p, are each 0, q is 1, W 1 and W 2 are each NH, and L is C 3 -C 6 cycloalkyl.
[0376] In some embodiments, m is 1, n, o, p, and q are each 0, W 1 is NH, W 2 is null, and L is
[0000]
[0377] In some embodiments, m is 1, n o, p, and q are each 0, W 1 is null, W 2 is NH, and L is
[0000]
[0378] In some embodiments, m is 1, n o, p, and q are each 0, W 1 is NH, W 2 is null, and L is
[0000]
[0379] In some embodiments, m is 1, n o, p, and q are each 0, W 1 is null, W 2 is NH, and L is
[0000]
[0380] In some embodiments, m is 1, n is 1, o, p, and q are each 0, W 1 is NH, W 2 is null, and L is
[0000]
[0381] In some embodiments, m is 1, n, o, p, are each 0, q is 1, W 1 is null, W 2 is NH, and L is
[0000]
[0382] In some embodiments, m is 1, n, o, p, and q are each 0, W 1 is NH, W 2 is null, and L is
[0000]
[0383] In some embodiments, m is 1, n, o, p, and q are each 0, W 1 is null, W 2 is NH, and L is
[0000]
[0384] In some embodiments, m is 1, n is 1, o, p, and q are each 0, W 1 is NH, W 2 is null, and L is
[0000]
[0385] In some embodiments, m is 1, n, o, p, are each 0, q is 1, W 1 is null, W 2 is NH, and L is
[0000]
[0386] In some embodiments, m is 1, n is 1, o, p, and q are each 0, W 1 is NH, W 2 is null, and L is
[0000]
[0387] In some embodiments, m is 1, n, o, p, are each 0, q is 1, W 1 is null, W 2 is NH, and L is
[0000]
[0388] In some embodiments, m is 1, n, o, p, q are each 0, W 1 and W 2 is null, and L is
[0000]
[0389] In some embodiments, m is 1, n, o, p, q are each 0, W 1 and W 2 is null, and L is
[0000]
[0390] In some embodiments, m is 1, n, o, p, q are each 0, W 1 is NH, W 2 is null, and L is
[0000]
[0391] In some embodiments, m is 1, n, o, p, q are each 0, W 1 is null, W 2 is NH, and L is
[0000]
[0392] In some embodiments, m is 1, n, o, p, are each 0, q is 1, W 1 and W 2 are each and NH, is null, L is
[0000]
[0393] In some embodiments, m is 1, n, o, p, are each 0, q is 1, W 1 and W 2 are each NH, is null, and L is a heteroaryl.
[0394] In some of the foregoing embodiments, r is 2, s is 6 and t is 1.
[0395] In some of the foregoing embodiments, r is 3, s is 5 and t is 1.
[0396] In Formula I, II, II′, III, IV, V, VI and VII, any one or more of H may be substituted with a deuterium. It is also understood in Formula I, II, II′, III, IV, V, VI and VII that a methyl substituent can be substituted with a C 1 -C 6 alkyl.
[0397] In other illustrative embodiments, compounds of Formula I, II, II′, III, IV, V, VI and VII used in the treatment of metabolic diseases described herein are as set forth below:
[0000]
N-(2-(2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethoxy)ethyl)nicotinamide (I-1)
[0398]
N-(2-((2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)(methyl)amino)ethyl)nicotinamide (I-2)
[0399]
N-(2-((2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)disulfanyl)ethyl)nicotinamide (I-3)
[0400]
N-(2-((1-(2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)-2,5-dioxopyrrolidin-3-yl)thio)ethyl)nicotinamide (I-4)
[0401]
4-methoxy-3-(nicotinamido)-4-oxobutan-2-yl 2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)-3-methylbutanoate (I-5)
[0402]
1,3-dihydroxypropan-2-yl 6-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)-2-(nicotinamido)hexanoate (I-6)
[0403]
N-(2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)nicotinamide (I-7)
[0404]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (I-8)
[0405]
(2S,3R)-methyl 3-(((S)-2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)propanoyl)oxy)-2-(nicotinamido)butanoate (I-9)
[0406]
(2S,3R)-methyl 3-(((S)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)propanoyl)oxy)-2-(nicotinamido)butanoate (I-10)
[0407]
(S)-methyl 6-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)-2-(nicotinamido)hexanoate (I-11)
[0408]
(4Z,7Z,10Z,13Z,16Z,19Z)-1-(4-nicotinoylpiperazin-1-yl)docosa-4,7,10,13,16,19-hexaen-1-one (I-12)
[0409]
(5Z,8Z,11Z,14Z,17Z)-1-(4-nicotinoylpiperazin-1-yl)icosa-5,8,11,14,17-pentaen-1-one (I-13)
[0410]
N-(2-((4Z,7Z,10Z,13Z,16Z,19Z)—N-methyldocosa-4,7,10,13,16,19-hexaenamido)ethyl)nicotinamide (I-14)
[0411]
N-(2-((5Z,8Z,11Z,14Z,17Z)—N-methylicosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (I-15)
[0412]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)-N-methylnicotinamide (I-16)
[0413]
N-methyl-N-(2-((5Z,8Z,11Z,14Z,17Z)—N-methylicosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (I-17)
[0414]
N-(3-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)propyl)nicotinamide (I-18)
[0415]
N-(4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)butyl)nicotinamide (I-19)
[0416]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-2-methylpropyl)nicotinamide (I-20)
[0417]
N-(1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-2-methylpropan-2-yl)nicotinamide (I-21)
[0418]
N-(1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)nicotinamide (I-22)
[0419]
(5Z,8Z,11Z,14Z,17Z)—N—((S)-1-nicotinoylpyrrolidin-3-yl)icosa-5,8,11,14,17-pentaenamide (I-23)
[0420]
N—((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)nicotinamide (I-24)
[0421]
N—((S)-1-((2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)amino)-3-methyl-1-oxobutan-2-yl)nicotinamide (I-25)
[0422]
N-(3-((2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)amino)-3-oxopropyl)nicotinamide (I-26)
[0423]
(S)—N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)-1-nicotinoylpyrrolidine-2-carboxamide (I-27)
[0424]
(5Z,8Z,11Z,14Z,17Z)—N-(1-nicotinoylpiperidin-4-yl)icosa-5,8,11,14,17-pentaenamide (I-28)
[0425]
(5Z,8Z,11Z,14Z,17Z)—N-((1-nicotinoylpiperidin-4-yl)methyl)icosa-5,8,11,14,17-pentaenamide (I-29)
[0426]
N-(2-((2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)amino)-2-oxoethyl)nicotinamide (I-30)
[0427]
N-((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)nicotinamide (I-31)
[0428]
(5Z,8Z,11Z,14Z,17Z)—N—(((S)-1-nicotinoylpyrrolidin-2-yl)methyl)icosa-5,8,11,14,17-pentaenamide (I-32)
[0429]
(5Z,8Z,11Z,14Z,17Z)—N—(((R)-1-nicotinoylpyrrolidin-2-yl)methyl)icosa-5,8,11,14,17-pentaenamide (I-33)
[0430]
N—(((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-2-yl)methyl)nicotinamide (I-34)
[0431]
N—(((R)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-2-yl)methyl)nicotinamide (I-35)
[0432]
N-(2-((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidine-2-carboxamido)ethyl)nicotinamide (I-36)
[0433]
N-(2-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)acetamido)ethyl)nicotinamide (I-37)
[0434]
N-(2-((S)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-3-methylbutanamido)ethyl)nicotinamide (I-38)
[0435]
N-(2-(3-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)propanamido)ethyl)nicotinamide (I-39)
[0436]
N—((R)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)nicotinamide (I-40)
[0437]
N-(((1R,4R)-4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)cyclohexyl)methyl)nicotinamide (I-41)
[0438]
N-((1R,4R)-4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)cyclohexyl)nicotinamide (I-42)
[0439]
N—(((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)methyl)nicotinamide (I-43)
[0440]
N—(((R)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)methyl)nicotinamide (I-44)
[0441]
N-((1R,4R)-4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamidomethyl)cyclohexyl)nicotinamide (I-45)
[0442]
(5Z,8Z,11Z,14Z,17Z)—N—(((S)-1-nicotinoylpyrrolidin-3-yl)methyl)icosa-5,8,11,14,17-pentaenamide (I-46)
[0443]
(5Z,8Z,11Z,14Z,17Z)—N—(((R)-1-nicotinoylpyrrolidin-3-yl)methyl)icosa-5,8,11,14,17-pentaenamide (I-47)
[0444]
(5Z,8Z,11Z,14Z,17Z)—N-methyl-N-((1-nicotinoylpiperidin-4-yl)methyl)icosa-5,8,11,14,17-pentaenamide (I-48)
[0445]
(5Z,8Z,11Z,14Z,17Z)—N-methyl-N—((S)-1-nicotinoylpyrrolidin-3-yl)icosa-5,8,11,14,17-pentaenamide (I-49)
[0446]
N-(4-((2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)carbamoyl)phenyl)nicotinamide (I-50)
[0447]
N—((S)-1-(4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperazin-1-yl)-3-methyl-1-oxobutan-2-yl)nicotinamide (I-51)
[0448]
N-(2-(4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperazin-1-yl)-2-oxoethyl)nicotinamide (I-52)
[0449]
N—(((R)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-2-yl)methyl)nicotinamide (I-53)
[0450]
(5Z,8Z,11Z,14Z,17Z)—N—((R)-1-nicotinoylpyrrolidin-3-yl)icosa-5,8,11,14,17-pentaenamide (I-54)
[0451]
N-(3-(4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperazin-1-yl)-3-oxopropyl)nicotinamide (I-55)
[0452]
N-(4-(4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperazine-1-carbonyl)phenyl)nicotinamide (I-56)
[0453]
N-(2-(2-((5Z,8Z,11Z,14Z,17Z)—N-methylicosa-5,8,11,14,17-pentaenamido)acetamido)ethyl)nicotinamide (I-57)
[0454]
N-(2-(1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)ethyl)nicotinamide (I-58)
[0455]
N-(2-((2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)carbamoyl)phenyl)nicotinamide (I-59)
[0456]
N-(2-(4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperazine-1-carbonyl)phenyl)nicotinamide (I-60)
[0457]
N—((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)-N-methylnicotinamide (I-61)
[0458]
N-((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)-N-methylnicotinamide (I-62)
[0459]
N-((3-hydroxy-6-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamidomethyl)-2-methylpyridin-4-yl)methyl)nicotinamide (I-63)
[0460]
N-((4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-2-methylpyrimidin-5-yl)methyl)nicotinamide (I-64)
[0461]
(5Z,8Z,11Z,14Z,17Z)—N-(3-nicotinoyl-3-azabicyclo[3.1.0]hexan-6-yl)icosa-5,8,11,14,17-pentaenamide (I-65)
[0462]
N-(((1S,4S)-4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamidomethyl)cyclohexyl)methyl)nicotinamide (I-66)
[0463]
5-chloro-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (I-67)
[0464]
5-fluoro-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (I-68)
[0465]
6-fluoro-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (I-69)
[0466]
6-chloro-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (I-70)
[0467]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)-6-methylnicotinamide (I-71)
[0468]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)-4-methylnicotinamide (I-72)
[0469]
4-chloro-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (I-73)
[0470]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)-5-methylnicotinamide (I-74)
[0471]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)benzamide (II-1)
[0472]
N-(2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)benzamide (II-2)
[0473]
N-(2-(2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethoxy)ethyl)benzamide (II-3)
[0474]
N-(2-((2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)(methyl)amino)ethyl)benzamide (II-4)
[0475]
N-(2-((2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)disulfanyl)ethyl)benzamide (II-5)
[0476]
2-benzamido-6-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)hexanoic acid (II-6)
[0477]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)-1-methyl-6-oxo-1,6-dihydropyridine-3-carboxamide (II-7)
[0478]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)isonicotinamide (II-8)
[0479]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)picolinamide (II-9)
[0480]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)pyrimidine-4-carboxamide (II-10)
[0481]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)pyrazine-2-carboxamide (II-11)
[0482]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)piperidine-3-carboxamide (II-12)
[0483]
(5Z,8Z,11Z,14Z,17Z)-1-(4-picolinoylpiperazin-1-yl)icosa-5,8,11,14,17-pentaen-1-one (II-13)
[0484]
N-(2-((5Z,8Z,11Z,14Z,17Z)—N-methylicosa-5,8,11,14,17-pentaenamido)ethyl)picolinamide (II-14)
[0485]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)-N-methylpicolinamide (II-15)
[0486]
N-(1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)picolinamide (II-16)
[0487]
(5Z,8Z,11Z,14Z,17Z)—N—((S)-1-picolinoylpyrrolidin-3-yl)icosa-5,8,11,14,17-pentaenamide (II-17)
[0488]
N—((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)picolinamide (II-18)
[0489]
N-((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)picolinamide (II-19)
[0490]
N—(((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)methyl)picolinamide (II-20)
[0491]
5-((2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)carbamoyl)-2-methylpyrazine 1-oxide (II-21)
[0492]
5-((2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)carbamoyl)-2-methylpyrazine 1-oxide (II-22)
[0493]
5-((2-((2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)disulfanyl)ethyl)carbamoyl)-2-methylpyrazine 1-oxide (II-23)
[0494]
5-((2-((2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)(methyl)amino)ethyl)carbamoyl)-2-methylpyrazine 1-oxide (II-24)
[0495]
5-((2-((2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)(methyl)amino)ethyl)carbamoyl)-2-methylpyrazine 1-oxide (II-25)
[0496]
5-((2-(2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethoxy)ethyl)carbamoyl)-2-methylpyrazine 1-oxide (II-26)
[0497]
5-((2-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethoxy)ethyl)carbamoyl)-2-methylpyrazine 1-oxide (II-27)
[0498]
N-(2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)-5-methyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide (II-28)
[0499]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)-5-methyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide (II-29)
[0500]
N-(2-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethoxy)ethyl)-5-methyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide (II-30)
[0501]
N-(2-((2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)(methyl)amino)ethyl)-5-methyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide (II-31)
[0502]
(4Z,7Z,10Z,13Z,16Z,19Z)—N-(2-(2-(4-chlorophenoxy)-2-methylpropanamido)ethyl)docosa-4,7,10,13,16,19-hexaenamide (II-32)
[0503]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(2-(4-chlorophenoxy)-2-methylpropanamido)ethyl)icosa-5,8,11,14,17-pentaenamide (II-33)
[0504]
(4Z,7Z,10Z,13Z,16Z,19Z)—N-(2-(5-(2,5-dimethylphenoxy)-2,2-dimethylpentanamido)ethyl)docosa-4,7,10,13,16,19-hexaenamide (II-34)
[0505]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(5-(2,5-dimethylphenoxy)-2,2-dimethylpentanamido)ethyl)icosa-5,8,11,14,17-pentaenamide (II-35)
[0506]
(4Z,7Z,10Z,13Z,16Z,19Z)—N-(2-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanamido)ethyl)docosa-4,7,10,13,16,19-hexaenamide (II-36)
[0507]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanamido)ethyl)icosa-5,8,11,14,17-pentaenamide (II-37)
[0508]
4-chloro-N-(4-((1-((2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)amino)-2-methyl-1-oxopropan-2-yl)oxy)phenethyl)benzamide (II-38)
[0509]
4-chloro-N-(4-((1-((2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)amino)-2-methyl-1-oxopropan-2-yl)oxy)phenethyl)benzamide (II-39)
[0510]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanamido)ethyl)-N-methylicosa-5,8,11,14,17-pentaenamide (II-40)
[0511]
4-chloro-N-(4-((2-methyl-1-((2-((5Z,8Z,11Z,14Z,17Z)—N-methylicosa-5,8,11,14,17-pentaenamido)ethyl)amino)-1-oxopropan-2-yl)oxy)phenethyl)benzamide (II-41)
[0512]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(5-(2,5-dimethylphenoxy)-2,2-dimethylpentanamido)ethyl)-N-methylicosa-5,8,11,14,17-pentaenamide (II-42)
[0513]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(2-(4-chlorophenoxy)-2-methylpropanamido)ethyl)-N-methylicosa-5,8,11,14,17-pentaenamide (II-43)
[0514]
(4Z,7Z,10Z,13Z,16Z,19Z)—N-(2-(2-(2-methoxyethoxy)ethoxy)ethyl)docosa-4,7,10,13,16,19-hexaenamide (III-1)
[0515]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(2-(2-methoxyethoxy)ethoxy)ethyl)icosa-5,8,11,14,17-pentaenamide (III-2)
[0516]
(4Z,7Z,10Z,13Z,16Z,19Z)—N-(2,5,8,11-tetraoxatridecan-13-yl)docosa-4,7,10,13,16,19-hexaenamide (III-3)
[0517]
(5Z,8Z,11Z,14Z,17Z)—N-(2,5,8,11-tetraoxatridecan-13-yl)icosa-5,8,11,14,17-pentaenamide (III-4)
[0518]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(2-(2-(2-(2-methoxyethoxy)ethoxy)ethoxy)ethoxy)ethyl)icosa-5,8,11,14,17-pentaenamide (III-5)
[0519]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(2-(2-(2-(2-(2-methoxyethoxy)ethoxy)ethoxy)ethoxy)ethoxy)ethyl)icosa-5,8,11,14,17-pentaenamide (III-6)
[0520]
(5Z,8Z,11Z,14Z,17Z)—N-(2-hydroxyethyl)icosa-5,8,11,14,17-pentaenamide (III-7)
[0521]
(4Z,7Z,10Z,13Z,16Z,19Z)—N-(2-hydroxyethyl)docosa-4,7,10,13,16,19-hexaenamide (III-8)
[0522]
2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)acetic acid (III-9)
[0523]
2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)acetic acid (III-10)
[0524]
(5Z,8Z,11Z,14Z,17Z)—N-(2-((E)-4-(pyridin-3-yl)but-3-enamido)ethyl)icosa-5,8,11,14,17-pentaenamide (IV-1)
[0525]
(4Z,7Z,10Z,13Z,16Z,19Z)—N-(2-((E)-4-(pyridin-3-yl)but-3-enamido)ethyl)docosa-4,7,10,13,16,19-hexaenamide (IV-2)
[0526]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(2-((E)-4-(pyridin-3-yl)but-3-enamido)ethoxy)ethyl)icosa-5,8,11,14,17-pentaenamide (IV-3)
[0527]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(2-((E)-4-(pyridin-3-yl)but-3-enamido)ethylamino)ethyl)icosa-5,8,11,14,17-pentaenamide (IV-4)
[0528]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(methyl(2-((E)-4-(pyridin-3-yl)but-3-enamido)ethyl)amino)ethyl)icosa-5,8,11,14,17-pentaenamide (IV-5)
[0529]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(2-(2-((E)-4-(pyridin-3-yl)but-3-enamido)ethyl)disulfanyl)ethyl)icosa-5,8,11,14,17-pentaenamide (IV-6)
[0530]
(S)-6-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-2-((E)-4-(pyridin-3-yl)but-3-enamido)hexanoic acid (IV-7)
[0531]
(S)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-6-((E)-4-(pyridin-3-yl)but-3-enamido)hexanoic acid (IV-8)
[0532]
(S)-1,3-dihydroxypropan-2-yl 6-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-2-((E)-4-(pyridin-3-yl)but-3-enamido)hexanoate (IV-9)
[0533]
(S)-1,3-dihydroxypropan-2-yl 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-6-((E)-4-(pyridin-3-yl)but-3-enamido)hexanoate (IV-10)
[0534]
(S)-5-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)-2-((E)-4-(pyridin-3-yl)but-3-enamido)pentanoic acid (IV-11)
[0535]
(S)-1,3-dihydroxypropan-2-yl 5-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)-2-((E)-4-(pyridin-3-yl)but-3-enamido)pentanoate (IV-12)
[0536]
(4Z,7Z,10Z,13Z,16Z,19Z)—N-(2-((E)-4-(6-methylpyridin-3-yl)but-3-enamido)ethyl)docosa-4,7,10,13,16,19-hexaenamide (IV-13)
[0537]
(5Z,8Z,11Z,14Z,17Z)—N-(2-((E)-4-(6-methylpyridin-3-yl)but-3-enamido)ethyl)icosa-5,8,11,14,17-pentaenamide (IV-14)
[0538]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(2-((E)-4-(6-methylpyridin-3-yl)but-3-enamido)ethoxy)ethyl)icosa-5,8,11,14,17-pentaenamide (IV-15)
[0539]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(2-((E)-4-(6-methylpyridin-3-yl)but-3-enamido)ethylamino)ethyl)icosa-5,8,11,14,17-pentaenamide (IV-16)
[0540]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(methyl(2-((E)-4-(6-methylpyridin-3-yl)but-3-enamido)ethyl)amino)ethyl)icosa-5,8,11,14,17-pentaenamide (IV-17)
[0541]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(2-(2-((E)-4-(6-methylpyridin-3-yl)but-3-enamido)ethyl)disulfanyl)ethyl)icosa-5,8,11,14,17-pentaenamide (IV-18)
[0542]
(S)-6-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-2-((E)-4-(6-methylpyridin-3-yl)but-3-enamido)hexanoic acid (IV-19)
[0543]
(S)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-6-((E)-4-(6-methylpyridin-3-yl)but-3-enamido)hexanoic acid (IV-20)
[0544]
(S)-1,3-dihydroxypropan-2-yl 6-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-2-((E)-4-(6-methylpyridin-3-yl)but-3-enamido)hexanoate (IV-21)
[0545]
(S)-1,3-dihydroxypropan-2-yl 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-6-((E)-4-(6-methylpyridin-3-yl)but-3-enamido)hexanoate (IV-22)
[0546]
(S)-5-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)-2-((E)-4-(6-methylpyridin-3-yl)but-3-enamido)pentanoic acid (IV-23)
[0547]
(S)-1,3-dihydroxypropan-2-yl 5-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)-2-((E)-4-(6-methylpyridin-3-yl)but-3-enamido)pentanoate (IV-24)
[0548]
(5Z,8Z,11Z,14Z,17Z)—N-(2-((E)-4-(6-(2-(pyrrolidin-1-yl)ethyl)pyridin-3-yl)but-3-enamido)ethyl)icosa-5,8,11,14,17-pentaenamide (IV-25)
[0549]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(2-((E)-4-(6-(2-(pyrrolidin-1-yl)ethyl)pyridin-3-yl)but-3-enamido)ethoxy)ethyl)icosa-5,8,11,14,17-pentaenamide (IV-26)
[0550]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(methyl(2-((E)-4-(6-(2-(pyrrolidin-1-yl)ethyl)pyridin-3-yl)but-3-enamido)ethyl)amino)ethyl)icosa-5,8,11,14,17-pentaenamide (IV-27)
[0551]
N-(2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)-6-(2-morpholinoethyl)nicotinamide (V-1)
[0552]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)-6-(2-morpholinoethyl)nicotinamide (V-2)
[0553]
N-(2-((2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)amino)ethyl)-6-(2-morpholinoethyl)nicotinamide (V-3)
[0554]
N-(2-((2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)(methyl)amino)ethyl)-6-(2-morpholinoethyl)nicotinamide (V-4)
[0555]
N-(2-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethoxy)ethyl)-6-(2-morpholinoethyl)nicotinamide (V-5)
[0556]
(S)-6-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-2-(6-(2-morpholinoethyl)nicotinamido)hexanoic acid (V-6)
[0557]
(S)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-6-(6-(2-morpholinoethyl)nicotinamido)hexanoic acid (V-7)
[0558]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)-6-(2-(pyrrolidin-1-yl)ethyl)nicotinamide (V-8)
[0559]
N-(2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)ethyl)-6-(2-(pyrrolidin-1-yl)ethyl)nicotinamide (V-9)
[0560]
N-(2-((2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)(methyl)amino)ethyl)-6-(2-(pyrrolidin-1-yl)ethyl)nicotinamide (V-10)
[0561]
N-(2-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethoxy)ethyl)-6-(2-(pyrrolidin-1-yl)ethyl)nicotinamide (V-11)
[0562]
(S)-6-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-2-(6-(2-(pyrrolidin-1-yl)ethyl)nicotinamido)hexanoic acid (V-12)
[0563]
(S)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-6-(6-(2-(pyrrolidin-1-yl)ethyl)nicotinamido)hexanoic acid (V-13)
[0564]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)-6-(2-(piperidin-1-yl)ethyl)nicotinamide (V-14)
[0565]
4-hydroxy-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (VI-1)
[0566]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)-5-phenylnicotinamide (VI-2)
[0567]
2-hydroxy-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (VI-3)
[0568]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)-2-phenylnicotinamide (VI-4)
[0569]
5-hydroxy-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (VI-5)
[0570]
N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)-2-methylnicotinamide (VI-6)
[0571]
2-fluoro-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (VI-7)
[0572]
2-chloro-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (VI-8)
[0573]
N-(1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)-5-methyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide (VII-1)
[0574]
N-((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)-5-methyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide
[0575]
N—((R)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)-5-methyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide (VII-3)
[0576]
N—((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)-5-methyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide (VII-4)
[0577]
N—(((R)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)methyl)-5-methyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide (VII-5)
[0578]
N—(((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)methyl)-5-methyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide (VII-6)
[0579]
N-(1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)-N,5-dimethyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide (VII-7)
[0580]
N-((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)-N,5-dimethyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide (VII-8)
[0581]
N—((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)-N,5-dimethyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide (VII-9)
[0582]
2-(((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)carbamoyl)-5-methylpyrazine 1-oxide (VII-10)
[0583]
2-(((R)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)carbamoyl)-5-methylpyrazine 1-oxide (VII-11)
[0584]
2-(((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)carbamoyl)-5-methylpyrazine 1-oxide (VII-12)
[0585]
2-((((R)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-2-yl)methyl)carbamoyl)-5-methylpyrazine 1-oxide (VII-13)
[0586]
2-((((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-2-yl)methyl)carbamoyl)-5-methylpyrazine 1-oxide (VII-14)
[0587]
3-((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)carbamoyl)-5-methylpyrazine 1-oxide (VII-15)
[0588]
2-(((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)(methyl)carbamoyl)-5-methylpyrazine 1-oxide (VII-16)
[0589]
2-(((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)(methyl)carbamoyl)-5-methylpyrazine 1-oxide (VII-17)
[0590]
N-((1r,4r)-4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)cyclohexyl)-5-methyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide (VII-18)
[0591]
2-(4-(4-chlorobenzoyl)phenoxy)-N-(1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)-2-methylpropanamide (VII-19)
[0592]
2-(4-(4-chlorobenzoyl)phenoxy)-N-((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)-2-methylpropanamide (VII-20)
[0593]
2-(4-(4-chlorobenzoyl)phenoxy)-N—((R)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)-2-methylpropanamide (VII-21)
[0594]
2-(4-(4-chlorobenzoyl)phenoxy)-N—((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)-2-methylpropanamide (VII-22)
[0595]
2-(4-(4-chlorobenzoyl)phenoxy)-N—(((R)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-2-yl)methyl)-2-methylpropanamide (VII-23)
[0596]
2-(4-(4-chlorobenzoyl)phenoxy)-N—(((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-2-yl)methyl)-2-methylpropanamide (VII-24)
[0597]
(5Z,8Z,11Z,14Z,17Z)—N-(1-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanoyl)piperidin-4-yl)icosa-5,8,11,14,17-pentaenamide (VII-25)
[0598]
(5Z,8Z,11Z,14Z,17Z)—N-((1-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanoyl)piperidin-4-yl)methyl)icosa-5,8,11,14,17-pentaenamide (VII-26)
[0599]
(5Z,8Z,11Z,14Z,17Z)—N—((R)-1-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanoyl)pyrrolidin-3-yl)icosa-5,8,11,14,17-pentaenamide (VII-27)
[0600]
(5Z,8Z,11Z,14Z,17Z)—N—((S)-1-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanoyl)pyrrolidin-3-yl)icosa-5,8,11,14,17-pentaenamide (VII-28)
[0601]
(5Z,8Z,11Z,14Z,17Z)—N—(((R)-1-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanoyl)pyrrolidin-2-yl)methyl)icosa-5,8,11,14,17-pentaenamide (VII-29)
[0602]
(5Z,8Z,11Z,14Z,17Z)—N—(((S)-1-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanoyl)pyrrolidin-2-yl)methyl)icosa-5,8,11,14,17-pentaenamide (VII-30)
[0603]
(S)-1-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanoyl)-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)pyrrolidine-2-carboxamide (VII-31)
[0604]
(5Z,8Z,11Z,14Z,17Z)—N-(2-((S)-2-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanamido)-3-methylbutanamido)ethyl)icosa-5,8,11,14,17-pentaenamide (VII-32)
[0605]
(5Z,8Z,11Z,14Z,17Z)—N-(2-(3-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanamido)propanamido)ethyl)icosa-5,8,11,14,17-pentaenamide (VII-33)
[0606]
(5Z,8Z,11Z,14Z,17Z)—N-((1r,4r)-4-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanamido)cyclohexyl)icosa-5,8,11,14,17-pentaenamide (VII-34)
[0607]
(5Z,8Z,11Z,14Z,17Z)—N-(((1s,4s)-4-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanamido)cyclohexyl)methyl)icosa-5,8,11,14,17-pentaenamide (VII-35)
[0608]
(5Z,8Z,11Z,14Z,17Z)—N-((1r,4r)-4-((2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanamido)methyl)cyclohexyl)icosa-5,8,11,14,17-pentaenamide (VII-36)
[0609]
2-(4-(4-chlorobenzoyl)phenoxy)-N-((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)-N,2-dimethylpropanamide (VII-37)
[0610]
2-(4-(4-chlorobenzoyl)phenoxy)-N—((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)-N,2-dimethylpropanamide (VII-38)
[0611]
4-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanamido)-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)benzamide (VII-39)
[0612]
2-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanamido)-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)benzamide (VII-40)
[0613]
(5Z,8Z,11Z,14Z,17Z)—N-(5-((2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanamido)methyl)-2-methylpyrimidin-4-yl)icosa-5,8,11,14,17-pentaenamide (VII-41)
[0614]
(5Z,8Z,11Z,14Z,17Z)-1-(4-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanoyl)piperazin-1-yl)icosa-5,8,11,14,17-pentaen-1-one (VII-42)
Methods for Using the Fatty Acid Bioactive Derivatives
[0615] The invention also includes methods for treating metabolic diseases such as the treatment or prevention of metabolic diseases including atherosclerosis, dyslipidemia, coronary heart disease, hypercholesterolemia, Type 2 diabetes, elevated cholesterol, metabolic syndrome and cardiovascular disease.
[0616] In one embodiment, the method involves the inhibition of PCSK9 by fatty acid derivatives. Inhibition of PCSK9 will lead to a reduction in LDL-C.
[0617] In one embodiment, the method comprises contacting a cell with a fatty acid derivative in an amount sufficient to decrease the release of triglycerides or VLDL or LDL or cause an increase in reverse cholesterol transport or increase HDL concentrations.
[0618] Also provided in the invention is a method for inhibiting, preventing, or treating a metabolic disease, or symptoms of a metabolic disease, in a subject. Examples of such disorders include, but are not limited to atherosclerosis, dyslipidemia, hypertriglyceridemia, hypertension, heart failure, cardiac arrhythmias, low HDL levels, high LDL levels, sudden death, stable angina, coronary heart disease, acute myocardial infarction, secondary prevention of myocardial infarction, cardiomyopathy, endocarditis, type 2 diabetes, insulin resistance, impaired glucose tolerance, hypercholesterolemia, stroke, hyperlipidemia, hyperlipoproteinemia, chronic kidney disease, intermittent claudication, hyperphosphatemia, carotid atherosclerosis, peripheral arterial disease, diabetic nephropathy, hypercholesterolemia in HIV infection, acute coronary syndrome (ACS), non-alcoholic fatty liver disease, arterial occlusive diseases, cerebral arteriosclerosis, cerebrovascular disorders, myocardial ischemia, and diabetic autonomic neuropathy. Because of the ability of fatty acid niacin conjugates and other fatty acid conjugates used as PCSK9 inhibitors to lower cholesterol and triglycerides, they can also be used to treat diseases of the liver such as fatty liver disease, nonalcoholic fatty liver disease (NFLD), nonalcoholic steatohepatitis (NASH).
[0619] In some embodiments, the fatty acid niacin conjugates and other fatty acid conjugates used as PCSK9 inhibitors can be used to treat familial hyperlipidemia. Hyperlipidemia are classified according to which types of lipids are elevated, that is hypercholesterolemia, hypertriglyceridemia, or both in combined hyperlipidemia. Elevated levels of lipoprotein may also be classified as a form of hyperlipidemia. There are five types of hyperlipoproteinemia (types I through V) and these are further classified according to the Fredrikson classification, based on the pattern of lipoproteins on electrophoresis or ultracentrifugation. Type I hyperlipoproteinemia has three subtypes: Type Ia (also called Buerger-Gruetz syndrome or familial hyperchylomicronemia), Type Ib (also called familial apoprotein CII deficiency) and Type Ic. Due to defects in either decreased in lipoprotein lipase (LPL), altered ApoC2 or LPL inhibitor in blood, all three subtypes of Type I hyperlipoproteinemia share the same characteristic increase in chylomicrons. The frequency of occurrence for Type I hyperlipoproteinemia is 1 in 1,000,000 and thus far treatment has consisted mainly of diet. Because of the ability of fatty acid niacin conjugates in affecting postprandial lipids, it can be especially useful in treating Type I hyperlipoproteinemia. Type II hyperlipoproteinemia has two subtypes: Type IIa (also called familial hypercholesterolemia) is characterized by an elevated level of low-density lipoprotein (LDL); and Type IIb (also called familial combined hyperlipidemia) is characterized by an elevated level of LDL and very-low density lipoprotein (VLDL). Type III hyperlipoproteinemia (also called familial dysbetalipoproteinemia) is characterized by an elevated level of intermediate-density lipoprotein (IDL). Type IV hyperlipoproteinemia (also called familial hypertriglyceridemia) is characterized by an elevated level of VLDL. Type V hyperlipoproteinemia is characterized by an elevated level of VLDL and chylomicrons. Treatment for Type V hyperlipoproteinemia thus far has not been adequate with using just niacin or fibrate. Because of the ability of fatty acid niacin conjugates in affecting postprandial lipids, it can be especially useful in treating Type V hyperlipoproteinemia.
[0620] In some embodiments, the subject is administered an effective amount of a fatty acid derivative.
[0621] The invention also includes pharmaceutical compositions useful for treating or preventing a metabolic disease, or for inhibiting a metabolic disease, or more than one of these activities. The compositions can be suitable for internal use and comprise an effective amount of a fatty acid derivative and a pharmaceutically acceptable carrier. The fatty acid derivatives are especially useful in that they demonstrate very low peripheral toxicity or no peripheral toxicity.
[0622] The fatty acid derivatives can each be administered in amounts that are sufficient to treat or prevent a metabolic disease or prevent the development thereof in subjects.
[0623] Administration of the fatty acid derivatives can be accomplished via any mode of administration for therapeutic agents. These modes include systemic or local administration such as oral, nasal, parenteral, transdermal, subcutaneous, vaginal, buccal, rectal or topical administration modes.
[0624] Depending on the intended mode of administration, the compositions can be in solid, semi-solid or liquid dosage form, such as, for example, injectables, tablets, suppositories, pills, time-release capsules, elixirs, tinctures, emulsions, syrups, powders, liquids, suspensions, or the like, sometimes in unit dosages and consistent with conventional pharmaceutical practices. Likewise, they can also be administered in intravenous (both bolus and infusion), intraperitoneal, subcutaneous or intramuscular form, all using forms well known to those skilled in the pharmaceutical arts.
[0625] Illustrative pharmaceutical compositions are tablets and gelatin capsules comprising a fatty acid niacin derivative and a pharmaceutically acceptable carrier, such as: a) a diluent, e.g., purified water, triglyceride oils, such as hydrogenated or partially hydrogenated vegetable oil, or mixtures thereof, corn oil, olive oil, sunflower oil, safflower oil, fish oils, such as EPA or DHA, or their esters or triglycerides or mixtures thereof, omega-3 fatty acids or derivatives thereof, lactose, dextrose, sucrose, mannitol, sorbitol, cellulose, sodium, saccharin, glucose and/or glycine; b) a lubricant, e.g., silica, talcum, stearic acid, its magnesium or calcium salt, sodium oleate, sodium stearate, magnesium stearate, sodium benzoate, sodium acetate, sodium chloride and/or polyethylene glycol; for tablets also; c) a binder, e.g., magnesium aluminum silicate, starch paste, gelatin, tragacanth, methylcellulose, sodium carboxymethylcellulose, magnesium carbonate, natural sugars such as glucose or beta-lactose, corn sweeteners, natural and synthetic gums such as acacia, tragacanth or sodium alginate, waxes and/or polyvinylpyrrolidone, if desired; d) a disintegrant, e.g., starches, agar, methyl cellulose, bentonite, xanthan gum, alginic acid or its sodium salt, or effervescent mixtures; e) absorbent, colorant, flavorant and sweetener; f) an emulsifier or dispersing agent, such as Tween 80, Labrasol, HPMC, DOSS, caproyl 909, labrafac, labrafil, peceol, transcutol, capmul MCM, capmul PG-12, captex 355, gelucire, vitamin E TGPS or other acceptable emulsifier; and/or g) an agent that enhances absorption of the compound such as cyclodextrin, hydroxypropyl-cyclodextrin, PEG400, PEG200.
[0626] Liquid, particularly injectable, compositions can, for example, be prepared by dissolution, dispersion, etc. For example, the fatty acid niacin derivative is dissolved in or mixed with a pharmaceutically acceptable solvent such as, for example, water, saline, aqueous dextrose, glycerol, ethanol, and the like, to thereby form an injectable isotonic solution or suspension. Proteins such as albumin, chylomicron particles, or serum proteins can be used to solubilize the fatty acid niacin derivatives.
[0627] The fatty acid derivatives can be also formulated as a suppository that can be prepared from fatty emulsions or suspensions; using polyalkylene glycols such as propylene glycol, as the carrier.
[0628] The fatty acid derivatives can also be administered in the form of liposome delivery systems, such as small unilamellar vesicles, large unilamellar vesicles and multilamellar vesicles. Liposomes can be formed from a variety of phospholipids, containing cholesterol, stearylamine or phosphatidylcholines. In some embodiments, a film of lipid components is hydrated with an aqueous solution of drug to a form lipid layer encapsulating the drug, as described in U.S. Pat. No. 5,262,564, the contents of which are herein incorporated by reference in their entirety.
[0629] Fatty acid derivatives can also be delivered by the use of monoclonal antibodies as individual carriers to which the fatty acid derivatives are coupled. The fatty acid derivatives can also be coupled with soluble polymers as targetable drug carriers. Such polymers can include polyvinylpyrrolidone, pyran copolymer, polyhydroxypropylmethacrylamide-phenol, polyhydroxyethylaspanamidephenol, or polyethyleneoxidepolylysine substituted with palmitoyl residues. Furthermore, the fatty acid derivatives can be coupled to a class of biodegradable polymers useful in achieving controlled release of a drug, for example, polylactic acid, polyepsilon caprolactone, polyhydroxy butyric acid, polyorthoesters, polyacetals, polydihydropyrans, polycyanoacrylates and cross-linked or amphipathic block copolymers of hydrogels. In one embodiment, fatty acid derivatives are not covalently bound to a polymer, e.g., a polycarboxylic acid polymer, or a polyacrylate.
[0630] Parenteral injectable administration is generally used for subcutaneous, intramuscular or intravenous injections and infusions. Injectables can be prepared in conventional forms, either as liquid solutions or suspensions or solid forms suitable for dissolving in liquid prior to injection.
[0631] Compositions can be prepared according to conventional mixing, granulating or coating methods, respectively, and the present pharmaceutical compositions can contain from about 0.1% to about 90%, from about 10% to about 90%, or from about 30% to about 90% of the fatty acid derivative by weight or volume.
[0632] The dosage regimen utilizing the fatty acid derivative is selected in accordance with a variety of factors including type, species, age, weight, sex and medical condition of the patient; the severity of the condition to be treated; the route of administration; the renal or hepatic function of the patient; and the particular fatty acid niacin derivative employed. A physician or veterinarian of ordinary skill in the art can readily determine and prescribe the effective amount of the drug required to prevent, counter or arrest the progress of the condition.
[0633] Effective dosage amounts of the present invention, when used for the indicated effects, range from about 20 mg to about 5,000 mg of the fatty acid derivative per day. Compositions for in vivo or in vitro use can contain about 20, 50, 75, 100, 150, 250, 500, 750, 1,000, 1,250, 2,500, 3,500, or 5,000 mg of the fatty acid derivative. In one embodiment, the compositions are in the form of a tablet that can be scored. Effective plasma levels of the fatty acid niacin derivative can range from 5 ng/mL to 5000 ng/mL. Appropriate dosages of the fatty acid derivatives can be determined as set forth in Goodman, L. S.; Gilman, A. The Pharmacological Basis of Therapeutics, 5th ed.; MacMillan: New York, 1975, pp. 201-226.
[0634] Fatty acid derivatives can be administered in a single daily dose, or the total daily dosage can be administered in divided doses of two, three or four times daily. Furthermore, fatty acid derivatives can be administered in intranasal form via topical use of suitable intranasal vehicles, or via transdermal routes, using those forms of transdermal skin patches well known to those of ordinary skill in that art. To be administered in the form of a transdermal delivery system, the dosage administration can be continuous rather than intermittent throughout the dosage regimen. Other illustrative topical preparations include creams, ointments, lotions, aerosol sprays and gels, wherein the concentration of the fatty acid derivative ranges from about 0.1% to about 15%, w/w or w/v.
Combination Therapies
[0635] Fatty acid derivatives may also be administered with other therapeutic agents such as cholesterol-lowering agents, fibrates and hypolipidemic agents, anti-diabetic agents, anti-diabetic agents, antihypertensive agents and anti-inflammatory agents.
[0636] In some embodiments, the other therapeutic agent is a cholesterol-lowering agents. Non limiting examples of cholesterol-lowering agents are atorvastatin, cerivastatin, fluvastatin, lovastatin, pitavastatin, pravastatin, rosuvastatin, simvastatin, ezetimibe, and the combination of ezetimibe/simvastatin (Vytorin®).
[0637] In some embodiments, the other therapeutic agent is a fibrate or hypolipidemic agent. Non-limiting examples of fibrates or hypolipidemic agents are acifran, acipimox, beclobrate, bezafibrate, binifibrate, ciprofibrate, clofibrate, colesevelam, gemfibrozil, fenofibrate, melinamide, niacin, and ronafibrate.
[0638] In some embodiments, the other therapeutic agent is a DPP-IV inhibitor as anti-diabetic agent. Non-limiting examples of DPP-IV inhibitors as anti-diabetic agents are sitagliptin, saxagliptin, vildagliptin, linagliptin, dutogliptin, gemigliptin and alogliptin.
[0639] In some embodiments, the other therapeutic agent is an Anti-diabetic agent. Non-limiting examples of anti-diabetic agents are acarbose, epalrestat, exenatide, glimepiride, liraglutide, metformin, miglitol, mitiglinide, nateglinide, pioglitazone, pramlintide, repaglinide, rosiglitazone, tolrestat, troglitazone, and voglibose.
[0640] In some embodiments, the other therapeutic agent is an antihypertensive agents. Non-limiting examples of antihypertensive agents include alacepril, alfuzosin, aliskiren, amlodipine besylate, amosulalol, aranidipine, arotinolol HCl, azelnidipine, barnidipine hydrochloride, benazepril hydrochloride, benidipine hydrochloride, betaxolol HCl, bevantolol HCl, bisoprolol fumarate, bopindolol, bosentan, budralazine, bunazosin HCl, candesartan cilexetil, captopril, carvedilol, celiprolol HCl, cicletanine, cilazapril, cinildipine, clevidipine, delapril, dilevalol, doxazosin mesylate, efonidipine, enalapril maleate, enalaprilat, eplerenone, eprosartan, felodipine, fenoldopam mesylate, fosinopril sodium, guanadrel sulfate, imidapril HCl, irbesartan, isradipine, ketanserin, lacidipine, lercanidipine, lisinopril, losartan, manidipine hydrochloride, mebefradil hydrochloride, moxonidine, nebivolol, nilvadipine, nipradilol, nisoldipine, olmesartan medoxomil, perindopril, pinacidil, quinapril, ramipril, rilmedidine, spirapril HCl, telmisartan, temocarpil, terazosin HCl, tertatolol HCl, tiamenidine HCl, tilisolol hydrochloride, trandolapril, treprostinil sodium, trimazosin HCl, valsartan, and zofenopril calcium.
[0641] In other embodiments, suitable angiotensin-converting-enzyme (ACE) inhibitors used in the above-described combination therapies include, without limitation, enalapril, ramipril, quinapril, perindopril, lisinopril, imidapril, zofenopril, trandolapril, fosinopril, and captopril.
Methods of Making
Methods for Making the Fatty Acid Bioactive Derivatives
[0642] Examples of synthetic pathways useful for making fatty acid derivatives described herein are described, for example, in US 2010/0041748 and US 2011/0053990, and specifically for compounds of Formula II are set forth in the Examples below and generalized in Schemes 1-9.
[0000]
[0000] wherein R 3 , r, and s are as defined above.
[0643] The mono-BOC protected amine of the formula B can be obtained from commercial sources or prepared according to the procedures outlined in Krapcho et al. Synthetic Communications 1990, 20, 2559-2564. Compound A can be amidated with the amine B using a coupling reagent such as DCC, CDI, EDC, or optionally with a tertiary amine base and/or catalyst, e.g., DMAP, followed by deprotection of the BOC group with acids such as TFA or HCl in a solvent such as CH 2 Cl 2 or dioxane to produce the coupled compound C. Activation of compound C with a coupling agent such as HATU in the presence of an amine such as DIEA followed by addition of a fatty acid of formula D affords compounds of the formula E. To those familiar in the art, compound A can be substituted with any other aryl, heteroaryl or heterocyclic carboxylic acid.
[0000]
[0000] wherein R, r, and s are as defined above.
[0644] The acylated amine of the formula F can be prepared using the procedures outlined in Andruszkiewicz et al. Synthetic Communications 2008, 38, 905-913. Compound A can be amidated with the amine F using a coupling reagent such as DCC, CDI, EDC, or optionally with a tertiary amine base and/or catalyst, e.g., DMAP, followed by deprotection of the BOC group with acids such as TFA or HCl in a solvent such as CH 2 Cl 2 or dioxane to produce the coupled compound G. Activation of compound G with a coupling agent such as HATU in the presence of an amine such as DIEA followed by addition of a fatty acid of formula D affords compounds of the formula H.
[0000]
[0000] wherein r and s are as defined above.
[0645] Compound A can be amidated with the corresponding amine I (where i=0, 1, 2 or 3) using a coupling reagent such as DCC, CDI, EDC, or optionally with a tertiary amine base and/or catalyst, e.g., DMAP, followed by deprotection of the BOC group with acids such as TFA or HCl in a solvent such as CH 2 Cl 2 or dioxane to produce the coupled compound J. Activation of compound J with a coupling agent such as HATU in the presence of an amine such as DIEA followed by addition of a fatty acid of formula D affords compounds of the formula K. Hydrolysis of the ester under basic conditions such as NaOH or LiOH produces the corresponding acid, which can be coupled with glycidol to afford compounds of the formula L.
[0000]
[0000] wherein r and s are as defined above.
[0646] The amine M can be prepared according to the procedures outlined in Dahan et al. J. Org. Chem. 2007, 72, 2289-2296. Compound A can be coupled with the amine M using a coupling reagent such as DCC, CDI, EDC, or optionally with a tertiary amine base and/or catalyst, e.g., DMAP, followed by deprotection of the BOC group with acids such as TFA or HCl in a solvent such as CH 2 Cl 2 or dioxane to produce the coupled compound N. Activation of compound N with a coupling agent such as HATU in the presence of an amine such as DIEA followed by addition of a fatty acid of formula D affords compounds of the formula O.
[0000]
[0000] wherein r and s are as defined above.
[0647] Compound A can be amidated with the commercially available amine P using a coupling reagent such as DCC, CDI, EDC, or optionally with a tertiary amine base and/or catalyst, e.g., DMAP, to afford compound Q. The BOC group in compound Q can be removed with acids such as TFA or HCl in a solvent such as CH 2 Cl 2 or dioxane and the resulting amine can be coupled with a fatty acid of formula D using a coupling agent such as HATU in the presence of an amine such as DIEA to afford compounds of the formula R. To those skilled in the art, the sulfur group in formula Q can be oxidized to the corresponding sulfoxide or sulfone using an oxidizing agent such as H 2 O 2 or oxone.
[0000]
[0000] wherein R 3 , r, and s are as defined above.
[0648] The amine T can be prepared from the commercially available diamine according to the procedures outlined in Dahan et al. J. Org. Chem. 2007, 72, 2289-2296. Compound A can be amidated with the amine T using a coupling reagent such as DCC, CDI, EDC, or optionally with a tertiary amine base and/or catalyst, e.g., DMAP, to afford compound U. The BOC group of compound U can be removed with acids such as TFA or HCl in a solvent such as CH 2 Cl 2 or dioxane and the resulting amine can be coupled with a fatty acid of formula D using HATU in the presence of an amine such as DIEA to afford compounds of the formula V. To those skilled in the art, the hydroxyl group in compound U can be further acylated or converted to an amino group by standard mesylation chemistry followed by displacement with sodium azide and hydrogenation over a catalyst such as Pd/C. The amine can be further acylated or alkylated, followed by the removal of the BOC group. The resulting amine can be coupled with a fatty acid of the formula D to afford compounds of the formula W.
[0000]
[0000] wherein r and s are as defined above.
[0649] Compound A can be amidated with the commercially available amine X using a coupling reagent such as DCC, CDI, EDC, optionally with a tertiary amine base and/or catalyst, e.g., DMAP to afford compound Y. The BOC group in compound Y can be removed with acids such as TFA or HCl in a solvent such as CH 2 Cl 2 or dioxane. The resulting amine can be coupled with a fatty acid of the formula D using a coupling agent such as HATU in the presence of an amine such as DIEA to afford compounds of the formula Z.
[0000]
[0000] wherein r and s are as defined above.
[0650] Compound A can be amidated with the commercially available cysteine methyl ester using a coupling reagent such as DCC, CDI, EDC, or optionally with a tertiary amine base and/or catalyst, e.g., DMAP, to afford compound AA. The commercially available maleimide derivative BB can be coupled with a fatty acid of the formula D using a coupling agent such as HATU or EDCI to afford compounds of the formula CC. Compound AA can be coupled to compounds of the formula CC in a solvent such as acetonitrile to afford compounds of the formula DD.
[0000]
[0000] wherein R 4 , a, r, and s are as defined above.
[0651] The commercially available amino acid esters EE can be coupled with a fatty acid of the formula D using a coupling agent such as EDCI or HATU, followed by alkaline hydrolysis of the methyl ester to afford compounds of the formula FF. Compounds of the formula FF can be coupled with the commercially available BOC-amino acid derivatives GG using a coupling agent such as EDCI or HATU. The BOC group can be removed by treatment with acids such as TFA or HCl to afford compounds of the formula HH which can then be coupled with compound A to afford compounds of the formula II.
EXAMPLES
[0652] The disclosure is further illustrated by the following examples, which are not to be construed as limiting this disclosure in scope or spirit to the specific procedures herein described. It is to be understood that the examples are provided to illustrate certain embodiments and that no limitation to the scope of the disclosure is intended thereby. It is to be further understood that resort may be had to various other embodiments, modifications, and equivalents thereof which may suggest themselves to those skilled in the art without departing from the spirit of the present disclosure and/or scope of the appended claims.
Example 1
Effect of Fatty Acid Derivatives on ApoA1 and ApoB Secretion in HepG2 Cells
[0653] Niacin has been reported to increase serum levels of HDL to LDL cholesterol in vivo. Similarly, niacin has been reported to increase the secretion of ApoA1 (Jin, F-Y. et al. Arterioscler. Thromb. Vasc. Biol. 1997, 17 (10), 2020-2028) while inhibiting the secretion of ApoB (Jin, F-Y. et al. Arterioscler. Thromb. Vasc. Biol. 1999, 19, 1051-1059) in the media supernatants of HepG2 cultures. Independently, DHA has been demonstrated to lower ApoB as well (Pan, M. et al. J. Clin. Invest. 2004, 113, 1277-1287) by a very different mechanism. Thus, the secretion of ApoA1 and ApoB from HepG2 cells possesses utility as a cell based read-out for niacin-DHA derivative small molecules.
[0654] HepG2 cells (ATCC) are seeded at 10,000 cells per well in 96 well plates. After adhering overnight, growth media (10% FBS in DMEM) is removed and cells are serum starved for 24 hours in DMEM containing 0.1% fatty acid free bovine serum albumin (Sigma). Cells are then treated with the compounds at 6 concentrations (2 fold dilutions starting at 100 μM). Niacin at 1.5 mM is used as a positive control. All treatments are performed in triplicate. Simultaneous with compound treatment, ApoB secretion is stimulated with addition of 0.1 oleate complexed to fatty acid free BSA in a 5:1 molar ratio. Incubation with compounds and oleate is conducted for 24 hours. Media supernatants are removed and ApoA1 and ApoB concentrations are measured using ELISA kits (Mabtech AB). ApoA1 is expressed as a percent increase over vehicle (0.1% ethanol) treated wells. Percent inhibition of ApoB secretion is determined by normalizing data to vehicle treated wells. For a given compound, an IC 50 (concentration at which 50% of ApoB secretion is inhibited) is determined by using a 4 parameter-fit inhibition curve model (Graph Pad Prism®). In each experiment, cell viability is determined using the ATPlite 1-Step kit (Perkin Elmer), such that compound effects due to cytotoxicity can be monitored.
Example 2
Effect of the Compounds of the Invention in the PCSK9 Assay
Cell Culture
[0655] HepG2 cells (from ATCC, Catalog no. HB-8065) were maintained in DMEM (Invitrogen) supplemented with 10% fetal bovine serum (Invitrogen). The day prior to the PCSK9 assay, cells are seeded in 96-well collagen coated plates at 25,000 cells/well.
Compound Preparation
[0656] The compounds of the invention were stored at −20° C. until used. The test article compound was dissolved in 100% ethanol to a 50 mM stock solution. This was then diluted in FBS to a final concentration of 1 mM. This solution was placed in a sonicating water bath for 30 minutes. Subsequent dilutions were then made in FBS supplemented with an equivalent volume of ethanol and mixed by vortexing.
PCSK9 Secretion Assay
[0657] HepG2 cells were seeded onto a collagen coated 96-well plate (Becton Dickinson, Catalog no. 35-4407) the day prior to the assay, as described above. The next day, the cell medium was removed, washed once with 1004 serum free DMEM to remove any residual PCSK9, and replaced with 904 of serum free DMEM. Ten microliters of each compound concentration prepared in FBS was then added. Each concentration of compound was tested in triplicate. The compound was incubated with the cells overnight for 16 hours. Following this incubation, 104 of AlamarBlue was added to each well and cells incubated for another 2 hours. The plates were then removed and AlamarBlue fluorescence was measured (excitation, 550 nm and excitation, 590 nm) to assess cell viability. Cell culture supernatant was then diluted 1:5 in 1:5 in 1×RDSP Calibrator Diluent and PCSK9 ELISA was then performed with 504 of this diluted sample, as per the manufacturer's instructions. The ELISA was measured on a Victor X5 multilabel plate reader (PerkinElmer) at an absorbance of 450 nm with background correction measured at 550 nm (The PCSK9 Elisa kits can be purchased from R&D System, Catalog no. DPC900).
[0658] The following 3 compounds were evaluated in this PCSK9 assay: N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (I-8), N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)benzamide (II-1) and (5Z,8Z,11Z,14Z,17Z)—N-(2-acetamidoethyl)icosa-5,8,11,14,17-pentaenamide (Compound A). As summarized in FIG. 1 , compounds I-8 and II-1 were active in this assay and both compounds showed significant lowering of PCSK9 at 25 and 50 μM. Compound A, with a simple acetate group instead of the aryl or heteroaryl group niacin, showed essentially no activity toward PCSK9 at the highest tested concentration of 50 μM.
[0659] Alternatively, an IC 50 could also be obtained when this type of assay was carried out using at least 6 different concentrations of the test compounds. Table 1 lists the IC 50 values for the compounds tested in this assay. In table 1, a ++ value denotes IC 50 of <25 μM; a + value denotes IC 50 that is >25 μM but <50 μM; a—value denotes IC 50 that is >50 μM.
[0660] FIG. 2 summarizes an experiment that demonstrates the synergy of the fatty acid niacin derivative in the same HepG2 assay. HepG2 cells were incubated with 10 μM of atorvastatin along with either compound I-8 or a combination of EPA and niacin. As shown in FIG. 2 , atorvastatin increases PCSK9 secretion. Compound I-8 decrease PCSK9 levels in a dose response manner to well below the atorvastatin level induced levels. The combination of EPA and niacin did not have a similar effect.
[0000]
TABLE 1
IC 50 in the PCSK9 assay
Compound
IC 50
I-2
++
I-7
++
I-8
++
I-13
+
I-14
++
I-19
++
I-21
++
I-22
++
I-23
++
I-25
+
I-26
+
I-27
++
I-28
++
I-29
++
I-30
+
I-31
++
I-32
++
I-33
++
I-34
++
I-41
++
I-42
−
I-48
++
I-49
+
I-59
−
I-60
−
I-61
−
I-64
+
II-1
+
II-7
−
II-8
−
II-9
+
II-10
−
II-11
−
II-33
++
II-34
++
II-36
++
II-39
++
V-2
+
V-8
++
VI-1
−
VI-2
+
VI-3
−
VI-4
−
VI-5
+
VI-6
+
VI-7
++
VII-1
++
VII-2
++
VII-3
++
VII-4
++
VII-5
++
VII-6
++
VII-7
++
VII-8
++
Compound
IC 50
VII-9
+
VII-10
++
VII-11
−
VII-12
−
VII-13
++
VII-14
+
VII-15
++
VII-16
+
VII-17
++
VII-19
++
VII-20
++
VII-21
++
VII-22
++
VII-23
++
VII-24
−
VII-25
++
VII-41
+
VII-42
++
III-1
−
III-2
−
III-3
++
Example 3
The Effect of Lowering Plasma Triglycerides after a High Fat Meal
[0661] In this experiment, healthy human volunteers are divided into 4 treatment groups. The first treatment group is a placebo group (n=6). The other three groups consists of the test compound, a fatty acid niacin conjugate, administered as a single oral dose at either 300 mg (n=6), 1000 mg (n=7) or 2000 mg (n=4). All subjects are given an NIH high fat breakfast in order to induce an elevated level of triglycerides (In a typical NIH high fat breakfast, 450 calories are derived from fat). The test compound is then administered as a single oral dose at the three indicated doses at three different time points: immediately following the high fat meal, 2 hours following the high fat meal and 4 hours following the high fat meal. At each of the time points, plasma triglyceride levels can be determined according to standard protocols. Test compound that lowers the plasma triglyceride level at these various time points is useful for the treatment of type I hyperlipoproteinemia and type 5 hyperlipoproteinemia.
Example 4
The Effect of the Compounds of the Invention on the Plasma Triglyceride Level of the Zucker Fa/Fa Rat Model of Dyslipidemia
[0662] Male Zucker rats (HsdHlr: Zucker-Lepr̂fa) between 8-10 weeks of age were purchased from Harlan and maintained on Purina Rodent Diet (5001) for the duration of the study. Animals were randomized and assigned to treatment arms based on body weight and plasma triglyceride (TG) levels (n=8). Inclusion criteria for the study include body weight >300 grams and fed TG levels in plasma >800 mg/dL. Dosing will be initiated on day 1 and continue through day 5. Dosing will be daily (qd) by oral gavage (po) for all treatment arms (Compound I-8 was administered orally at 4 different doses, 10, 30, 100 and 300 mg/kg; in addition, a combination of niacin/EPA in a ratio of 100/200 mg/kg was also employed). Body weights will be measured for all rats on days 1 through 5. On day 4, a blood sample (fed) will be collected from each rat, processed for plasma and stored at −80° C. Plasma triglyceride level was determined from commercial kits using standard protocols. FIG. 3 showed the dose dependent decrease of fed plasma triglyceride level upon oral administration of compound I-8. As shown in FIG. 3 , this effect could not be replicated by a simple combination of niacin and EPA. Because compound I-8 was able to lower fed plasma triglyceride, it is useful to treat dyslipidemia as well as other diseases such as type I hyperlipoproteinemia and type 5 hyperlipoproteinemia.
Example 5
The Effect of a Combination of Compound I-8 and Atorvastatin on Plasma Cholesterol and Other Lipids in ApoE3Leiden Mice
[0663] The study was conducted using female APOE*3Leiden mice (groups of each n=10) and one untreated reference control group on chow (n=5). To induce dyslipidemia, a high cholesterol Western type diet containing 1% cholesterol, 15% cacao butter, 40.5% sucrose and 1% corn oil (WTD) was fed to the mice for a total experimental period of 20 weeks (of which 4 weeks are a run-in period). To prevent oxidation of the test compound (I-8), 30 mg/kg alpha-tocopherol was added to the high cholesterol diets, i.e. also in the high cholesterol diet control.
[0664] In the first 4 weeks (run-in period), a pro-atherogenic state of dyslipidemia characterized by elevated plasma cholesterol levels (about 15-20 mM) was induced in all mice by feeding them an atherogenic diet containing 1% cholesterol. The mice were then separated into a control group (no treatment) and three treatment groups: i) compound I-8, ii) atorvastatin and iii) compound I-8+atorvastatin as as described below. The dyslipidemic mice were grouped on the basis of plasma cholesterol at t=0 assayed in 4 h fasting blood. Mice with low cholesterol after the run-in period were excluded so that homogenous experimental groups were obtained. A group of reference mice (n=5) remained on a chow diet during the complete study period (normolipidemic reference mice).
[0665] The doses of the test compounds were as follows:
Compound I-8: 0.75% w/w in diet. Atorvastatin: 0.0015% w/w in diet (to achieve about 20% reduction in plasma cholesterol). Alpha-tocopherol: 0.0030% w/w in diet
[0669] The test compounds, sufficient for approx. 3 kg of diet (i.e. 25 g of compound I-8), and alpha-tocopherol (>200 mg) were formulated before the start of the treatment period (t=0), by adding the test compounds to melted, hand warm cocoa butter and mixed for 5 min. This mix was then added to the master mix (containing the rest of the ingredients) and mixed thoroughly. The diet was frozen to −20° C. On the subsequent day, the diet was broken into small pellets (approx 5 g per piece) and freeze dried, and stored in vacuum sealed bags (approx 500 g) at −20° C. until use. The diets were refreshed daily and unused diet was discarded.
[0670] The following parameters were taken at the indicated timepoints (individually unless mentioned otherwise):
[0000] 1) Body weight at −4, 0, 2, 4 weeks
2) Food intake (g/day/mouse) at 0, 2, 4 weeks (per cage)
3) Plasma total cholesterol at −4, 0, 2, 4 weeks (individually)
4) Plasma triglycerides at −4, 0, 2, 4 weeks (individually)
5) Lipoprotein profiles at 0 (pool of all animals) and 4 weeks (cholesterol distribution over VLDL, LDL and HDL-sized particles, analysis on group level).
[0671] EDTA plasma was collected in weeks −4, 0, 2 and 4 weeks. Plasma cholesterol, plasma triglyceride levels and lipoprotein profiles were assayed immediately in fresh plasma. FIG. 4 shows the cholesterol level at t=2 weeks of treatment between the control group, the group treated with compound I-8, the group treated with atorvastatin, and the group treated with a combination of compound I-8 and atorvastatin. There was a statistically significant reduction of plasma cholesterol at t=2 weeks for groups treated with either compound I-8 and atorvastatin. The group treated with the combination of compound I-8 and atorvastatin showed a more substantial decrease in plasma cholesterol. FIGS. 5 and 6 show the plasma cholesterol and triglyceride levels respectively after 4 weeks of treatment. As shown in FIG. 5 , the reduction in plasma cholesterol level was maintained after 4 weeks of treatment across all treatment groups. Comparable level of cholesterol reduction was observed in groups treated with either compound I-8 or atorvastatin. A significant reduction in plasma cholesterol was observed in the groups treated with a combination of compound I-8 and atorvastatin.
[0672] FIG. 6 shows the corresponding plasma triglyceride levels in the same treatment groups after 4 weeks of treatment. ApoE*3 Leiden mice treated with compound I-8 showed a significant reduction in triglycerides after 4 weeks of treatment. In sharp contrast, ApoE*3 Leiden mice treated with atorvastatin failed to show a statistically significant change triglyceride level after 4 weeks of treatment. ApoE*3 Leiden mice treated with a combination of compound I-8 and atorvastatin showed a significant reduction in plasma triglycerides after 4 weeks of treatment.
Example 7
The Effect Administering Compound I-8 on Liver Weight of ApoE*3 Leiden Mice
[0673] The same experimental design used in example 6 was used. Two treatment groups were used (n=15). The control animals were kept on a Western type diet (WTD) consisting of 1% cholesterol, 15% cacao butter, 40.5% sucrose, and 1% corn oil. For the treatment group, compound I-8 was administered in the above WTD at a ratio of 7.5 g/kg. Animals were maintained on the WTD or treatment group for 16 weeks. At the conclusion of the study, plasma cholesterol and triglyceride levels were recorded, as well as the weight of the liver. There was a significant decrease in plasma cholesterol, triglyceride levels as well as liver weight in the treatment group. After 16 weeks of treatment, the cholesterol level of the treatment group was 420 mg/dL, compared with a level of 750 mg/dL for the control group; the triglyceride level was 110 mg/dL, compared with a level of 160 mg/dL for the control group. The statistically significant drop in liver weight is shown in FIG. 7 .
Compounds
[0674] The following non-limiting compound examples serve to illustrate further embodiments of the fatty acid niacin derivatives. It is to be understood that any embodiments listed in the Examples section are embodiments of the fatty acid niacin derivatives and, as such, are suitable for use in the methods and compositions described above.
Example 8
Preparation of N-(2-(4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamidoethyl)nicotinamide (I-7)
[0675]
[0676] In a typical run, nicotinic acid (2.0 g, 16.2 mmol) was taken up in CH 2 Cl 2 (20 mL) along with oxalyl chloride (1.4 mL, 16.2 mmol). After a few drops of DMF were added, the reaction mixture was stirred at room temperature until all the solids had dissolved and all gas evolution had ceased (1 h). This freshly prepared solution of the acid chloride was added dropwise at 0° C. to a solution containing tert-butyl 2-aminoethylcarbamate (2.6 g, 16.2 mmol) and Et 3 N (3.4 mL, 24.2 mmol) in CH 2 Cl 2 (200 mL). The resulting reaction mixture was warmed to room temperature and stirred for 2 h. It was then washed with brine, dried over Na 2 SO 4 , filtered and concentrated under reduced pressure. Purification by silica gel chromatography (CH 2 Cl 2 ) afforded tert-butyl 2-(nicotinamido)ethylcarbamate (3.1 g, 74%).
[0677] tert-Butyl 2-(nicotinamido)ethylcarbamate (3.1 g, 11.7 mmol) was taken up in 25% TFA in CH 2 Cl 2 (10 mL). The resulting reaction mixture was allowed to stand at room temperature for 1 h. At this point, a considerable amount of precipitate formed and the clear filtrate was removed. The remaining solids were dried to afford of the TFA salt of N-(2-aminoethyl)nicotinamide (1.6 g).
[0678] The TFA salt of N-(2-aminoethyl)nicotinamide (5.0 mmol) was taken up in CH 3 CN (20 mL) along with (4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenoic acid (5.0 mmol), HATU (5.5 mmol) and DIEA (15 mmol). The resulting reaction mixture was stirred at room temperature for 2 h and diluted with EtOAc. The organic layer was washed with saturated aqueous NaHCO 3 , brine, dried over Na 2 SO 4 , filtered and concentrated under reduced pressure. Purification by silica gel chromatography (5% MeOH—CH 2 Cl 2 ) afforded N-(2-(4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamidoethyl)nicotinamide. MS calculated for C 30 H 41 N 3 O 2 : 475.32; found: [M+H] + 476.
Example 9
Preparation of N-(2-(5Z,8Z,11Z,14Z,17Z)-eicosa-5,8,11,14,17-pentaenamidoethyl)nicotinamide (I-8)
[0679]
[0680] The TFA salt of N-(2-aminoethyl)nicotinamide (1.6 g, 5.7 mmol) was taken up in CH 3 CN (15 mL) along with (5Z,8Z,11Z,14Z,17Z)-eicosa-5,8,11,14,17-pentaenoic acid (1.7 g, 5.7 mmol), HATU (2.4 g, 6.3 mmol) and DIEA (3 mL, 17 mmol). The resulting reaction mixture was stirred at room temperature for 2 h and diluted with EtOAc. The organic layer was washed with saturated aqueous NaHCO 3 , brine, dried over Na 2 SO 4 , filtered and concentrated under reduced pressure. Purification by silica gel chromatography (5% MeOH—CH 2 Cl 2 ) afforded N-(2-(5Z,8Z,11Z,14Z,17Z)-eicosa-5,8,11,14,17-pentaenamidoethyl)nicotinamide (1.6 g, 62%). MS calculated for C 28 H 39 N 3 O 2 : 449.3; found: [M+H] + 450.
Example 10
Preparation of N-(2-(2-(2-(4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamidoethyl)disulfanyl)ethyl)nicotinamide (I-3)
[0681]
[0682] Cystamine dihydrochloride (1.0 g, 4.44 mmol) was dissolved in MeOH (50 mL). Triethylamine (1.85 mL, 3 eq) was added at room temperature, followed by dropwise addition of Boc 2 O (0.97 g, 4.44 mmol) as a solution in MeOH (5 mL). The resulting reaction mixture was stirred at room temperature for 3 h. It was then concentrated under reduced pressure and the resulting residue was taken up in 1M aqueous NaH 2 PO 4 (20 mL). The aqueous layer was washed with a 1:1 solution of pentane/EtOAc (10 mL), basified to pH 9 with 1M aqueous NaOH, and extracted with EtOAc. The combined organic layers were washed with brine, dried over Na 2 SO 4 , filtered and concentrated under reduced pressure to afford tert-butyl 2-(2-(2-aminoethyl)disulfanyl)ethylcarbamate (500 mg, 44%).
[0683] Separately, nicotinic acid (246 mg, 2.0 mmol) was taken up in CH 3 CN (10 mL) along with tert-butyl 2-(2-(2-aminoethyl)disulfanyl)ethylcarbamate (503 mg, 2.0 mmol), EDCI (422 mg, 2.2 mmol). The resulting reaction mixture was stirred at room temperature for 4 h and then diluted with EtOAc. The organic layer was washed with dilute aqueous NaHCO 3 , brine, dried over Na 2 SO 4 , filtered and concentrated under reduced pressure. Purification by silica gel chromatography (CH 2 Cl 2 ) afforded tert-butyl 2-(2-(2-(nicotinamido)ethyl)disulfanyl)ethylcarbamate (400 mg, 56%).
[0684] tert-Butyl 2-(2-(2-(nicotinamido)ethyl)disulfanyl)ethylcarbamate (200 mg, 0.56 mmol) was taken up in 25% TFA in CH 2 Cl 2 solution (5 mL) and allowed to stand at room temperature for 4 h. The reaction mixture was then concentrated under reduced pressure to afford the TFA salt of N-(2-(2-(2-aminoethyl)disulfanyl)ethyl)nicotinamide. This material was taken up in CH 3 CN (10 mL) along with (4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenoic acid (184 mg, 0.56 mmol), HATU (234 mg, 0.62 mmol) and DIEA (0.30 mL). The resulting reaction mixture was stirred at room temperature for 2 h. It was then diluted with EtOAc and washed successively with saturated aqueous NaHCO 3 and brine. The organic layer was dried over Na 2 SO 4 , filtered and concentrated under reduced pressure. Purification by silica gel chromatography (5% MeOH—CH 2 Cl 2 ) afforded (N-(2-(2-(2-(4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamidoethyl)disulfanyl)ethyl)nicotinamide (300 mg, 86%). MS calculated for C 32 H 45 N 3 O 2 S 2 : 567.3; found: [M+H] + 568.
Example 11
Preparation of N-(2-(2-(4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamidoethoxy)ethyl)nicotinamide (I-1)
[0685]
[0686] In a typical run, sodium hydroxide (400 mg, 10 mmol) was dissolved in MeOH (70 mL) and 2-(2-aminoethoxy)ethanamine dihydrochloride (1.0 g, 5.65 mmol) was added. The resulting reaction mixture was stirred at room temperature for 30 min. A solution containing Boc 2 O (740 mg, 3.40 mmol) in THF (15 mL) was then added dropwise, at room temperature, over a period of 15 min. The resulting reaction mixture was stirred at room temperature for 18 h. It was then concentrated under reduced pressure. The resulting residue was taken up in CH 2 Cl 2 (200 mL) and stirred vigorously at room temperature for 4 h. The mixture was filtered and the filtrate was concentrated under reduced pressure to afford tert-butyl 2-(2-aminoethoxy)ethylcarbamate (850 mg, 74%).
[0687] tert-Butyl 2-(2-aminoethoxy)ethylcarbamate (420, 2.06 mmol) was then taken up in CH 3 CN (20 mL) along with nicotinic acid (253 mg, 2.06 mmol) and EDCI (434 mg, 2.3 mmol). The resulting reaction mixture was stirred at room temperature for 18 h. It was then diluted with EtOAc (20 mL), washed with saturated aqueous NaHCO 3 , brine, dried over Na 2 SO 4 , filtered and concentrated under reduced pressure. The resulting residue was purified by silica gel chromatography (9:1 CH 2 Cl 2 /MeOH) to afford tert-butyl 2-(2-(nicotinamido)ethoxy)ethylcarbamate (280 mg, 44%). MS calculated for C 15 H 23 N 3 O 4 : 309.17; found: [M+H] + 310.
[0688] tert-Butyl 2-(2-(nicotinamido)ethoxy)ethylcarbamate (140 mg, 0.453 mmol) was taken up in 25% TFA in CH 2 Cl 2 (10 mL). The reaction mixture was allowed to stand at room temperature for 2 h and then concentrated under reduced pressure to afford the TFA salt of N-(2-(2-aminoethoxy)ethyl)nicotinamide. This material was then taken up in CH 3 CN (10 mL) along with (4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenoic acid (148 mg, 0.453 mmol), HATU (190 mg, 0.498 mmol) and DIEA (0.24 mL). The resulting reaction mixture was stirred at room temperature for 2 h. It was then diluted with EtOAc and washed successively with saturated aqueous NaHCO 3 and brine. The organic layer was dried over Na 2 SO 4 , filtered and concentrated under reduced pressure. Purification by silica gel chromatography (9:1 CH 2 Cl 2 /MeOH) afforded N-(2-(2-(4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamidoethoxy)ethyl)nicotinamide (75 mg, 31%). MS calculated for C 31 H 46 N 2 O 5 : 526.34; found: [M+H] + 527.
Example 12
Preparation of N-(2-((2-(4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamidoethyl)(methyl)amino)ethyl)nicotinamide (I-2)
[0689]
[0690] N1-(2-Aminoethyl)-N1-methylethane-1,2-diamine (5.0 g, 42.7 mmol) was dissolved in CH 2 Cl 2 (100 mL) and cooled to 0° C. A solution of Boc 2 O (0.93 g, 4.27 mmol) in CH 2 Cl 2 (10 mL) was then added dropwise at 0° C. over a period of 15 min. The resulting reaction mixture was stirred at 0° C. for 30 min and then warmed to room temperature. After stirring at room temperature for 2 h, the reaction mixture was diluted with CH 2 Cl 2 (100 mL). The organic layer was washed with brine (3×25 mL), dried over Na 2 SO 4 , filtered and concentrated under reduced pressure to afford tert-butyl 2-((2-aminoethyl)(methyl)amino)ethylcarbamate (1.1 g).
[0691] tert-Butyl 2-((2-aminoethyl)(methyl)amino)ethylcarbamate (400 mg, 1.84 mmol) was taken up in CH 3 CN (10 mL) along with nicotinic acid (227 mg, 1.84 mmol) and EDCI (353 mg, 2.02 mmol). The resulting reaction mixture was stirred at room temperature for 18 h and then diluted with EtOAc. The organic layer was washed with saturated aqueous NaHCO 3 , brine, dried over Na 2 SO 4 , filtered and concentrated under reduced pressure. The resulting residue was purified by silica gel chromatography (5% MeOH—CH 2 Cl 2 ) to afford tert-butyl 2-(methyl(2-(nicotinamido)ethyl)amino)ethylcarbamate (180 mg, 30%). MS calculated for C 16 H 26 N 4 O 3 : 322.2; found: [M+H] + 323.
[0692] tert-Butyl 2-(methyl(2-(nicotinamido)ethyl)amino)ethylcarbamate (90 mg, 0.279 mmol) was taken up in a 25% TFA in CH 2 Cl 2 solution (5 mL) and allowed to stand at room temperature for 3 h. The reaction mixture was concentrated under reduced pressure to afford the TFA salt of N-(2-((2-aminoethyl)(methyl)amino)ethyl)nicotinamide. This material was taken up in CH 3 CN (10 mL) along with (4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenoic acid (90 mg, 0.279 mmol), HATU (117 mg, 0.31 mmol) and DIEA (0.15 mL). The resulting reaction mixture was stirred at room temperature for 2 h. It was then diluted with EtOAc and washed successively with saturated aqueous NaHCO 3 and brine. The organic layer was dried over Na 2 SO 4 , filtered and concentrated under reduced pressure. Purification by silica gel chromatography (5% MeOH—CH 2 Cl 2 ) afforded N-(2-((2-(4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamidoethyl)(methyl)amino)ethyl)nicotinamide (30 mg, 20%). MS calculated for C 33 H 48 H 4 O 2 : 532.38; found: [M+H] + 533.
Example 13
Preparation of (2S,3R)-methyl 3-((S)-2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)propanoyloxy)-2-(nicotinamido)butanoate (I-9)
[0693]
[0694] L-Alanine methyl ester hydrochloride (0.85 g, 6.1 mmol) was taken up in CH 3 CN (20 mL) along with (4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenoic acid (2.0 g, 6.1 mmol), EDCI (1.3 g, 6.72 mmol) and DIEA (1.3 mL). The resulting reaction mixture was stirred at room temperature for 2 h. It was then diluted with EtOAc and washed with dilute aqueous NaHCO 3 and brine. The organic layer was dried over Na 2 SO 4 , filtered and concentrated under reduced pressure to afford (S)-methyl 2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)propanoate (2.0 g, 79%).
[0695] (S)-methyl 2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)propanoate (2.0 g, 4.8 mmol) was taken up in THF (8 mL) along with 5M aqueous NaOH (5 mL) and stirred vigorously at room temperature for 3 h. The reaction mixture was diluted with water and concentrated under reduced pressure. Enough 6N HCl was then added to adjust the pH to 2. The resulting mixture was extracted with EtOAc. The combined organic layers were dried over Na 2 SO 4 , filtered and concentrated under reduced pressure to afford (S)-2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)propanoic acid. This was taken up in CH 3 CN (15 mL) along with N-Boc-L-threonine methyl ester (1.11 g, 4.78 mmol), HATU (2.0 g, 5.3 mmol) and DIEA (1.2 mL). The resulting reaction mixture was stirred at room temperature for 6 h and diluted with EtOAc. The organic layer was washed with NaHCO 3 , brine, dried over Na 2 SO 4 , filtered and concentrated under reduced pressure. Purification by silica gel chromatography (CH 2 Cl 2 ) afforded (2S,3R)-methyl 2-(tert-butoxycarbonyl)-3-((S)-2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)propanoyloxy)butanoate (1.0 g).
[0696] (2S,3R)-methyl 2-(tert-butoxycarbonyl)-3-((S)-2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)propanoyloxy)butanoate (300 mg, 0.488 mmol) was taken up in 4M HCl in dioxane (2 mL) and allowed to stand at room temperature for 10 min. The reaction mixture was then diluted with EtOAc and concentrated under reduced pressure to afford the HCl salt of (2S,3R)-methyl 2-amino-3-((S)-2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)propanoyloxy)butanoate. This material was taken up in CH 3 CN (5 mL) along with nicotinic acid (60 mg, 0.488 mmol), HATU (204 mg, 0.54 mmol) and DIEA (0.25 mL, 1.46 mmol). The resulting reaction mixture was stirred at room temperature for 1 h and concentrated under reduced pressure. The resulting oily residue was purified by silica gel chromatography (9:1 CH 2 Cl 2 /MeOH) to afford (2S,3R)-methyl 3-((S)-2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)propanoyloxy)-2-(nicotinamido)butanoate (120 mg, 40%). MS calculated for C 36 H 49 N 3 O 6 : 619.36; found: [M+H] + 620.
Example 14
Preparation of (2S,3R)-methyl 3-((S)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)propanoyloxy)-2-(nicotinamido)butanoate (I-10)
[0697]
[0698] The same synthetic sequence outlined above for the preparation of (2S,3R)-methyl 3-((S)-2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)propanoyloxy)-2-(nicotinamido)butanoate was used, except that (5Z,8Z,11Z,14Z,17Z)-eicosa-5,8,11,14,17-pentaenoic acid (EPA) was used instead of DHA. MS calculated for C 34 H 47 N 3 O 6 : 593.35; found: [M+H] + 594.
Example 15
Preparation of (S)-methyl 6-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)-2-(nicotinamido)hexanoate (I-11)
[0699]
[0700] H-Lysine-(BOC)-OMe hydrochloride (500 mg, 1.68 mmol) was taken up in CH 3 CN (10 mL) along with nicotinic acid (207 mg, 1.68 mmol), EDCI (354 mg, 1.85 mmol) and DIEA (0.90 mL). The resulting reaction mixture was stirred at room temperature for 18 h and diluted with EtOAc. The organic layer was washed with dilute aqueous NaHCO 3 , brine, dried over Na 2 SO 4 , filtered and concentrated under reduced pressure. Purification by silica gel chromatography (CH 2 Cl 2 ) afforded (S)-methyl 6-(tert-butoxycarbonyl)-2-(nicotinamido)hexanoate (520 mg, 85%).
[0701] (S)-Methyl 6-(tert-butoxycarbonyl)-2-(nicotinamido)hexanoate (260 mg, 0.71 mmol) was taken up in 4M HCl in dioxane (2 mL) and allowed to stand at room temperature for 1 h. The reaction mixture was diluted with EtOAc and concentrated under reduced pressure to afford the HCl salt of (S)-methyl 6-amino-2-(nicotinamido)hexanoate. This material was taken up in CH 3 CN (5 mL) along with (4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenoic acid (233 mg, 0.71 mmol), HATU (297 mg, 0.78 mmol) and DIEA (0.4 mL). The resulting reaction mixture was stirred at room temperature for 2 h and diluted with EtOAc. The organic layer was washed with dilute aqueous NaHCO 3 , brine, dried over Na 2 SO 4 , filtered and concentrated under reduced pressure. Purification by silica gel chromatography (9:1 CH 2 Cl 2 /MeOH) afforded (S)-methyl 6-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenamido)-2-(nicotinamido)hexanoate (280 mg, 72%). MS calculated for C 35 H 49 N 3 O 4 : 575.37; found: [M+H] + 576.
Example 16
Preparation of N-(2-((5Z,8Z,11Z,14Z,17Z)—N-methylicosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (I-15)
[0702]
[0703] N-(2-((5Z,8Z,11Z,14Z,17Z)—N-Methylicosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide was prepared according to the procedures outlined in example 8, substituting the commercially available tert-butyl (2-aminoethyl)(methyl)carbamate for the diamine and EPA for the fatty acid component. MS calculated for C 29 H 41 N 3 O 2 : 463.32; found: [M+H] + 464.
Example 17
Preparation of N-((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)nicotinamide
[0704]
[0705] N-((1-((5Z,8Z,11Z,14Z,17Z)-Icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)nicotinamide was prepared according to the procedures outlined in example 8, substituting the commercially available tert-butyl 4-(aminomethyl)piperidine-1-carboxylate for the diamine and EPA for the fatty acid component. MS calculated for C 32 H 45 N 3 O 2 : 503.35; found: [M+H] + 504.
Example 18
Preparation of (5Z,8Z,11Z,14Z,17Z)—N-((1-nicotinoylpiperidin-4-yl)methyl)icosa-5,8,11,14,17-pentaenamide (I-29)
[0706]
[0707] The commercially available tert-butyl 4-(aminomethyl)piperidine-1-carboxylate (1 mmol) was taken up in 25 mL of CH 2 Cl 2 along with EPA (1 mmol) and EDC (1.1 mmol). The resulting reaction mixture was stirred at room temperature for 4 h and then washed with saturated NH 4 Cl, brine, dried (Na 2 SO 4 ) and concentrated under reduced pressure. The resulting residue was purified by silica gel chromatography (95% CH 2 Cl 2 , 5% MeOH) to afford tert-butyl 4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamidomethyl)piperidine-1-carboxylate. tert-Butyl 4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamidomethyl)piperidine-1-carboxylate (0.5 mmol) was taken up in 3 mL of 4 N HCl in dioxane and allowed to stir at room temperature for 15 min. The resulting reaction mixture was diluted with EtOAc and concentrated under reduced pressure to afford the HCl salt of (5Z,8Z,11Z,14Z,17Z)—N-(piperidin-4-ylmethyl)icosa-5,8,11,14,17-pentaenamide. This material was taken up in 20 mL of CH 2 Cl 2 along with nicotinic acid (0.5 mmol), HATU (1.1 mmol) and DIEA (0.75 mmol). The resulting reaction mixture was stirred at room temperature for 6 h. It was then washed with saturated NH 4 Cl, brine, dried (Na 2 SO 4 ) and concentrated under reduced pressure. The resulting residue was purified by silica gel chromatography (95% CH 2 Cl 2 , 5% MeOH) to afford (5Z,8Z,11Z,14Z,17Z)—N-((1-nicotinoylpiperidin-4-yl)methyl)icosa-5,8,11,14,17-pentaenamide. MS calculated for C 32 H 45 N 3 O 2 : 503.35; found: [M+H] + 504.
Example 19
Preparation of N-(((1R,4R)-4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)cyclohexyl)methyl)nicotinamide (I-41)
[0708]
[0709] N-(((1R,4R)-4-((5Z,8Z,11Z,14Z,17Z)-Icosa-5,8,11,14,17-pentaenamido)cyclohexyl)methyl)nicotinamide was prepared according to the procedures outlined in example 8, using the commercially available tert-butyl ((1r,4r)-4-(aminomethyl)cyclohexyl)carbamate as the diamine. MS calculated for C 33 H 47 N 3 O 2 : 517.37; found: [M+H] + 518.
Example 20
Preparation of N—((S)-1-(4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperazin-1-yl)-3-methyl-1-oxobutan-2-yl)nicotinamide (I-51)
[0710]
[0711] To a suspension of (S)-2-(((benzyloxy)carbonyl)amino)-3-methylbutanoic acid (25.1 g, 100 mmol), EDC.HCl (23 g, 120 mmol), HOBt (16.2 g, 120 mmol) and Boc-piperazine (18.6 g, 100 mmol) in 250 mL of CH 2 Cl 2 was added Et 3 N (20.2 g, 200 mmol) at 0° C. The resulting reaction mixture was stirred at room temperature for 18 h and then diluted with CH 2 Cl 2 (250 mL). The organic layer was washed with saturated aq. NH 4 Cl (3×200 mL) and brine (3×200 mL). The organic layer was dried over anhydrous Na 2 SO 4 and concentrated under reduced pressure. The resulting residue was purified by silica gel chromatography (EtOAc/pentanes) to afford 20.0 g of (S)-tert-butyl 4-(2-(((benzyloxy)carbonyl)amino)-3-methylbutanoyl)piperazine-1-carboxylate (48%).
[0712] A mixture of (S)-tert-butyl 4-(2-(((benzyloxy)carbonyl)amino)-3-methylbutanoyl)piperazine-1-carboxylate (20.0 g, 47.7 mmol) and 10% Pd/C (2 g) in MeOH (150 mL) was stirred under 1 atmosphere of H 2 at room temperature for 18 h. The solution was filtered through Celite, and the filtrate was concentrated under reduced pressure to afford (S)-tert-butyl 4-(2-amino-3-methylbutanoyl)piperazine-1-carboxylate (11.4 g, 40 mmol) as a white solid (84%). N—((S)-1-(4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperazin-1-yl)-3-methyl-1-oxobutan-2-yl)nicotinamide was then prepared using the procedures outlined in example 8, substituting (S)-tert-butyl 4-(2-(((benzyloxy)carbonyl)amino)-3-methylbutanoyl)piperazine-1-carboxylate for the diamine component. MS calculated for C 35 H 46 N 4 O 3 : 574.39; found: [M+H] + 575.
Example 21
Preparation of N-(4-(4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperazine-1-carbonyl)phenyl)nicotinamide (I-56)
[0713]
[0714] To a suspension of 4-nitrobenzoic acid (16.7 g, 100 mmol), EDC.HCl (22.92 g, 120 mmol), HOBt (16.2 g, 120 mmol) and Boc-piperazine (18.6 g, 100 mmol) in 400 mL of CH 2 Cl 2 was added Et 3 N (20.2 g, 200 mmol) at 0° C. The resulting reaction mixture was stirred at room temperature for 18 h and then diluted with CH 2 Cl 2 (200 mL). The organic layer was washed with saturated aq.NH 4 Cl (3×200 mL) and brine (3×200 mL). The organic layer was dried over anhydrous Na 2 SO 4 and concentrated under reduced pressure. The resulting residue was purified by silica gel chromatography (EtOAc/pentanes) to afford 20 g of tert-butyl 4-(4-nitrobenzoyl)piperazine-1-carboxylate (60%).
[0715] A mixture of tert-butyl 4-(4-nitrobenzoyl)piperazine-1-carboxylate (20 g, 60 mmol) and 10% Pd/C (4 g) in MeOH (600 mL) was stirred under 1 atmosphere of H 2 at room temperature for for 18 h. The solution was filtered through Celite and the filtrate was concentrated under reduced pressure to afford 18 g of tert-butyl 4-(4-aminobenzoyl)piperazine-1-carboxylate as a white solid (100%).
[0716] N-(4-(4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperazine-1-carbonyl)phenyl)nicotinamide was then prepared according to the procedures outlined in example 8, substituting tert-butyl 4-(4-aminobenzoyl)piperazine-1-carboxylate for the diamine component. MS calculated for C 37 H 46 N 4 O 3 : 594.36; found: [M+H] + 595.
Example 22
Preparation of N-(2-(2-((5Z,8Z,11Z,14Z,17Z)—N-Methylicosa-5,8,11,14,17-pentaenamido)acetamido)ethyl)nicotinamide (I-57)
[0717]
[0718] The same procedures outlined in example 21 were used to prepare tert-butyl (2-(2-(methylamino)acetamido)ethyl)carbamate, substituting 2-(((benzyloxy)carbonyl)(methyl)amino)acetic acid and tert-butyl (2-aminoethyl)carbamate as the appropriate starting materials. N-(2-(2-((5Z,8Z,11Z,14Z,17Z)—N-Methylicosa-5,8,11,14,17-pentaenamido)acetamido)ethyl)nicotinamide was then prepared using tert-butyl (2-(2-(methylamino)acetamido)ethyl)carbamate according to the procedures outlined in example 18. MS calculated for C 31 H 44 N 4 O 3 : 520.34; found: [M+H] + 521.
Example 23
Preparation of N-((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)-N-methylnicotinamide (I-62)
[0719]
[0720] N-((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)nicotinamide (example 17) was used as the starting material.
[0721] To 0.4 mmol of N-((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)nicotinamide, was added 1 mL DMF, followed by 3.0 equivalents of 60% NaH and 1.3 equivalents of methyl iodide under Argon. The resulting reaction mixture was stirred at room temperature for 1 hour and then quenched with half-saturated NH 4 Cl. The mixture was diluted with ethyl acetate (100 mL). The organic layer was separated and washed with brine (3×10 mL), dried over Na 2 SO 4 and concentrated under reduced pressure. The resulting residue was purificed by silica gel chromatography (gradient elution from 0-10% methanol in dichloromethane) to afford N-((1-((5Z,8Z,11Z,14Z,17Z)-icosa-5, 8,11,14,17-pentaenoyl)piperidin-4-yl)methyl)-N-methylnicotinamide (95%). MS calculated for C 33 H 47 N 3 O 2 : 517.37; found: [M+H] + 518.
Example 24
Preparation of N-((4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-2-methylpyrimidin-5-yl)methyl)nicotinamide (I-64)
[0722]
[0723] A mixture of 2-cyanoacetamide (50 g, 595 mmol), pyridine (4.7 g, 60 mmol), and DMF (91 g, 1.26 mol) was cooled to −10° C. Then POCl 3 was to the cooled mixture dropwise over a period of 2 hours. After the addition was completed, the reaction was poured into ice-water (2 L) and then enough 30% aqueous NaOH solution was added to adjust the pH=3. The resulting mixture was extracted with ethyl acetate (3×1 L). The combined organic layers were dried (Na 2 SO 4 ) and concentrated under reduced pressure to afford 45 g of 2-((dimethylamino)methylene)malononitrile (62%).
[0724] To an ice-cooled solution of sodium methoxide (15.9 g, 294 mmol) in methanol (150 mL) was added acetamidine hydrochloride (27.9 g, 292 mmol). The reaction mixture was stirred for 10 min and quickly filtered from precipitated sodium chloride. To the cooled filtrate was added a solution of 2-((dimethylamino)methylene)malononitrile (32.4 g, 223 mmol) in methanol (100 mL) over a period of 30 min. After stirring for 12 hrs at room temperature, the mixture was cooled to 0° C., and the precipitate was collected by filtration and dried to afford 29 g of 4-amino-2-methylpyrimidine-5-carbonitrile (97%).
[0725] In an autoclave the mixture of 4-amino-2-methylpyrimidine-5-carbonitrile (16 g, 119 mmol), modified Raney nickel (wet weight 15 g), and saturated methanol solution of ammonia (200 mL) was heated to 60° C. and stirred for 24 hrs at this temperature under 4 MPa of hydrogen pressure. The resulting reaction mixture was cooled to room temperature and filtered. The filtrate was concentrated under reduced pressure and the resulting residue was purified by silica gel chromatography (CH 2 Cl 2 /MeOH=30/1-10/1) to afford 14.8 g of 5-(aminomethyl)-2-methylpyrimidin-4-amine (90%).
[0726] 5-(Aminomethyl)-2-methylpyrimidin-4-amine (10 g, 72.5 mmol) was dissolved in 100 mL of CH 2 Cl 2 and 50 mL of methanol, and triethylamine (8 mL, 109 mmol) was added, followed by (Boc) 2 O. The resulting reaction mixture was stirred at room temperature for 12 hrs and then concentrated under reduced pressure. The resulting residue was purified by silica gel chromatography (CH 2 Cl 2 /MeOH=50/1) to afford 14.63 g of tert-butyl ((4-amino-2-methylpyrimidin-5-yl)methyl)carbamate (85%).
[0727] MS calculated for C 11 H 18 N 4 O 2 : 238.2; found: 239.1 [M+H]
[0728] 1 H NMR (300 MHz, DMSO_d6): δ 7.80 (s, 1H), 7.24-7.28 (t, J=11.1 Hz, 1H), 6.64 (s, 2H), 3.86-3.88 (d, J=6 Hz, 2H), 2.28 (s, 3H), 1.37 (s, 9H).
[0729] To 1 g (4.2 mmol) of tert-butyl ((4-amino-2-methylpyrimidin-5-yl)methyl)carbamate in 20 mL dichloromethane and 20 mL dimethylformamide, was added 0.9 equivalents (5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoic acid, 1.2 equivalents EDC, 1.2 equivalents HOBt and 6 equivalents triethylamine. The reaction was purged with nitrogen and run at room temperature. Upon completion, the crude reaction was washed with half-saturated NH 4 Cl, brine, dried over Na 2 SO 4 , concentrated under reduced pressure. The resulting residue was purified by silica gel chromatography using a mixture of CH 2 Cl 2 /MeOH (gradient elution, from 0-10% methanol in dichloromethane) to give N-((4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-2-methylpyrimidin-5-yl)methyl)nicotinamide in 40% isolated yield. This intermediate was dissolved in THF, to which 4 equivalents of 4N HCl in dioxane was added and reaction was stirred for 45 minutes. The reaction mixture was diluted with ethyl acetate and concentrated under reduced pressure to give (5Z,8Z,11Z,14Z,17Z)—N-(5-(aminomethyl)-2-methylpyrimidin-4-yl)icosa-5,8,11,14,17-pentaenamide hydrochloride.
[0730] To 1.15 mmol of (5Z,8Z,11Z,14Z,17Z)—N-(5-(aminomethyl)-2-methylpyrimidin-4-yl)icosa-5,8,11,14,17-pentaenamide hydrochloride in 2 mL dimethylformamide was added 1.1 equivalents niacin, followed by 1.2 equivalents HATU, and 6.0 equivalents diisopropylethylamine. The resulting reaction mixture was stirred at room temperature for 16 hours. The crude reaction mixture was washed with half-saturated NH 4 Cl, brine, dried over Na 2 SO 4 , and concentrated under reduced pressure. The resulting residue was purified by silica gel chromatography using a mixture of CH 2 Cl 2 /MeOH (gradient elution from 0-10% methanol in dichloromethane) to afford N-((4-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)-2-methylpyrimidin-5-yl)methyl)nicotinamide (30%). MS calculated for C 32 H 41 N 5 O 2 : 527.33; found: [M+H] + 528.
Example 25
Preparation of 2-fluoro-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide (VI-7)
[0731]
[0732] 2-Fluoro-N-(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenamido)ethyl)nicotinamide was prepared according to the procedures outlined in example 8, substituting 2-fluoronicotinic acid as the appropriate starting material. MS calculated for C 28 H 38 FN 3 O 2 : 467.29; found: [M+H] + 468.
Example 28
Preparation of N—((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)-5-methyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide (VII-4)
[0733]
[0734] N—((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)-5-methyl-4-oxo-5-phenyl-4,5-dihydrofuran-2-carboxamide was prepared according to the procedures outlined in example 8, substituting acifran as the appropriate starting material. MS calculated for C 36 H 46 N 2 O 4 : 570.35; found: [M+H] + 571.
Example 29
Preparation of 2-(((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)carbamoyl)-5-methylpyrazine 1-oxide (VII-12)
[0735]
[0736] 2-(((S)-1-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoyl)pyrrolidin-3-yl)carbamoyl)-5-methylpyrazine 1-oxide was prepared according to the procedures outlined in example 8, substituting acipimox as the appropriate starting material. MS calculated for C 30 H 42 N 4 O 4 : 506.33; found: [M+H] + 507.
Example 30
Preparation of (5Z,8Z,11Z,14Z,17Z)—N—((S)-1-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanoyl)pyrrolidin-3-yl)icosa-5,8,11,14,17-pentaenamide (VII-28)
[0737]
[0738] (5Z,8Z,11Z,14Z,17Z)—N—((S)-1-(2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanoyl)pyrrolidin-3-yl)icosa-5,8,11,14,17-pentaenamide was prepared according to the procedures outlined in example 8, substituting 2-(4-(4-chlorobenzoyl)phenoxy)-2-methylpropanoic acid as the appropriate starting material. MS calculated for C 41 H 51 ClN 2 O 4 : 670.35; found: [M+H] + 671.
[0739] The present invention is not to be limited in scope by the specific embodiments disclosed in the examples which are intended as illustrations of a few aspects of the invention and any embodiments that are functionally equivalent are within the scope of this invention. Indeed, various modifications of the invention in addition to those shown and described herein will become apparent to those skilled in the art and are intended to fall within the scope of the appended claims. All patents, patent applications, and publications cited herein are hereby incorporated by reference in their entireties.
EQUIVALENTS
[0740] Those skilled in the art will recognize, or be able to ascertain, using no more than routine experimentation, numerous equivalents to the specific embodiments described specifically herein. Such equivalents are intended to be encompassed in the scope of the following claims.
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The invention relates to new methods of modulating cholesterol by inhibiting proprotein convertase subtilisin/kexin type 9 (PCSK9) with fatty acid derivatives; and new methods for treating or preventing a metabolic disease comprising the administration of an effective amount of a fatty acid derivative. The present invention is also directed to fatty acid bioative derivatives and their use in the treatment of metabolic diseases.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a U.S. National Stage Application under 35 U.S.C. §371 of International Application No. PCT/IB2013/050623, filed Jan. 24, 2013, which claims the benefit of and priority to French Patent Application No. 1250717, filed Jan. 25, 2012. Each of these applications is hereby incorporated by reference in its entirety.
BACKGROUND
The present invention relates to the control of the production of sulfites, of hydrogen sulfide and of acetaldehyde during alcoholic fermentation by yeasts.
Sulfur dioxide (SO 2 ) and its various forms in equilibrium in solution (HSO 3 − , SO 3 − ), collectively denoted sulfites, are used as additives in enology, principally to improve the conservation of wines, owing to its antioxidant and antibacterial properties. However, an excessive amount of sulfites in wine can lead to intolerances and allergies in certain consumers; they may also be prejudicial to its organoleptic qualities, given that they give, if there in excess, drying sensations. Excessive amounts of sulfites at the end of alcoholic fermentation can thus be disadvantageous when the wine producer wants to carry out malolactic fermentation. Lactic acid bacteria, responsible for this fermentation, are inhibited by low sulfite contents, and an excess delays the initiation of said fermentation. Hydrogen sulfide is also a metabolite formed by yeasts in fermentation which is prejudicial to the quality of wines when it is present in excess owing to the “rotten egg” or “reduced” tastes that it imparts.
It is therefore important to be able to optimize the amount of sulfites and of hydrogen sulfide in wines and during winemaking. A major difficulty in this context comes from the fact that part of the sulfites and of the hydrogen sulfide present in the wine comes from the fermentative metabolism of yeasts, where they constitute intermediates in the synthesis of sulfur-containing amino acids. Inorganic sulfate enters the cell by means of a sulfate permease. It is activated to give adenosylphosphosulfate (APS) by ATP-sulfurylase, then the APS is phosphorylated by adenosylphosphosulfate kinase to produce phosphoadenosylphosphosulfate (PAPS). The PAPS is then reduced to SO 2 by PAPS reductase. The SO 2 is reduced to H 2 S by sulfite reductase. Homocysteine, which is the precursor of sulfur-containing amino acids, is synthesized by reaction of H 2 S with O-acetylhomoserine, catalyzed by O-acetylhomoserine sulfhydrylase.
Since the amount of sulfites produced by yeasts during fermentation varies from one yeast strain to another, this complicates the control of the overall sulfite content. The same is true for hydrogen sulfide, the amount of which formed depends greatly on the yeast strain.
Another compound, the presence of which in wine above certain amounts is considered to be undesirable, is acetaldehyde. Acetaldehyde at too high a concentration gives wines “musty” notes which are considered to be negative. It is produced by yeasts during fermentation, and its production appears to correlate with the SO 2 content, and like that of the SO 2 , varies from one yeast strain to another.
Various approaches have been proposed for obtaining yeast strains producing reduced amounts of sulfites and/or of hydrogen sulfide.
PCT application WO 2008/115759 and PCT application WO 2009/046485, and also the publications by Cordente et al. (FEMS Yeast Res, 9, 446-59, 2009) and Linderholm et al. (Appl Environ Microbiol, 76, 7699-707, 2010), describe various mutations in the METS or MET10 genes (encoding the 2 catalytic subunits of sulfite reductase) which have the effect of reducing hydrogen sulfide production. Application WO 2009/030863 and the publication by Marullo et al. (FEMS Yeast Res, 7, 1295-306, 2007) describe various markers associated with characteristics of interest in enological yeasts. One of these markers (YOL083w) located on chromosome XV is associated with a reduced H 2 S production.
SUMMARY
The inventors have now identified alleles of two genes involved in sulfur metabolism in Saccharomyces , as being associated with a reduced production of SO 2 , of acetaldehyde and, in the case of one of these genes, of H 2 S.
The first of these genes is the SKP2 gene, located on chromosome XIV (nt 49397 to 51688 in the Saccharomyces genome database). The corresponding cDNA sequence and the corresponding polypeptide sequence (for the reference Saccharomyces cerevisiae S288C strain) are available in the GenBank database under the respective accession numbers NM_001183149.1 (GI:296147470) and NP_014088.1 (GI:6324018). SKP2 encodes a protein of F-box type which is involved in the stability of various sulfur metabolism proteins and in particular of adenosylphosphosulfate kinase responsible for the conversion of APS to PAPS. It has recently been shown (Yoshida et al., Yeast, 28, 109-21, 2011) that the inactivation of the SKP2 gene results in a stabilization of adenosylphosphosulfate kinase, and in an increase in the production of H 2 S and of SO 2 .
The inventors have identified, in the SKP2 gene, two mononucleotide polymorphisms which differentiate the JN10 strain from the JN17 strain: one in position 50 618 of chromosome XIV, where the JN10 strain has a G and the JN17 strain has an A, and the other in position 50 640 bp where the JN10 strain has a C, whereas the JN17 strain has a T. These polymorphisms are reflected by the changing of a valine for JN10, to isoleucine for JN17, at position 350 of the Skp2 protein (V350I), and also of a threonine in JN10 at position 357 of Skp2, to isoleucine in JN17 (T357I).
The SKP2 gene allele present in the JN17 strain had not been previously identified in any other strain of Saccharomyces . The cDNA sequence of this allele is indicated in the appended sequence listing under the number SEQ ID NO: 1, and the deduced polypeptide sequence under the number SEQ ID NO: 2.
The second gene is the MET2 gene, also located on chromosome XIV (nt 117349 to 118809, coordinates indicated in the Saccharomyces genome database (http:www.yeastgenome.org) on Dec. 27, 2011). The corresponding cDNA sequence and the corresponding polypeptide sequence (for the reference Saccharomyces cerevisiae strain S288C) are available in the GenBank database under the respective accession numbers NM_001183115.1 (GI:296147504) and NP_014122.1 (GI:6324052). MET2 encodes homoserine-O-acetyl transferase which catalyzes the conversion of homoserine to O-acetyl homoserine, which is then condensed with H 2 S to form homocysteine. It has been shown (Hansen & Kielland-Brandt, J Biotechnol, 50, 75-87, 1996) that the inactivation of the MET2 gene in Saccharomyces leads to an increase in the production of sulfites and of hydrogen sulfide.
The inventors have identified, in position 118 249 of chromosome XIV, a mononucleotide polymorphism which differentiates the MET2 genes of two Saccharomyces cerevisiae strains, one (JN10 strain) a strong producer of SO 2 , H 2 S and acetaldehyde under certain fermentation conditions, and the other (JN17 strain) a weak producer of these same compounds. The JN10 strain has a C whereas the JN17 strain has (like the reference strain S288C) a G, which leads to an amino acid change and the conversion of an arginine in the JN10 strain to glycine in the JN17 strain in position 301 of the Met2 protein (R301G).
A subject of the present invention is a method for obtaining a yeast strain of the Saccharomyces genus producing a lower amount of SO 2 , hydrogen sulfide and acetaldehyde than that produced by the parent strain from which it is derived, said method being characterized in that it comprises:
the selection of a parent strain containing an allele of the SKP2 gene, hereinafter known as SKP2 (350/357)X , encoding an Skp2 protein in which the amino acid in position 350 and/or the amino acid in position 357 is (are) other than an isoleucine or isoleucines, and/or an allele of the MET2 gene, hereinafter known as MET2 301X , encoding a Met2 protein in which the amino acid in position 301 is other than a glycine; the introduction, into said parent strain, of an allele of the SKP2 gene, hereinafter known as SKP2 (350/357)I , encoding an Skp2 protein in which the amino acid in position 350 and/or the amino acid in position 357 is (are) an isoleucine or isoleucines, and/or of an allele of the MET2 gene, hereinafter known as MET2 301G , encoding a Met2 protein in which the amino acid in position 301 is a glycine.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the impact of allelic change on the formation of SO 2 (A), of H 2 5 (B) and of acetaldehyde (C) for the JN10 MET2 JN17 and JN17 MET2 JN10 strains and the corresponding parent JN10 and JN17 strains.
FIG. 2 illustrates the formation of SO 2 (A), of H 2 S (B) and of acetaldehyde (C) for the diploid strains JN17/JN10skp2□::HPH and JN10/JN17skp2□::HPH, which have just one functional allele of SKP2 (respectively the SKP2 JN17 allele and the SKP2 JN10 allele). And the corresponding parent JN10 and JN17 strains.
FIG. 3 illustrates the formation of SO 2 (A), of H 2 S (B) and of acetaldehyde (C) for haploid derivatives ( 4 th backcross spores 1 to 4 ) having the following allele combinations: SKP 2 JN17 /MET 2 JN17 ; SKP 2 JN10 /MET2 JN17 ; SKP 2 JN17 /MET JN10 ; SKP 2 JN10 /MET 2 JN10 on virtually identical genetic backgrounds.
For example, if the parent strain contains an SKP2 (350/357)X allele and a MET2 301G allele, it will be possible to introduce herein an SKP2 (350/357)I allele. Conversely, if the parent strain contains an SKP2 (350/357)I allele and a MET2 301X allele, it will be possible to introduce herein a MET2 301G allele. If the parent strain contains an SKP2 (350/357)X allele and a MET2 301X allele, it is possible to introduce herein either an SKP2 (350/357)I allele or a MET2 301G allele. Preferably, it will be chosen to introduce herein both an SKP2 (350/357)I allele and a MET2 301G allele.
DETAILED DESCRIPTION
In the context of the disclosure of the present invention, the name “SKP2 (350/357)I allele” encompasses: an allele (more specifically known as SKP2 350I/357X allele) encoding an Skp2 protein in which the amino acid in position 350 is an isoleucine and the amino acid in position 357 is other than an isoleucine; an allele (more specifically known as SKP2 350X/357I allele) encoding an Skp2 protein in which the amino acid in position 350 is other than an isoleucine; an allele (more specifically known as SKP2 350I/357I allele) in which the amino acid in position 350 and the amino acid in position 357 are both isoleucines, the latter allele being particularly preferred.
According to one preferred embodiment of the present invention, said parent strain contains an allele of the SKP2 gene, hereinafter known as SKP2 350V/357T , encoding an Skp2 protein in which the amino acid in position 350 is a valine and/or the amino acid in position 357 is a threonine, and/or an allele of the MET2 gene, hereinafter known as MET2 301R , encoding a Met2 protein in which the amino acid in position 301 is an arginine.
Advantageously, said yeast strain belongs to the Saccharomyces cerevisiae species.
The SKP2 (350/357)I allele and/or the MET2 301G allele can be introduced into the parent strain by various methods, well known in themselves to those skilled in the art. They can be introduced, for example, by crossing with a strain which has the desired SKP2 (350/357)I allele and/or MET2 301G allele, and selection from the descendants of this cross, of those to which said allele has been transmitted.
The SKP2 (350/357)I allele and/or the MET2 301G allele can also be introduced by replacement of the initial allele (respectively SKP2 (350/357)X and MET2 301X ) or in addition to said allele, using conventional genetic engineering techniques (cf. for example AMBERG et al., Methods in yeast genetics: a Cold Spring Harbor Laboratory course manual, Cold Spring Harbor Laboratory Press, 2005).
If the method in accordance with the invention is carried out using a haploid parent strain carrying the SKP2 (350/357)X allele, the introduction, into said strain, of a copy of the SKP2 (350/357)I allele by crossing produces a heterozygous SKP2 (350/357)X /SKP2 (350/357)I strain, producing an amount of sulfites, hydrogen sulfide and acetaldehyde which is lower than that produced by the parent strain from which it is derived. It is also possible to obtain haploid descendants of this strain which have the SKP2 (350/357)I allele and therefore produce low amounts of sulfites, of hydrogen sulfide and of acetaldehyde. By means of the series of backcrosses between descendants having the SKP2 (350/357)I allele and the parent strain, it is thus possible to obtain a strain with a genome close to that of the parent strain, having acquired the SKP2 (350/357)I allele and producing low amounts of sulfites, of hydrogen sulfide and of acetaldehyde. Likewise, if the method in accordance with the invention is carried out using a parent strain carrying the MET2 301X allele, the crossing of said strain with a strain having the MET2 301G allele produces a heterozygous MET2 301X /MET2 301G strain, producing an amount of sulfites, of hydrogen sulfide and of acetaldehyde which is lower than that produced by the parent strain from which it is derived. It is also possible, as in the case of SKP2, to obtain haploid descendants of this strain having the MET2 301G allele, and by means of backcrosses with the parent strain, to obtain a strain having the MET2 301G allele on the genetic background of the parent strain.
The subject of the present invention is also an isolated polynucleotide encoding the Skp2 protein of sequence SEQ ID NO: 2, which corresponds to the SKP2 350I/357I allele.
According to one preferred embodiment of the present invention, this polynucleotide is defined by the sequence SEQ ID NO: 1.
This polynucleotide can be used, in the context of the method in accordance with the invention described above, to introduce the SKP2 350I/357I allele into a yeast strain.
A subject of the present invention is also a nucleic acid vector containing a polynucleotide of sequence SEQ ID NO: 1, or a fragment thereof containing at least the region 1045-1075 of SEQ ID NO: 1.
Said vector may be any type of vector usable in yeast, in particular in Saccharomyces . Such vectors are well known in themselves. Use may, for example, be made of extrachromosomal replicating vectors, such as the Yep vectors or the Yrp vectors. Use may also be made of integrating vectors such as the Yip vectors.
In the context of an integrating vector, the polynucleotide of sequence SEQ ID NO: 1, or said fragment, is flanked upstream and downstream by sequences of at least 20 bp, preferably of 40 to 60 bp, which are homologues to those flanking the SKP2 gene or the region 1045-1075 of said gene in the strain into which it is desired to introduce the SKP2 350I/357I allele.
The DNA fragment containing the sequence SEQ ID NO: 1, or at least the region 1045-1075 of SEQ ID NO: 1, will be optionally combined with a marker gene (gene encoding a protein which confers resistance to an inhibitor or gene which makes it possible to complement a mutation responsible for an auxotrophy of the recipient strain) facilitating the selection of the clones having acquired the fragment by transformation.
A subject of the present invention is also a method for evaluating the capacity of a strain of Saccharomyces , preferably of Saccharomyces cerevisiae , to produce SO 2 , hydrogen sulfide and acetaldehyde, characterized in that it comprises:
genotyping of said strain for the SKP2 gene, and the detection of the presence of an SKP2 (350/357)X allele and in particular of the SKP2 350V/357T allele, and/or of an SKP2 (350/357)I allele, and in particular of the SKP2 350I/357I allele; and/or the genotyping of said strain for the SKP2 gene, and the detection of the presence of an SKP2 (350/357)X allele and in particular of the SKP2 350V/357T allele, and/or of an SKP2 (350/357)I allele, and in particular of the SKP2 350I/357I allele.
A subject of the present invention is also reagents for carrying out the genotyping method in accordance with the invention.
These reagents comprise in particular:
allele-specific oligonucleotide probes for differentiating the SKP2 350V/357T allele from an SKP2 (350/357)I allele, and in particular from the SKP2 350I/357I allele, or for differentiating the MET2 301R allele from the MET2 301G allele, by hybridizing selectively with one or other of the alleles to be differentiated; specific primers for differentiating the SKP2 350V/357T allele from an SKP2 (350/357)I allele, and in particular from the SKP2 350I/357I allele, or for differentiating the MET2 301R allele from the MET2 301G allele, and also kits of primers containing at least one specific primer in accordance with the invention. Generally, these kits of primers comprise a primer specific for each allele to be detected, and a common primer, capable of hybridizing, under the same amplification conditions, with all the alleles of the gene concerned.
Probes in accordance with the invention for differentiating the SKP2 350V/357T allele from an SKP2 (350/357)I allele, and in particular from the SKP2 350I/357I allele, can for example be made up of fragments of 15 to 30 bp of the sequence: CTAGAAAATGTAACGRTAGACACCGAATCGCTAGATAYTCCAATGGAATTCTT (SEQ ID NO: 4, where A, T, C, G, R and Y have their usual meaning in the IUPAC code), said fragments containing at least the locus of the G/A polymorphism, or at least the locus of the C/T polymorphism, and where appropriate the 2 polymorphic loci of said sequence, or made up of the sequences complementary thereto.
The probes in which R=G, and also the probes in which Y═C, can hybridize selectively with the SKP2 350V/357T allele, while the probes in which R=A and those in which Y=T can hybridize selectively with an SKP2 (350/357)I allele, and in particular the SKP2 350I/357I allele.
Probes in accordance with the invention for differentiating the MET2 301R allele from the MET2 301G allele can for example be made up of fragments of 15 to 30 bp of the sequence: ATTTCTGGGCAAAAASGTCAAAGCGTGGTGT (SEQ ID NO: 3, where A, T, C, G and S have their usual meaning in the IUPAC code), said fragments containing the locus of the CIG polymorphisms of said sequence, or made up of the sequences complementary thereto. The probes in which S═C can hybridize selectively with the MET2 301R allele, while the probes in which S=G can hybridize selectively with the MET2 301G allele.
Specific primers in accordance with the invention for differentiating SKP2 350V from SKP2 350I can for example be made up of fragments of 15 to 30 bp of the sequence SEQ ID NO: 4 containing at least the locus of the G/A polymorphism or the sequence complementary thereto. The primers in which R=G can be used for the selective amplification of SKP2 350V , while the primers in which R=A can be used for the selective amplification of SKP2 350I .
Specific primers in accordance with the invention for differentiating SKP2 357T from SKP2 357I can for example be made up of fragments of 15 to 30 bp of the sequence SEQ ID NO: 4 containing at least the locus of the C/T polymorphism, or the sequences complementary thereto.
The primers in which Y═C can be used for the selective amplification of SKP2 357T and those in which Y=T can be used for the selective amplification of SKP2 357I .
According to one preferred embodiment of a kit of primers in accordance with the invention for differentiating the SKP2 350V/357T allele from an SKP2 (350/357)I allele, it comprises a pair of specific primers for differentiating SKP2 350V from SKP2 350I , and a pair of specific primers for differentiating SKP2 357T from SKP2 357I .
Specific primers in accordance with the invention for differentiating the MET2 301R allele from the MET2 301G allele can for example be made up of fragments of 15 to 30 bp of the sequence SEQ ID NO: 3 containing at least the locus of the C/G polymorphism in said sequence, or made up of the sequences complementary thereto. The primers in which S═C can be used for the selective amplification of the MET2 301R allele, while the primers in which S=G can be used for the selective amplification of the MET2 301G allele.
Common primers which can be used in combination with the specific primers for differentiating the MET2 301R allele from the MET2 301G allele in the kits of primers in accordance with the invention can for example be made up of fragments of 15 to 30 bp of the following sequence: ATGTTATGCCTGAGGTATGTGTGGTATCTA (SEQ ID NO: 5, where A, T, C and G have their usual meaning in the IUPAC code), or made up of the sequences complementary thereto.
Common primers which can be used in combination with the specific primers for differentiating SKP2 350V from SKP2 350I and/or with the specific primers for differentiating SKP2 357T from SKP2 357I in the kits of primers in accordance with the invention can for example be made up of fragments of 15 to 30 bp of the following sequence: AGTCCACTACAAAAAGTCATTTATTTTTGC (SEQ ID NO: 6, where A, T, C and G have their usual meaning in the IUPAC code), or made up of the sequences complementary thereto.
The present invention will be understood more clearly from the further description which follows, which refers to nonlimiting examples illustrating the effects of the alleles of the MET2 and SKP2 genes on the production of SO 2 , of hydrogen sulfide and of acetaldehyde.
THE EXAMPLES
EXAMPLE 1
Effect of the Alleles of the MET2 Gene on the Production of SO 2 , of Hydrogen Sulfide and of Acetaldehyde
The Saccharomyces cerevisiae JN10 strain (strong producer of SO 2 , H 2 S and acetaldehyde) has a MET2 gene allele which encodes a Met2 protein in which the amino acid in position 301 is an arginine, whereas the JN17 strain (weak producer of these same compounds) has a MET2 gene allele encoding a Met2 protein in which the amino acid in position 301 is a glycine.
The impact of the replacement of the MET2 allele of JN10 (MET2 JN10 ) with that of JN17 (MET2 JN17 ), or conversely that of the replacement of the MET2 allele of JN17 with that of JN10, were evaluated.
Firstly, the initial MET2 JN10 or MET2 JN17 allele was deleted and replaced with a cassette containing a geneticin-resistance gene (KANMX4), according to the method described by Wach et al. (Yeast, 10, 1793-808, 1994). The transformed cells are selected on the basis of their resistance to the antibiotic, and of their methionine auxotrophy.
The MET2 JN17 allele amplified from the genomic DNA of the JN17 strain was then introduced, as a replacement for the geneticin-resistance cassette, into the JN10 strain, and vice versa, the MET2 JN10 allele amplified from the genomic DNA of the JN10 strain was introduced, as a replacement for the geneticin-resistance cassette, into the JN17 strain. The transformed strains are selected on the basis of the restoration of their methionine prototrophy.
The impacts of the allelic change on the formation of SO 2 , of H 2 S and of acetaldehyde were evaluated during alcoholic fermentations under enological conditions.
The results are represented in FIG. 1 . A: production of SO 2 ; B: production of H 2 S; C: production of acetaldehyde.
The replacement of the MET2 JN10 allele with the MET2 JN17 allele in the JN10 strain (JN10-MET2 JN17 strain) leads to a reduction in the concentration of SO 2 formed of approximately 40%. Likewise, the production of H 2 S is significantly reduced, 1 on a scale ranging from 0 to 2. The acetaldehyde level is also decreased by close to 40%. The reverse allelic replacement (MET2 JN10 allele on the genetic background of the JN17 strain: JN17-MET2 JN10 strain) has no impact on the production of SO 2 , nor on that of acetaldehyde; on the other hand, an increase in the production of H 2 S is observed compared with the JN17 parental strain.
EXAMPLE 2
Effect of the Alleles of the SKP2 Gene in the Production of SO 2 , of Acetaldehyde and of Hydrogen Sulfide
The SKP2 gene allele present in the Saccharomyces cerevisiae JN10 strain) (SKP2 JN10 ) encodes an Skp2 protein in which the amino acid in position 350 is a valine and the amino acid in position 357 is a threonine, whereas the allele present in the JN17 strain (SKP2 JN17 ) encodes an Skp2 protein in which the amino acids in positions 350 and 357 are isoleucines.
The impact of the allelic form of the SKP2 gene (SKP2 JN10 or SKP2 JN17 ) was evaluated via the construction of hemizygotes. The allelic replacement was in fact a method that was more difficult to carry out than in the case of the MET2 gene since the inactivation of the SKP2 gene results only in a delay of growth on minimum medium (Yoshida et al., 2011, mentioned above), this being a phenotype which, contrary to the methionine auxotrophy observed in the case of the MET2 gene, is not easily usable as a selectable marker.
Firstly, the SKP2 gene was inactivated in each of the JN10 and JN17 parental strains, by insertion of the HPH cassette which confers resistance to hygromycin B, so as to obtain respectively the JN10skp2Δ::HPH strains and the JN17skp2Δ::HPH strain. The JN10skp2Δ::HPH strain was then crossed with the JN17 strain, and the JN17skp2Δ::HPH strain was crossed with the JN10 strain, so as to obtain respectively the diploid strains JN17JN10skp2Δ::HPH and JN10/JN17skp2Δ::HPH, which have just one functional allele of SKP2 (respectively the SKP2 JN17 allele and the SKP2 JN10 allele). The production of sulfites, of acetaldehyde and of hydrogen sulfide by these strains which are hemizygote for SKP2 was evaluated under enological alcoholic fermentation conditions. The results are shown in FIG. 2 . A: production of SO 2 ; B: production of acetaldehyde; C: production of hydrogen sulfide.
It is noted that the production of SO 2 is lower in the hemizygote which has the SKP2 JN17 allele than in that which has the SKP2 JN10 allele. Likewise, the acetaldehyde content is lower when the SKP2 JN17 allele is active than when the allele is the one derived from the JN10 strain. Finally, the hydrogen sulfide content is lower when the SKP2 JN17 allele is active than when the allele is the one derived from the JN10 strain. The SKP2 JN17 allele therefore results in a reduction in SO 2 , acetaldehyde and hydrogen sulfide contents.
EXAMPLE 3
Combined Effect of the Alleles of the MET2 and SKP2 Gene of the Production of SO 2 and of Hydrogen Sulfide
The impact of a combination of the two allelic forms SKP2 JN17 and MET2 JN17 was evaluated by means of the construction of virtually isogenic strains having more than 93% of the genome of the JN10 strain, following cycles of backcrosses. The backcrosses consist of a series of successive crosses with the same strain (in this case JN10). The JN17 strain is first of all hybridized with the JN10 strain. The hybrid obtained, which has 50% of the genome of the JN10 strain and 50% of the genome of the JN17 strain and has the following genotype: SKP2 JN17 /SKP2 JN10 and MET2 JN17 /MET2 JN10 , is induced to sporulate. After sporulation, the haploid spores having the following genotype: SKP2 JN17 and MET2 JN17 are selected by allele-specific PCR for these two genes. These spores are then crossed again with the JN10 strain. A new hybrid is obtained, which has 75% of the genome of the JN10 strain and 25% of the genome of the JN17 strain and has the following genotype: SKP2 JN17 /SKP2 JN10 and MET2 JN17 /MET2 JN10 ; this hybrid is in turn induced to sporulate. The asci are dissected and a spore having the following genotype: SKP2 JN17 and MET2 JN17 is selected. The cycles of crossing/sporulation/selection of a spore are continued until derivatives having a very high percentage of the genome of the JN10 strain, in this case 93.25%, are obtained.
By sporulation of the diploid clones obtained during the final cycle, haploid derivatives (4th backcross spores 1 to 4) having the following allele combinations: SKP2 JN17 /MET2 JN17 ; SKP2 JN10 /MET2 JN17 ; SKP2 JN 17/MET2 JN10 ; SKP2 JN10 /MET2 JN10 on virtually identical genetic backgrounds are obtained. The production of SO 2 , of H 2 S and of acetaldehyde of these various derivatives was evaluated under enological alcoholic fermentation conditions. The results are shown in table I below, and by FIG. 3 .
TABLE I
Acetaldehyde
SKP2 allele
MET2 allele
SO 2 (mg/l)
H 2 S
(mg/l)
JN10
JN10
46
2
43
JN10
JN17
28
1
20
JN17
JN10
5
1
6
JN17
JN17
5
0
6
H 2 S scale:
0 = production not detected,
1 = medium production,
2 = strong production
It is noted that the SO 2 production of a derivative which has the two alleles SKP2 JN10 /MET2 JN10 is identical to that of the initial JN10 strain, whereas a derivative which has a combination of alleles of SKP2 JN10 /MET2 JN17 type produces intermediate amounts of SO 2 . Moreover, derivatives which have either the SKP2 JN17 /MET2 JN10 allele combination or the two alleles of the JN17 strain, SKP2 JN17 /MET2 JN17 , both produce very low amounts of SO 2 which are identical to those of the initial JN17 strain.
The effect of the various allele combinations on the production of acetaldehyde is identical to that observed on the production of SO 2 .
Furthermore, the derivatives which have the two alleles of the JN10 strain produce high amounts of H 2 S, identical to the JN10 parental strain, while the derivatives which have one of the two alleles of the JN17 strain, and therefore have the following genotypes: SKP2 JN17 /MET2 JN10 or SKP2 JN10 /MET2 JN17 , produce H 2 S in intermediate amounts and only the derivative which has the two alleles SKP2 JN17 /MET2 JN17 does not produce detectable H 2 S, in the same way as the JN17 parental strain.
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The present invention relates to the identification of alleles of the MET2 and SKP2 genes having the effect of reducing the production of sulphites, of hydrogen sulphide and of acetaldehyde by Saccharomyces , and to the use of these alleles in methods for controlling the production of these compounds during alcoholic fermentation.
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[0001] This application claims priority to U.S. Patent Appln. No. 62/055,504, filed Sep. 25, 2014, the contents of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to methods of curing composite structures. More particularly, the invention relates to systems, methods, and apparatuses for electrically curing composite structures.
BACKGROUND INFORMATION
[0003] Modern vehicles and wind turbines often contain structures fabricated from composite materials, such as, for example, carbon fiber composites. In use, such composite materials undergo tensile strain due to environmental factors such as: extreme wind-speeds, air-resistance, and in-flight vibration.
[0004] Using traditional methods, curing composite structures is costly and typically requires a significant amount of time and energy to provide the required heat for curing. A common curing process uses an autoclave, which typically applies a combination of high temperature and pressure to heat a desired composite structure. In an autoclave, the temperature within the chamber must first increase prior to the composite structure. The composite structure is then heated from the outer surfaces, and sufficient time must be allowed to ensure that the inner core reaches similar temperatures. Typically, curing large structures such as wing skins and wind turbine blades requires very large autoclaves. However, these conditions make it extremely expensive to cure such large structures, where investment in specialized equipment or transportation is needed to secure autoclaves (or ovens, in some cases, as discussed below) of sufficient size. As a result, a wide variety of problems arise including increased manufacturing costs due to the significant amount of time and energy required to heat an autoclave, and size restrictions on composite structures desired to be cured imposed by the dimensions of an autoclave chamber.
[0005] In an effort to save time and costs, the aerospace industry has moved toward out-of-autoclave (OOA) materials, which only require atmospheric pressure via a vacuum to cure. However, ovens are still used to provide heat during the curing process of OOA materials. While OOA materials provide advantages over using autoclaves, the ovens used to cure them still suffer from the above deficiencies. For example, like autoclaves, ovens cure composite structures by heating an intermediate material inside a size-restrictive chamber. Another drawback of traditional ovens and autoclaves is that preheating an autoclave or oven to the curing temperature requires a significant amount of time and energy, which reduces throughput while increasing manufacturing costs.
[0006] Thus, what is needed is an economical curing system capable of heating a composite structure without requiring the aforementioned autoclaves and ovens, without sacrificing quality, or strength, of the composite structure. Curing of these composite structures internally during manufacture may significantly reduce cost, improve strength, and remove size limitations of cured composites.
SUMMARY
[0007] The present disclosure endeavors to provide an electrical curing system for curing composite materials.
[0008] According to a first aspect of the present invention, a method of electrically heating a composite material comprises the steps of: electrically coupling a first lead to a first portion of said composite material; electrically coupling a second lead to a second portion of said composite material; and using an electric power source to pass electric current through said composite material from said first portion to said second portion, wherein passing said electric current through said composite material causes the temperature of said composite material increase to a predetermined temperature at a predetermined location.
[0009] According to a second aspect of the present invention, a composite structure is cured by the process of: electrically coupling a first lead to a first portion of said composite structure; electrically coupling a second lead to a second portion of said composite structure; and using an electric power source to pass electric current through said composite structure from said first portion to said second portion, wherein passing said electric current through said composite structure causes the temperature of at least a portion of said composite structure increase to a predetermined temperature.
[0010] In certain aspects, said predetermined temperature cures said predetermined location.
[0011] In certain aspects, said composite structure, or material, comprise two layers of pre-impregnated composite carbon fiber material having carbon nanotubes positioned between said two layers of pre-impregnated composite carbon fiber material.
[0012] In certain aspects, an electrical contact (e.g., copper tape) may be positioned at each of said first position and said second position to improve conductivity across the composite structure, or material.
[0013] In certain aspects, one or more resistors are electrically connected in parallel with said composite structure, or material, wherein said resistors may be cooled by vacuum exhaust.
[0014] In certain aspects, said composite structure, or material, is insulated from a tool using an insulated material.
[0015] In certain aspects, (1) said first portion is at a first distal end and the said second portion a second distal end, and/or (2) said predetermined location is at least the region defined between said first distal end and second distal end.
[0016] In certain aspects, the composite structure, or material, is (1) laid up using a low-cost tool to form a composite structure, and (2) cured while the composite structure is freestanding. The low-cost tool and the composite structure may have a same or a similar coefficient of thermal expansion
[0017] In certain aspects, the temperature of at least a portion of said composite structure is measured via a thermocouple positioned on a surface of said composite structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] These and other advantages of the present invention will be readily understood with reference to the following specifications and attached drawings wherein:
[0019] FIG. 1 illustrates an exemplary diagram of a vacuum cure setup.
[0020] FIG. 2 illustrates a table summarizing composite material samples to be tested.
[0021] FIG. 3 illustrates a circuit schematic of the composite material test set up.
[0022] FIG. 4 illustrates a chart of the effects of various tool materials on the composite material samples.
[0023] FIG. 5 illustrates a circuit model used to estimate the conductive heat transfer through the materials involved in the tooling process.
[0024] FIGS. 6 and 7 illustrate graphs of the recorded temperatures from samples with fibers oriented perpendicular to the flow of current.
[0025] FIG. 8 a shows the maximum temperature attained with the tested power supply.
[0026] FIG. 8 b illustrates temperature data from sample 2A.
[0027] FIG. 8 c illustrates temperature data from sample 3A.
[0028] FIG. 9 shows a direct force to displacement comparison between the oven and resistively cured samples.
[0029] FIG. 10 illustrates a chart of the short-beam shear test results for the oven and resistively cured samples.
[0030] FIG. 11 illustrates a chart of the short-beam strength comparison between the oven and resistively cured samples.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] Preferred embodiments of the present invention will be described hereinbelow with reference to the accompanying drawings. In the following description, certain well-known functions or constructions are not described in detail since they would obscure the invention in unnecessary detail. For this application the following terms and definitions shall apply:
[0032] The term “composite material” as used herein, refers to a material comprising an additive material and a matrix material. For example, a composite material may comprise a fibrous additive material (e.g., fiberglass, glass fiber (“GF”), carbon fiber (“CF”), aramid/para-aramid synthetic fibers, Fibre Metal Laminate (“FML”), etc.) and a matrix material (e.g., epoxies, polyimides, aluminum, titanium, and alumina, including, without limitation, plastic resin, polyester resin, polycarbonate resin, casting resin, polymer resin, thermoplastic, acrylic resin, chemical resin, and dry resin). Further, composite materials may comprise specific fibers embedded in the matrix material, while hybrid composite materials may be achieved via the addition of some complementary materials (e.g., two or more fiber materials) to the basic fiber/epoxy matrix.
[0033] The term “composite laminates” as used herein, refers to a type of composite material assembled from layers (i.e., a “ply”) of additive material and a matrix material. For example, layers of additive material, such as fibrous composite materials, may be joined to provide desired engineering properties, including in-plane stiffness, bending stiffness, strength, and coefficient of thermal expansion. Layers of different materials may be used, resulting in a hybrid laminate. The individual layers may be orthotropic (i.e., principal properties in orthogonal directions) or transversely isotropic (i.e., isotropic properties in the transverse plane) with the laminate then exhibiting anisotropic (i.e., variable direction of principal properties), orthotropic, or quasi-isotropic properties. Quasi-isotropic laminates exhibit isotropic (i.e., independent of direction) in-plane response, but are not restricted to isotropic out-of-plane (bending) response. Depending upon the stacking sequence of the individual layers, the laminate may exhibit coupling between in-plane and out-of-plane response. An example of bending-stretching coupling is the presence of curvature developing as a result of in-plane loading.
[0034] The term “composite structure” as used herein, refers to structures, parts, or components, fabricated, at least in part, using a composite material, including, without limitation, composite laminates.
[0035] Methods to reduce energy consumption during the manufacture of composite structures are constantly being explored. The mechanical properties of carbon fiber reinforced polymers have proven to be greatly superior to metal alloys for many applications. As explained above, the method of curing carbon fiber composites has remained largely unchanged over the last three decades. That is, ovens and autoclaves are traditionally used to provide the heat required to cure the composite structures. For example, in the aerospace industry, the autoclave process is commonly used to cure the matrix material in composite structures due to the high temperatures and pressures achievable. The combination of high temperature and pressure directly affects composite structure quality.
[0036] In an effort to save time and costs, the aerospace industry has moved toward OOA materials. While these materials only require atmospheric pressure via a vacuum to cure, they still require the use of an oven to provide heat during the curing process. However, as will be discussed below with reference to examples, the method of electrically curing a composite material (e.g., carbon fiber) requires significantly less energy and is capable of curing composites at a much faster rate since the path length for conduction would be greatly reduced. That is, without relying on conduction from the outside surface through the thickness, there is no need to wait for the oven/autoclave chamber to heat up. The result is a higher throughput and reduced costs (e.g., less time, less energy, fewer parts, etc.). Markets such as aerospace, whether military or commercial, and wind energy may utilize this method of curing carbon fiber composites, particularly where the size of large structures (e.g., wing skins or wind turbine blades) would prohibit the use of an oven or autoclave, or would make investment in such equipment incredibly expensive. The approach disclosed herein would allow for the rapid, inexpensive, and even on-site manufacture (e.g., where transportation becomes an issue, such as is the case of wind turbine blades) of composite structures.
[0037] As will be discussed in greater detail below, an improved curing system and method may be facilitated by electrically curing the composite structure. Indeed, a composite structure, as disclosed herein, may be resistively cured under an atmospheric-pressure vacuum bag without requiring an autoclave or oven. This OOA method is advantageous for a number or reasons. For example, an autoclave is expensive to operate and limits the size of components. Further, autoclaves are also relatively labor intensive and can yield only a limited production. However electrically curing the composite structure reduces time and energy, without requiring pre-heating or sacrificing quality/strength. Known OOA methods, such as oven curing, on the other hand, have large energy consumption.
[0038] In certain aspects, electrical curing, also referred to as electrical resistance curing, methods may be accomplished using, for example, CF pre-impregnated resin systems (“pre-preg” or “pre-preg material”, i.e., composite fibers having uncured matrix material already present), embeddable conductors, which may function as resistors, (e.g., carbon nanotubes (“CNT”) material), electrical contacts, and/or a tool (e.g., a mold). While additional aspects will be discussed below in greater detail, in one aspect, the curing system may be provided using one or more power supplies, electrical contacts (e.g., copper tape), and the consumables that are part of a vacuum bag layup (e.g., breather material, peel ply, etc.), which may be used along with vacuum bagging to provide consolidation thereof. During layup, carbon pre-preg plies, for instance, may be laid up onto a foam/composite tool (e.g., foam/composite/3D printed material) with low thermal conductivity and similar coefficient of thermal expansion (“CTE”). Indeed, other materials, such as aluminum tooling, for example, may draw too much heat away from the composite structure being cured and, therefore, may not always enable higher temperatures to be achieved. With 3D printed tooling, specifically tooling that is comprised of polymer materials, the tooling can be designed with internal conduits to pass through a cooling gas or fluid. By actively cooling the tooling, a lower temperature polymer can be used for the tooling material. Lower temperature polymers, for example ABS vs. Ultem (high temp), are favorable from a cost and ease of use standpoint. The cooling of the tooling and the heating of the composite would be monitored in real-time with thermal couples (temperature sensors) placed at multiple locations across both the tooling and the composite material. These temperature measurements would be used by a control system to ensure that the temperature of the tooling and the composite remain in an acceptable range. For example, hot spots in the tooling would receive a higher flow of cooling fluid. This ability to cool or heat local spots in the tooling would be enabled by throttles (valves) located at various points across the cooling conduits. Similiarly for the composite material, there would be multiple points for connecting electrical heat lines to the composite material. Each heat line would be associated with heating a spatial area on the composite material.
[0039] To reduce tooling costs, while maintaining dimensional accuracy during cure (e.g., to avoid, or mitigate, shrinkage, warping, etc.), a low-cost tool may be employed where the composite structure may be removed and cured while free standing. While electrical curing is particularly beneficial when fabricating larger composite structures, it also enables low quantity/volume component fabrication due, in part, to the low-cost tooling capabilities.
[0040] To provide electrical contacts, a conductor material, such as copper tape, may be laid down at each end of the composite structure (whether by hand or via automated fiber placement). Depending on composite structure thickness (e.g., laminate thickness), one or more connections may be made to the copper tape ends via, for example (1) a detachable coupling (e.g., alligator clips, terminal blocks, posts, crimp-on connectors, insulation displacement connectors, plug and socket connectors, blade connectors, ring and spade terminals, etc.) or (2) a permanent, or semi-permanent, means (e.g., by soldering connections to the conductor material). In certain embodiments, electrodes onto the copper tape using three dimensional printing technology
[0041] Experimental testing has shown that an equivalent cure of the composite structure may be achieved at lower temperatures when using electrical curing methods (versus oven curing) with improved short-beam shear (“SBS”) properties. Indeed, by heating the composite structure from within, greater densification is achieved, thereby leading to enhance mechanical properties. For example, temperatures above 300° F. (Fahrenheit) can be achieved to cure an 8-ply laminate using only a 150 watt Power Supply (15 Amps, 10 Volts). Conversely, a small 0.95 cubic foot oven uses 1200 watt of power. Even assuming a similar cure time, the subject electrical curing methods would use less than 87% of the power that would be used by the oven (and thus 87% less cost in utility costs). Because electrical curing cures from the inside out, cure cycle time is also less than that required for conventional oven curing, thereby realizing even greater cost savings.
[0042] While the disclosure is generally described as employing CNT material as the embeddable conductor, other embeddable conductors may be used. However, over the last decade, CNT has become an increasingly viable material for structural and electrical uses. CNTs are allotropes of carbon with a cylindrical nanostructure and are an ideal conductor for embedment within composite materials. Another possible carbon conductor may be carbon nanofibers/nanofilaments (CNF). CNFs (aka vapor grown carbon fibers (VGCFs) or vapor grown carbon nanofibers (VGCNFs)) are nanostructures with graphene layers arranged as stacked cones, cups, or plates, whereas CNTs are CNFs with graphene layers wrapped into cylinders.
[0043] Electrical curing of carbon composites has shown to save significant amounts of energy. In certain aspects, vertically aligned CNTs may be implemented between one or more layers of carbon/epoxy pre-preg to homogenize the conductivity of the carbon composite and reduce the dependence on fiber direction. Testing indicated the composite structures with CNTs resulted in greater uniformity of temperature across the composite structure's surface. Conversely, when fibers are simply oriented perpendicular to the fiber direction, no increase in efficiency was observed. Further, using various tool materials to insulate the composite has proven to significantly reduce the energy requirements as well. To verify the effectiveness of the electrical cure procedure, various fiber orientations, CNT distributions, CNC distributions and cure temperatures were explored. For example, with regard to CNT distributions, the CNTs may be vertically-aligned, aligned in-plane with the carbon fibers, and/or arranged in a zig-zag pattern.
[0044] Temperature measurements were recorded with thermocouples and infrared (IR) cameras, while SBS tests were used to validate samples as completely cured. In addition, recommendations for further study were given.
[0045] The results of the testing indicate that electrical curing can be used to provide the heat necessary for curing OOA composite structures, such as CF, under vacuum pressure. Applying energy directly to the object desired in lieu of applying the energy to an intermediate material to heat the desired composite structure is much more efficient. In a traditional oven or autoclave, however, the temperature within the chamber must first increase prior to the composite structure. The composite structure is then heated from the outer surfaces, and sufficient time must be allowed to ensure that the inner core reaches similar temperatures. With electrical curing, the current flows through the composite material (e.g., CFs), transferring heat via conduction to the adjacent matrix which then generates heat as a by-product of the crosslinking polymers. The high conductivity of CFs makes this process of heating from the inside out possible without embedding additional material. Suitable OOA epoxies include, for example, TC 350-1 and TC 275 resin matrices, available from TenCate Advanced Composites USA Inc.
[0046] Testing.
[0047] A number of experiments were performed to confirm that enough heat could be generated to cure a CF composite using less power/energy and in less time than with an oven or an autoclave, without sacrificing mechanical properties. CNTs were added to various samples to determine if and how the cure cycle was affected. SBS tests were performed on the samples to compare their mechanical properties and qualitatively compare degree of cure. CF pre-preg material was cut and layered for samples. Some samples were to be oven-cured and others would use resistive curing. A limited number of samples could be prepared with CNTs due to their availability. Resistive curing was performed on 2-ply and 8-ply samples. All samples were cured under vacuum pressure (about 26 in. Hg).
[0048] The samples were fabricated from pre-preg CF material cut to 30 mm by 80 mm samples. Copper tape was applied to layer edge to improve conductivity across fibers. In certain samples, CNTs were applied in-between layers where specified. The vacuum bag procedure was followed pursuant to the pre-preg manufacturer's specifications, where FIG. 1 illustrates an exemplary diagram of a vacuum cure setup 100 . As illustrated, a vacuum cure setup 100 may comprise: a vacuum bag 102 , breather fabric 104 , first release film 106 (e.g., non-perforated release film), a bleeder fabric 108 , a second release film 110 (e.g., perforated release film), a first layer of peel ply 112 , a composite material to be cured 114 (e.g., pre-preg), a second layer of peel ply 116 , a release agent 118 , and a tool 120 . The vacuum bag 102 may be sealed to the tool 120 at the edges to form an air tight seal using a seal 126 . Air may then be vacuumed from the vacuum cure setup 100 using a pump via a vacuum nozzle 124 . An edge dam 122 may be provided along the perimeter of the composite material 114 , or portion thereof, to maintain alignment and prevent deformation.
[0049] FIG. 2 illustrates a summary of the composite samples prepared and tested based on the CF orientation, type of cure and CNT position within the stacking sequence. An objective of this test was to improve the methods of resistance curing and increase its potential to be applied in industry.
[0050] Several parameters were of interest, including orientation of the CFs, addition of the CNTs, and placement of the CNTs within the laminate. To determine the degree of cure, SBS tests were performed on the cured 8-layer samples.
[0051] A first sample of 8 layers was oven-cured from pre-preg material, while the remaining samples were resistively cured similar 8-layer samples of pre-preg material. Copper tape was inserted between the layers at each end of the sample and wires were soldered to the copper tape. Five resistors (5 ohms each) were connected together in parallel to increase the resistance of the circuit by 1 ohm to avoid tripping the failsafe on the power supply. Alligator clips were used to connect the wires from the sample and resistors to the power supply. A circuit schematic of the set-up is illustrated in FIG. 3 . The power supply was capable of outputting 15 Amps and 10 volts. An IR gun was used during the curing process to check the surface temperatures of the sample and the resistors and changes of geometry and locations near connections. The resistor temperatures rose to over 135° C. Therefore, in order to avoid overheating, they were placed in the path of the vacuum system exhaust on a large aluminum plate.
[0052] In an attempt to further conserve energy, various insulated materials were explored during the resistive curing of the carbon pre-preg. As shown in FIG. 4 , the temperature step is more than doubled by implementing a fiberglass tool (k=0.04 W/m-K) in place of a conventional aluminum tool (k=205 W/m-K at 25° C.). The same fiberglass tool was then used in the resistive curing process of all samples tested. Thus, a tool material of the same or a similar CTE may be used. A circuit model can be used to estimate the conductive heat transfer through the materials involved in the tooling process. For the model shown in FIG. 5 , T A refers to the temperature at the centerline as the model is using a symmetric setup. Further model refinement can be made to account for complex tool shapes, other vacuum bagging materials, and convective heat transfer. Variation of thermal conductivity with temperature can also be accounted for.
[0000]
q
=
T
A
-
T
B
Δ
x
kA
+
Δ
x
kA
+
1
hA
Equation
1
k
=
k
0
(
1
-
β
T
)
Equation
2
[0053] Where: β is the temperature coefficient of thermal conductivity (1/C°), k is the thermal conductivity (W/m 2 C°), q is the heat transfer rate (KJ/s), and h is the heat transfer coefficient (W/m 2 C°).
[0054] FIGS. 6 and 7 show the recorded temperatures from samples with fibers oriented perpendicular to the flow of current. In this orientation, the conductivity of the epoxy dominates as there are now continuous fibers for current to travel on. Sample 5A (without CNTs) showed higher temperatures at all but one location for this test. Sample 6A showed a lower standard deviation amongst temperature readings. The gaps in FIG. 7 are the result of a failure in the data logging equipment. The application of current was continuous for both samples. FIG. 8 a shows the maximum temperature attained with the available power supply, while FIGS. 8 b and 8 c illustrate temperature data from samples 2A and 3A, which were fabricated using 8-ply 0° laminate with and without CNTs, respectively.
[0055] SBS tests were performed on samples 1A, 1B, 2A, 3A, and 4A. The various samples were cured under an atmospheric-pressure vacuum bag, where parameters investigated were: (1) cure type (i.e., resistive vs. oven); (2) orientation of CFs; and (3) presence of CNTs (e.g., Variable layering, and Channeling). The SBS test is a destructive test designed to compare the short-beam strength of composite structures and layups. The short-beam strength of a composite is directly related to interlaminar shear strength. Before the testing begins the short-beam strength can be estimated using Equation 3:
[0000]
F
sbs
=
3
P
m
4
bh
Equation
3
[0056] Where: Fsbs=short-beam strength MPa (psi), Pm=maximum load observed during the test, N (lbf), b=measured specimen width, mm (in.), and h=measured specimen thickness, mm (in.).
[0057] The approximate size of a specimen for SBS tests has a width of 4 times the thickness and a length of 6 times the thickness. The setup of the SBS test is performed akin to a 3-point bend test, where two-spaced cylindrical supports are positioned on one side of the sample, and a single cylindrical supports is positioned on the opposite side approximately, about midway between the two cylindrical supports on the other side. The diameters of the cylindrical supports employed during the shear test were each 0.25 in.
[0058] FIG. 9 shows a direct force to displacement comparison between the oven-cured samples, 1A/B and the resistively cured samples 2A. FIG. 9 reveals that the force required to displace an electrically cured short-beam specimen are greater than the force required to displace an oven-cured short-beam specimen. The test specimen from 1A and 1B require a force of 2.5 kN to displace a specimen 1 mm while the 2A specimen are resistively cured and require a force of nearly 2 kN to displace a specimen 1 mm. This correlation can be directly related to the increase in the short-beam strength. The resistive heating of the carbon composite cures the matrix from the inside to the outside allowing the matrix to cure more consistently throughout the composite leading to an increase in interlaminate shear strength. The heat input from the oven is being absorbed by the carbon rather than of having the carbon exhaust the heat into the matrix. Using Equation 3 for samples with a thickness of 1.016 mm (0.04 in), a width of 6.33 mm (0.249 in), and an estimated short-beam strength of 100 MPa, an estimated force to cause failure was calculated to be close to 850 N. The reliability of this calculation depends on a variety of conditions including cure pressure and temperature. Looking at FIG. 9 , the failure has a wide range on the averaging around the expected force of 850 N.
[0059] SBS tests performed on specimen gathered from CNT sample 3A were compared to the non-CNT sample 2A. Instead of sample 3A having a stronger interlaminar shear strength, the test results were unexpectedly similar to the test results obtained by sample 2A as shown in FIG. 10 . The resistively cured samples cured at a lower temperature than the oven-cured samples had greater SBS strength as shown in FIG. 11 .
[0060] The results from the resistive-cure vs. the oven-cure analysis verified the lower cure temperatures. Improving mechanical properties was also verified by the SBS test results. However, there was no improvement found to thermal or mechanical properties due to the application of CNTs within the laminate structure. Due to the low conductivity of the epoxy, orientation of the fibers other than 0° greatly increased the resistance thus requiring more power to achieve the same curing temperature.
[0061] There is currently a very high incentive to pursue OOA processes to save large amounts of time and money while still achieving the required final mechanical properties. By taking advantage of the low electrical resistance of CF reinforcements, composite structures can be heated via electric current to assist the curing process. Experiments provided have shown several advantages. The advantages are, without limitations, lower energy input requirement, greater temperature control, smaller equipment size, more complete curing, and possible improvements in mechanical properties.
[0062] The laminate used for this project had a high cure temperature. To cure a 90° laminate, a larger power supply may be needed, or using low-temperature epoxy laminates. Because the resistive-cured samples cured at a lower temperature, temperature profiles may be created specifically for resistance cure similar to those for oven cure. Further, a 2-part tool may be used to minimize heat loss through radiation.
[0063] While the present technology is generally described in the context of aerial vehicles, other composite structures may similarly benefit from such technology, such as automobiles, watercraft, windmill blades, helicopter blades, etc. Further, while the present invention has been described with respect to what are presently considered to be the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
[0064] All U.S. and foreign patent documents, all articles, brochures, and all other published documents discussed above are hereby incorporated by reference into the Detailed Description of the Preferred Embodiments.
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A composite structure cured by the process of: electrically coupling a first lead to a first portion of said composite structure; electrically coupling a second lead to a second portion of said composite structure; and using an electric power source to pass electric current through said composite structure from said first portion to said second portion, wherein passing said electric current through said composite structure causes the temperature of at least a portion of said composite structure increase to a predetermined temperature.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] None.
FIELD OF THE INVENTION
[0002] The present invention relates generally to substrates intended for business and other communications such as marketing, advertising and personal communications as well as, intermediates, materials, documents or the like related thereto and more particularly to business and marketing communication documents having a variably applied, printed or imaged ferromagnetic material suitable for use in accentuating a message, marketing theme or event, advertising or the like. In addition, the present invention describes the method of using the ferromagnetic material as well as the composition suitable for use with the present invention and the system for applying the material to the communication substrate.
BACKGROUND OF THE INVENTION
[0003] Ferromagnetic materials or magnets as they are more commonly known have heretofore been used in a wide variety of applications and are often given away as part of a promotional offering or the like. For example, magnets have been applied to calendars, detachable reference cards, commercial services, restaurants, emergency numbers and the like.
[0004] More recently, however, ferromagnetic materials, magnets, have been used in connection with providing business cards, advertising collateral and the like and can be attached to card stock and other substrates. Such products, particularly those intended for small office or home office (“SOHO”) have been pre-printed with indicia related to the SOHO application. Other products are intended for larger commercial distribution and may be manufactured in connection with a national food delivery service. However, the level of personalization, if any has been extremely limited.
[0005] Alternatively, where such installations or applications permit, magnets can be provided in a blank format thereby enabling the SOHO user to provide some level of personalization, such as a phone number or name to the magnet prior to distributing the magnet, such as through promotional giveaways, direct mail offerings and other solicitations and the like. However, there still has not been a significant amount of personalization available for such products.
[0006] Unfortunately, such magnetic material products typically require that the magnetic material usually be “tipped on” the material or may form part of a laminate during the construction of the form assembly. Such magnetic material is normally supplied in a sheet form, which is then cut to the intended size and then either juxtaposed on top of the substrate and adhered or connected to the substrate through the use of a bridge or adhesive securement. Each of these forgoing arrangements regrettably results in a substrate having a differing thickness either between the substrate and the magnetic material or in the area of the attachment or bridge thereby creating a “bump” in the construction which can be difficult to process through printers or other imaging devices or sheet feeding equipment.
[0007] The result of such differing thickness or bumps in the construction can create feeding problems as the sheet on which the magnetic material is applied or the bridge connecting the magnet to the substrate is higher or extends upwardly a distance greater than the distance of the substrate itself. As such, a desktop or other printer when encountering such bumps may jam as the thickness of the construction is to significant or large to fit within the nip of the feed rollers of the printer.
[0008] Alternatively, if the printer is able to advance the form construction, that is the printer feed rollers can grasp and advance the leading edge of the form, the form may subsequently splay out of alignment with the direction of travel as a portion of the leading edge will likely advance ahead of the remainder of the form. This unfortunately causes the image to appear either in an unintended portion of the form or at the very least the printing will likely be skewed away from the intended alignment of the magnet attached or connected to the form.
[0009] What is therefore needed is a highly personalizable substrate that can be used as a business, marketing, advertising or personal communication piece that overcomes the foregoing drawbacks while enabling the recipient to have a magnetic component, which may be detachable, to call to mind the communication being supplied to the recipient in a convenient to use manner.
BRIEF SUMMARY OF THE INVENTION
[0010] The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention.
[0011] The present invention provides a communication substrate having a magnetic portion which does not suffer from the drawbacks referenced above, in that the magnetic material does not rise above the surface of the substrate a significant height so as to interfere with the operation of the printer, imaging or other sheet feeding device or document handling equipment.
[0012] In one embodiment of the present invention a business, personal or marketing communication piece is described and includes a substrate having first and second faces, first and second longitudinally extending side edges and first and second transversely extending end edges. One of the first and second faces of the substrate is capable of receiving a ferromagnetic material and non-ferromagnetic indicia. The ferromagnetic material is applied to the substrate in a variable pattern through use of printing or imaging rollers to create a communication piece having a magnetic portion that is printed or imaged directly on to the substrate as well as a non-magnetic portion. Each of the imaged or printed portions cooperated to convey information to the recipient, and the magnetic portion has a thickness of less than 25 mils.
[0013] In a still further embodiment of the present invention method of communicating a variable marketing or business message is described and includes a ferromagnetic component. The method of the present invention includes the steps of initially, providing a substrate that is capable of receiving both ferromagnetic and non-ferromagnetic indicia. Then creating a message for communicating to a pre-selected recipient based on information received from a pre-existing database or in response to a particular informational demand or other demographic. The substrate is then advanced to at least a first printing area for printing a ferromagnetic component of the message. The message is then transferred to the substrate through the use of cooperating rollers. Finally, the substrate is moved through at least one curing station to cure the ferromagnetic component of the message.
[0014] In a yet still further embodiment of the present invention a ferromagnetic slurry for use in creating indicia for a communication document is described and includes a ferrite power provided in an amount ranging from about 50 to about 90% by weight of the slurry and more preferably from about 50 to about 70% by weight; a stabilizer provided in an amount ranging from about 5 to about 20% by weight of the slurry; a varnish provided in an amount ranging from about 15 to about 30% by weight of the slurry and the slurry is curable.
[0015] In yet a still further embodiment of the present invention a system for creating a substrate having a ferromagnetic portion and a non ferromagnetic portion each of which are applied directly to the substrate is described and includes a reservoir containing a ferromagnetic slurry; a series of cooperating rollers for transferring a predetermined pattern formed from the ferromagnetic slurry to the substrate to create a ferromagnetic image; and at least first and second curing stations for curing the ferromagnetic image applied to the substrate with each of the first and second curing stations curing a different portion of the ferromagnetic image.
[0016] The foregoing embodiments will be further clarified by reference to the following sections and figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These, as well as other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings, of which:
[0018] FIG. 1 depicts a schematic of the present invention and the method of making the form construction contemplated herein; and
[0019] FIG. 2 provides an illustration of an exemplary form produced in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The present invention is now illustrated in greater detail by way of the following detailed description, but it should be understood that the present invention is not to be construed as being limited thereto.
[0021] Surprisingly, it has been found that certain ferromagnetic material can be supplied in a slurry to a print deck through use of a printing reservoir so that a variably applied, unique image can be created on a plurality of substrates.
[0022] The present invention overcomes the foregoing drawbacks in that the ferromagnetic or magnetic material is imaged, printed or applied directly onto the surface of the substrate and is not applied as a separate and distinct magnet that rises substantially above the surface of the substrate. That is, the ferromagnetic material that is applied in accordance with the present invention does not rise significantly above the surface so that there is no bump or other interference to interrupt the flow of the substrate through a printer or other handling equipment.
[0023] The term substrates as used herein include but are not limited to cellulosic-based materials such as card stock, corrugated material, paper as well as plastic and other films, and combinations thereof. Substrates include generally planar substrates. Substrates also include finished substrates, those to which printing or other ancillary items have been attached, such as labels, cards and tags as well as substrates that are provided in an intermediate form and which undergo a further processing step such as printing, cutting, adhering, folding, sealing or the like prior to being delivered, such as through the mail service, to an end user or recipient.
[0024] The message that is produced in accordance with the present invention may be obtained from a data base related to marketing, advertising, business or personal communications to be distributed to recipients or may be in response to informational requests received from a target audience or in connection with other demographics to be addressed by the communication or as part of a general solicitation for business or commercial services.
[0025] Application of the magnetic slurry of the present invention may be accomplished by any suitable means such as flexographic, electrostatic, gravure, ion or electronic charge deposition, electro-coagulation printing and the like. Generally, however, printing of the present invention of an exemplary embodiment is done by means of surface tension, whereas the slurry is picked up from the reservoir chamber by the anilox cylinder, in which it is then transferred or pulled by the magnetic section or plate on the print cylinder, and in turn, is then pulled by the mag cylinder which resides underneath the desired substrate. This process creates the corresponding image on top of the substrate residing below the print cylinder. The slurry may also be applied by means of slot die, mirod, blade applicator, and the like, but should be understood as not limited thereto.
[0026] The term magnetic or ferromagnetic slurry as used herein, refers to a slurry that is applied in-line during printing operations and undergoes several processing steps prior to reaching its final destination. In one exemplary embodiment of the present invention, the slurry is curable by ultraviolet energy (UV curable) and includes as an exemplary formulation 410 Ferrite Powder, 30 LI Varnish, and a stabilizer additive which gives the invention its unique capability of being able to bind and adhere to substrates during a printing operation.
[0027] In one embodiment of the present invention, and exemplary formula breaks includes the following components. Approximately 50-70% of 410 Ferrite Powder by weight of the slurry with about 60-65% by weight being preferred, and about 61-63% by weight being more preferred. Roughly 5-20% of a stabilizer, such as corn starch, by weight of the slurry with approximately 10-15% being preferred and 11-13% being more preferred. A stabilizer, such as corn starch, may include, but is not limited to, low amylose & high amylose corn starches and combinations thereof. Approximately 15-30% by weight of the slurry of 30 LI Varnish with about 20-27% by weight of the slurry being preferred and about 23-26% by weight being more preferred. The 410 Ferrite powder is available from Hoosier Magnetics, Inc., Holland, Ohio; the 30 LI Varnish is available from North West Coatings, Oak Creek, Wis. and the stabilizer, corn starch, is available from National Starch and Chemical Company, Chicago, Ill.
[0028] The slurry of the present invention is formulated so that the slurry once coated, applied, printed or imaged on the product is UV curable. Application of the slurry to a substrate, after curing results in a layer of cured ferromagnetic material having a thickness ranging from about 0.5 mil to about 25 mil and more preferably the cured thickness of the ferromagnetic material is in the range of about 1 to about 15 mil thickness and still more preferably in the range of approximately 2 to 12 mil thickness.
[0029] UV curing is a technology that regularly evolves and efforts are continually sought out in order to achieve improved curing performance so that the printing operation may proceed at optimum speeds. That is, UV curing typically requires a “dwell time” in which the UV curable substance dries before it can be further processed in any additional equipment. As such, it is preferable to achieve faster curing speeds under a variety of difficult and complex environments so as to minimize if not completely eliminate the need for dwell or drying time.
[0030] Turning now to FIG. 1 , which shows a schematic illustration of one embodiment of the present invention. The process is generally depicted by reference to numeral 10 . A substrate, designated by the reference “S” is drawn from a supply (not shown), which may either be a supply of cut sheet stock or alternatively, a continuous stock such as provided from a roll of material. The substrate “S” is supplied in a machine direction, however, the substrate S may be reversed or travel in an orientation other than a machine direction in order to meet processing or needs related to the manufacture of the form construction to be produced.
[0031] Turning now to the function of supplying the ferromagnetic material to the substrate S. A reservoir or well 20 is filled with a ferromagnetic material, as described above (ferrite powder, stabilizer and a varnish). An imaged created with a cylinder, by means of surface tension, 30 , the surface tension cylinder helping to create the image configuration, picks up the UV curable magnetic or ferromagnetic slurry from reservoir 20 . The magnetic slurry adheres to the roller 30 , by the charge, surface tension or other means known in the art.
[0032] Next, the roller, 30 , transfers the magnetic slurry material to the print cylinder, 40 . The print cylinder, 40 , has a magnetic plate affixed to the surface of the print cylinder. The magnetic plate, 50 , then transfers the magnetic slurry to the desired substrate S now depicted as reference numeral 60 . The magnetic slurry now applied to the desired substrate 60 is represented by reference numeral 70 .
[0033] FIG. 1 further depicts a magnetic cylinder, 80 disposed beneath the substrate S and in operative association with print cylinder 40 . The magnetic cylinder, 80 , aids in pulling the magnetic slurry 50 , to the predetermined position on the substrate 60 . The magnetic cylinder, 80 , also provides for and maintains a consistent transfer of the UV curable magnetic slurry to the substrate as shown at 70 .
[0034] Once the magnetic slurry is affixed to the substrate 70 , the substrate with the slurry applied 70 then passes through at least one if not additional UV curing stations which contain UV bulbs for curing purposes. The “H” bulbs described below and depicted by reference to numerals 90 and 100 , and the Gallium bulb, also described below, is depicted by reference numeral 110 .
[0035] In practicing an exemplary embodiment of the present invention, as shown in FIG. 1 a series of UV curing bulbs, positioned side by side, adjacent or sequential configuration is used. In an exemplary embodiment, a single bulb may allow a UV cure rate of approximate 50 feet per minute, while plural bulbs disposed in a side-by-side adjacent configuration, permits a higher curing rate of approximately 75 feet per minute. Obviously, other curing station configurations may be used in order to increase the possible through put rate of the equipment and processing of the substrates to be printed.
[0036] Exemplary bulbs used in the embodiment depicted in FIG. 1 of the present invention are “H” bulbs and Gallium doped bulb suitable for use in the UV curing processes depicted herein, however, it should be understood that other UV curing may be used in accordance with the present invention and the present invention is not limited hereto.
[0037] The “H” bulb is generally known as a mercury vapor bulb and is used typically for top surface curing applications. The Gallium doped bulb is used in connection with a requirement for penetrating deep within the slurry mix. The UV bulbs such as those described above along with reflectors are available from the GEW Company, located in North Royalton, Ohio. The combination of topical and penetration curing result in a combination of curing energies sufficient to carry out the present invention.
[0038] The present invention also contemplates additional processing steps (not show) that may include, but are not limited to, one or more additional printing stations such as for applying other indicia. Other operations may include the addition of label, card or tag stock to the construction, cutting, perforating, sheeting, folding, sealing and the like. A product such as with the present invention can be provided in both an intermediate condition, as well as a finished condition so that a customer can have a finished product that accommodates an infinite variety of uses or may further modify the intermediate assembly to add some additional degree of personalization.
[0039] Turning now to FIG. 2 , and exemplary embodiment of the product produced in accordance with the present invention is depicted generally by reference to numeral 200 . The substrate 200 has a first face 205 and a second face (not shown) which is on the obverse side of the substrate. The substrate 200 has first and second longitudinally extending side edges 210 and 220 , respectively and first and second transversely extending end edges 230 and 240 , respectively. The substrate 200 is shown with a first printable area that contains the printed magnetic slurry 250 and a second printable area that receives a second type of printing 260 . The face 205 is one that is suitable for receiving each of the first and second types of printing. The printable face 205 of the substrate 200 may however also be coated, either entirely or in a spot wise fashion with a tie coating or like material, such as a poly vinyl alcohol so as to better tie or bind the magnetic slurry to the substrate.
[0040] The invention also contemplates other features that may be supplemental or ancillary to the main features of the invention, these include but are not limited to perforations or cuts 270 so that the substrate 200 may be separated in to first and second parts and an integrated label or card, depicted as reference numeral 280 .
[0041] It will thus be seen according to the present invention a highly advantageous process and system for producing a communication piece having a ferromagnetic portion has been provided. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiment, that many modifications and equivalent arrangements may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products.
[0042] The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of their invention as it pertains to any apparatus, system, method or article not materially departing from but outside the literal scope of the invention as set out in the following claims.
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The present invention relates generally to substrates intended for business and other communications such as marketing, advertising and personal communications as well as, intermediates, materials, documents or the like related thereto and more particularly to business and marketing communication documents having a variably applied or imaged ferromagnetic material suitable for use in accentuating a message, marketing theme or event. In addition, the present invention describes the method of using the ferromagnetic material as well as the composition suitable for use with the present invention.
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This is a continuation of application Ser. No. 134,801, filed Apr. 11,1980, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to improvements in load sensing hydraulic brake pressure control apparatus for use in the hydraulic circuit between the master cylinder and the rear wheel brake cylinders. The apparatus is adapted for sensing variations in the distance between the vehicle chassis and the suspended axle shaft.
It is known that changes in vehicle loading cause changes in braking capability. For example, when a vehicle is fully loaded, the rear wheels will have nearly the same braking capability as the front wheels. However, when the vehicle is lightly loaded, the rear wheels may exhibit less braking capability than the front wheels. Thus the potential for premature rear wheel lock up is much greater when stopping the lightly loaded vehicle than when stopping the fully loaded vehicle. In order to compensate for the inherent imbalance between front and rear braking action, it has been customary in past years to provide a proportioning valve which restricts fluid communication to the rear wheel brake cylinders after a predetermined pressure level is generated. However, such proportioning valves represent a compromise between the desirable system characteristics for the full load condition and those for the light load condition. Thus the selected proportioning valve characteristic is neither suitable for the full load condition nor the light load condition. Many load sensing or vehicle height sensing valve mechanisms have heretofore been presented in the prior art however, they are unnecessarily complex or otherwise unsuitable for modern vehicle use. For example see U.S. Pat. Nos. 3,362,758; 3,503,657; 3,649,084; 3,684,329; 3,734,574; 3,768,876; 3,848,932; 4,150,855; 4,159,855.
The present invention relates to improvements in load responsive hydraulic brake pressure control apparatus which is placed in the hydraulic circuit upstream of the rear wheels and senses changes in the distance between the chassis and the axle of an automotive vehicle and controls the hydraulic pressure delivered from the master cylinder to the rear wheel brake cylinders in response to such changes.
SUMMARY OF THE INVENTION
The present invention provides for a first and second proportioning valve assembly hydraulically in series with each other. The first proportioning valve assembly being positioned downstream of the master cylinder and the second positioned between the first valve assembly and the vehicle rear brakes. The first proportioning valve produces an output pressure suitable for a vehicle under a full load condition. The second proportioning valve, which receives the first valve's output pressure as input pressure, acts to modify or proportion the pressure received from the first valve producing an output pressure suitable for a lightly loaded vehicle.
The second proportioning valve assembly is rigidly attached to the vehicle frame and includes a rotatable digital cam driven by mechanical linkage attached to the vehicle axle. As the vehicle is loaded compression of the suspension system reduces the distance between the vehicle frame and the axle. The mechanical linkage in response to the reduction in distance rotates the digital cam to a position whereby the second proportioning valve mechanism is disabled. Thus the output pressure of the first proportioning valve is passed undisturbed through the second proportioning valve assembly to the rear wheel brakes.
The digital cam is rotatingly seated upon an axial drive shaft so as to allow relative rotation therebetween. A torsional spring affixed to the digital cam has one leg anchored thereon and the other leg engaging a flat diametric camming surface provided in the drive shaft. Thus the digital cam is caused to rotate in concert with the drive shaft. However by reason of the torsion spring a unique drive mechanism is provided which accommodates relative motion between the vehicle frame and the axle during vehicle operation by permitting relative rotation between the cam and the driveshaft whenever rotation of the cam is restricted by the functional operation of the proportioning valve mechanism.
Although the load sensing proportioning valve assembly is herein described as being in series with a first proportioning valve assembly it is to be understood that the load sensing valve may be used alone in systems where the master cylinder output pressure is suitable, without an intervening proportional valve, for direct transmission to the vehicle brakes in the heavily loaded condition.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a hydraulic brake system incorporating a load sensing proportioning valve according to the present invention.
FIG. 2 is a graphical illustration of the performance of a brake proportioning system incorporating the present invention.
FIG. 3 pictorially depicts a typical vehicle installation of a load sensing proportioning valve embodying the present invention.
FIG. 4 is a partial cross-sectional view of the load sensing proportioning valve used in the braking system illustrated in FIG. 1.
FIG. 5 is a cross-sectional view taken along line 5--5 in FIG. 4.
FIG. 6 is a partial cross-sectional view taken along line 6--6 in FIG. 4.
FIG. 7 is a partial cross-sectional view taken along line 7--7 in FIG. 4.
FIG. 8 is an exploded pictorial view showing the assembly of elements comprising the digital cam portion of my load sensing proportioning valve.
FIG. 9 is an isolated pictorial view of the digital cam rotated 180° from that shown in FIG. 8.
FIG. 10 is a schematic illustration of the load sensing proportioning valve configuration when the vehicle is lightly loaded.
FIG. 11 is a schematic illustration of the load sensing proportioning valve configuration when the vehicle is heavily loaded.
FIGS. 12 and 13 present schematic illustrations of load sensing proportioning valve configurations accommodating over-rotation of the digital cam driveshaft.
FIG. 14 presents a partial cross-sectional view of the load sensing proportioning valve, similar to that of FIG. 6, wherein the digital cam mechanism is configured activation by clockwise rotation of the digital cam driveshaft.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings a vehicle hydraulic braking system embodying my invention is shown in FIG. 1. Master cylinder 11 provides brake activating hydraulic fluid pressure by means of conduit F to the vehicle front wheel brakes 13L and 13R first passing through a metering valve assembly, not shown, contained in combination valve 12. Conduit R similarly provides an independent source of brake activating hydraulic fluid pressure to a first proportioning valve assembly 14, shown schematically in combination valve 12, for supply to the vehicle rear wheel brakes 15L and 15R.
Proportioning valve 14 may be of any known design to the art, such as shown in U.S. Pat. No. 3,423,936, having a single split point relationship between input hydraulic pressure and output hydraulic pressure. In accord with the present invention proportioning valve 14 is designed to produce an output pressure relationship to input pressure as shown in FIG. 2 and identified as "LOADED". The split point at which valve 14 begins proportioning being indicated as point L. The curve identified as "LOADED" in FIG. 2 represents a master cylinder to rear brake pressure relationship acceptable for a vehicle loaded beyond a given mid-load condition and up to its full gross vehicle weight (GVW). The output hydraulic fluid pressure from proportioning valve 14 is transmitted to the vehicle rear brakes by conduits R1 and R2 passing through load sensing proportioning valve (LSPV) device 20.
LSPV 20 includes a second proportioning valve assembly 16, hereinafter described in greater detail, having a similar construction as that of proportioning valve assembly 14 contained in combination valve 12. Proportioning vavle assembly 16, when permitted to function, operates upon the output hydraulic pressure received from proportioning valve 14 such that the relationship between master cylinder pressure (input to proportioning valve 14) to rear brake pressure (output from proportioning valve 16) is represented by the curve identified as "EMPTY" in FIG. 2. The "EMPTY" curve shown in FIG. 2 represents a master cylinder to rear brake pressure relationship acceptable for a vehicle load condition falling below the selected mid-load condition.
A digital cam mechanism 25 is provided within LSPV 20 to selectively disable proportioning valve assembly 16 in the full open configuration when the vehicle is heavily loaded. Thus when the vehicle is loaded beyond the selected mid-load condition, proportioning valve 16 is disabled by action of digital cam 25 thereby permitting undisturbed, the transmission of hydraulic pressure therethrough and resulting in the desired "LOADED" pressure relationship shown in FIG. 2. However, when the vehicle is lightly loaded proportioning valves 14 and 16 function in series and produce a master cylinder pressure to rear brake pressure relationship as indicated by the curve "EMPTY" in FIG. 2.
FIG. 3 pictorially depicts a typical vehicle installation of my load sensing proportioning valve. LSPV 20 is rigidly affixed to a non-suspended portion of the vehicle frame 35. Driveshaft 50 is firmly attached to linkage 30 so that as linkage 30 rotates driveshaft 50 rotates digital cam 25 by a drive mechanism hereinafter described in greater detail. Linkage 30 is firmly attached to the vehicle axle tube 31 or any other suitable element of the suspended portion of the rear wheel assembly.
Digital cam 25, through action of linkage 30 attached to vehicle axle 31 responds to compression or expansion of the vehicle suspension system (not shown). When the linkage is extended, as indicated by the numeral 30, the vehicle is lightly loaded and proportioning valve 16 is permitted to function. However, when the linkage is compressed, as indicated by numeral 30, the vehicle is heavily loaded and digital cam 25 is rotated into position so as to disable the operation of proportioning valve 16.
Referring to FIG. 3 proportioning valve assembly 16 as shown and described herein is merely representative of known proportioning valve mechanisms and does not represent a part of my invention. Recognizing that any known proportioning valve mechanism which may be modified to function as herein described is suitable for use with the present invention, the operation of proportioning valve assembly 16 will be described only to the extent necessary to understand its interrelationship with my digital cam and its function with respect to the overall brake hydraulic system.
Proportioning valve assembly 16 comprises valve piston 40 positioned axially within bore 45 and extends into bore 45a of smaller diameter which in turn opens into digital cam cavity 70. O-ring seal 47 is provided to hydraulically seal bore 45 from bore 45a thereby preventing the flow of hydraulic fluid into bore 45a. Piston 40 is provided with a pin like extension 48 projecting into bore 49. Piston 40 is permitted to axially translate within bore 45a so that pin 48 may project into the digital cam cavity 70 as will be described hereinafter.
The opposite end of piston 40, includes valve head 43 which is less in diameter than that of bore 45b thus permitting the unrestricted flow of hydraulic fluid thereby. Piston 40 is further provided extension cap 41 having notch 42 therein. Piston 40 is normally biased to the left by action of spring 46 such that extension 41 is urged abuttingly against the end of bore 45b. Hydraulic fluid is thus permitted to enter inlet port R1, freely pass between piston 40 and elastomeric valve seat 44, past valve head 43, through notch 42 and exit through outlet port R2. Thus in the configuration as shown in FIG. 5 the fluid pressure at outlet port R2 will be equal to the fluid pressure at inlet port R1.
During brake application the above described fluid path through proportioning valve 16 remains open until the fluid pressure delivered at inlet port R1 attains a predetermined level. At this time valve head 43 will close against vale seat 44. The level of pressure at which this occurs is dependent upon the force of spring 46 as compared to the effective area of the valve piston 40, acted upon by inlet fluid pressure in a direction opposing the force of spring 46. This effective area is equal to the diameter D of piston 40 since the right hand end of piston 40 projecting into bore 45a is sealed off from the inlet fluid pressure by O-ring seal 47 while the inlet fluid pressure acts against all of the remaining portions of piston 40.
After valve head 43 closes against valve seat 44 and the fluid pressure at inlet port R1 is further increased, the increased pressure will act against piston 40 over an effective circular area having a diameter equal to the main sealing diameter of valve head 43 less the cross-sectional area of piston 40 extending into bore 45a. This produces a force acting upon piston 40 in the same direction as an assisting spring 46 to reopen valve head 43 so as to deliver at least a portion of the increased fluid pressure to outlet port R2. However, any increased fluid pressure delivered to outlet port R2 creates an opposing force upon piston 40. The opposing force tends to reclose valve head 43 against valve seat 44. The opposing forces tend to keep valve head 43 closely adjacent to valve seat 44 thereby restricting the flow of fluid from inlet port R1 to outlet port R2 creating a pressure at the outlet port R2 which increases at a lower rate than the pressure at inlet port R1. The ratio of the pressures is determined by the relationship of the effective areas previously referred to and hence the fluid pressure passing through proportioning valve 16 may be proportioned to follow a predetermined relationship.
During that portion of a brake application in which the applied pedal effort is reduced subsequent to a brake application of sufficient intensity to have moved piston 40 to the restricted flow position the forces tending to move piston 40 to the left are reduced and piston 40 translates to the right under the influence of the pressure at outlet port R2. As the piston 40 moves right valve head 43 is permitted to slide within the inner peripheral surface of valve seat 41, thereby increasing the available volume for the fluid at the rear brake cylinders 15L and 15R and accomplishing a reduction in pressure at outlet port R2. The pressure at outlet port R2 can never be greater than the pressure at inlet port R1 because valve seat 44 also acts as a fluid check valve permitting the flow of fluid from port R2 and into bore 45.
For a more detailed description relating to proportioning valve operation and the design of particular proportioning valve elements refer to U.S. Pat. No. 3,423,936 issued to William Stelzer on Jan. 28, 1969.
FIGS. 4 through 9 are to be referred to for the following description of the digital cam 25, its construction and operation. LSPV housing 19 is provided with a two step bore 60. Floor 69 of bore 60 contains recessed therein semicircular slot 67 and journal recess 68. Cam driveshaft 50 is supported and retained as shown in FIG. 4. Journal 51 of driveshaft 50 is rotationally received within journal recess 68. Shaft 50 extends generally normal to bore floor 69 passing through and rotationally supported by end cap 61. End cap 61 is snugly retained within bore 60a and against shoulder 62 by action of snap ring 63. O-ring 55 is provided to seal the digital cam chamber 70 from the entrance of any contamination thereto. Cam driveshaft 50 protrudes externally of end cap 61 sufficiently to permit rigid engagement thereof by linkage 30 (see FIG. 3). Thus driveshaft 50 is caused to rotate through the same angular displacement as that of linkage 30.
Digital cam 25 is rotationally supported on cam journal 52 of driveshaft 50 such that cam 25 may rotate relative to driveshaft 50. Cam 25 is provided with a peripheral recess 26 and axial directed knurls 24 over at least the working peripheral portion of cam 25. The working portion of cam 25 will become apparent as the function and operation are further described hereinafter. Pin 32 projects axially from cam 25 into and slidably engaging slot 67 in bore floor 69 thereby limiting the angular rotation of cam 25 to that are inscribed by slot 67. The inboard side 22 of cam 25 is milled providing inboard facing stepped surface 27. Circular recess 21 extends axially through cam 25 from the outboard surface 28 and slightly past the inboard facing stepped surface 27 thereby providing passage way 23 between outboard surface 28 and inboard surface 27. Mandrel 33 is axially positioned within circular recess 21 extending outboard and slightly past outboard surface 28. Torsion spring 34 is seated about mandrel 33 the helical portion thereof being seated within circular recess 21 such that inboard leg 34a extends through passage way 23 in juxtaposed relation with inboard facing stepped surface 27 and engages spring retention hole 29. Outboard spring leg 34b extends in juxtaposed relation with outboard surface 28 of cam 25 extending into slot 54 of driveshaft 50 and engaging the flat camming surface 53. In their normal assembled state as hereinabove described and shown in FIG. 6, torsion spring legs 34a and 34b are spring loaded so as to apply an angularly outward force upon spring retention hole 29 and the flat camming surface 53 of driveshaft 50. Slot 56 is provided at the external and outboard end of cam driveshaft 50 to permit external adjustment.
In operation cam 25 is caused to rotate with cam driveshaft 50 by reason of torsion spring 34 applying spring force upon camming surface 53 of shaft 50. However should cam 25 be restricted from rotating because of interference between pin 32 and slot 67 or because of interference between cam 25 and pin 48 on valve piston 40, cam driveshaft 50 may however, rotate relative to cam 25 by further compressing torsion spring 34. Thus a spring drive mechanism is provided between cam driveshaft 50 and digital cam 25 which allows for over travel of shaft 50 when rotation of cam 25 is otherwise restricted.
FIGS. 3, 5 through 7 and 10 depict the configuration of LSPV 20 under conditions of light vehicle loading. The vehicle frame 35 is riding relatively high with respect to suspended axle 31. Thus linkage 30 positions digital cam 25 such that peripheral recess 26 permits pin 48 of piston 40 to axially translate in and out of digital cam chamber 70. Proportioning valve 16 is permitted to freely function resulting in a master cylinder pressure to rear brake pressure relationship as shown by the curve identified as "EMPTY" in FIG. 2.
So long as the vehicle is lightly loaded proportioning valve 16 is functional. Peripheral slot 26 accommodates operation of valve 16. However, should valve piston pin 48 protrude into cam chamber 70 as a result of vehicle braking and the vehicle encounter an extreme road condition causing cam driveshaft 50 to momentarily, over rotate from excessive compression of the vehicle suspension system, cam 25 will momentarily engage valve piston pin 48 stopping the cam's counterclockwise rotation. However, cam driveshaft 50 is permitted to continue its counterclockwise rotation by compressing torsion spring 34. Such a condition is illustrated in FIG. 13.
When the vehicle is loaded heavy the suspension system is compressed such that the vertical separation between frame 35 and axle 31 is reduced. Linkage 30 assumes a configuration as depicted in FIG. 11 thereby rotating digital cam 25 counterclockwise as shown. In this configuration the outermost periphery of cam 25 is rotated into a position that disables proportioning valve 16 by preventing the free translation piston 40. Thus in the loaded condition, as illustrated in FIG. 11, the master cylinder pressure to rear brake pressure relationship is as shown by the curve identified as "LOADED" in FIG. 2. So long as the vehicle is in the loaded condition the outer periphery of cam 25 will remain in the valve piston disabling configuration as illustrated in FIGS. 11 and 12. In this configuration and when the applied braking load is such that valve piston 40 attempts to translate to the right valve piston pin 48 buts against cam 25 and engages the axial knurls 24 on the outer periphery of cam 25. Thus cam 25 is restricted from freely rotating. Any further rotation of cam driveshaft 50 resulting from road induced vacillations of axle 31 will be accommodated by compression of torsion spring 34 as illustrated in FIG. 12.
The angle A (FIG. 6) between the pin 48 centerline and digital cam step 26a determines the vehicle load condition at which proportioning valve 16 is disabled therefore it is necessary that this angle be accurately fixed. Angle A is determined for an unloaded vehicle and represents that angle through which driveshaft 50 will rotate as the vehicle is loaded to that mid-load condition at which it is desired to change from the "EMPTY" curve to the "LOADED" curve as shown in FIG. 2. Step 26b is located so as not to interfere with the operation of proportioning valve 16; pin 32 and slot 67 may also be configured so as to limit the clockwise rotation of cam 25 thereby preventing step 26b interfering with the operation of proportioning valve 16.
The LSPV as illustrated in FIGS. 1 through 13 accommodate counterclockwise rotation of cam driveshaft 50 upon compression of the vehicle suspension system. However, the LSPV may be easily adapted to accommodate clockwise rotation as is illustrated in FIG. 14. By relocation of slot 67 as shown in FIG. 14 the mechanism is adapted for clockwise rotation.
While the invention has been described herein with considerable particularity, it will be understood that the scope thereof is to be determined by the appended claims.
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A hydraulic braking system is provided for vehicles which frequently experience variable loading conditions ranging from maximum to near minimum gross vehicle weights. The system comprises dual proportioning valves, hydraulically in series with one another, one valve includes a unique spring driven digital cam which, in response to compression of the vehicle suspension system, selects the desired master cylinder to brake pressure relationship for the vehicle load condition.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority of Korean Patent Application No. 2004-28471, filed on Apr. 24, 2004, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a disk drive, and more particularly, to a disk drive capable of preventing a disk from deviating from a turntable by an external force and capable of preventing damage to a movable tray holding the disc.
[0004] 2. Description of the Related Art
[0005] In general, a disk drive is a device which reproduces information stored on a disk or records the information to the disk while sliding an optical pickup unit in a radial direction of the disk.
[0006] The disk drive used in an information device such as a notebook is necessarily manufactured in a thin form due to its characteristics. Thus, the height or width of the disk drive is limited to a predetermined size.
[0007] FIG. 1 is an exploded perspective view of a conventional disk drive, FIG. 2 is a cross-sectional view of the disk drive of FIG. 1 , and FIG. 3 is a plan view of a cut stopper.
[0008] The disk drive of FIG. 1 includes a lower case 10 , an upper case 30 which covers the lower case 10 , and a tray 20 which slides in the lower case 10 and on which a disk D is seated (see FIG. 2 ).
[0009] The tray 20 includes a turntable 22 on which the disk D is seated, a spindle motor 24 (see FIG. 2 ) which is installed on the same axis as that of the turntable 22 and which rotates the turntable 22 , and a base frame 21 having an optical pickup unit 23 which slides in a radial direction of the disk D and reproduces information stored on the disk D or records the information on the disk D.
[0010] The tray 20 is guided on guide rails 13 installed at both sides of the lower case 10 . A guide unit 11 is installed to on both sides of the tray 20 and to slide relative to the guide rails 13 , and is attached and detached to and from the lower case 10 .
[0011] A stopper 12 is formed in a portion of the guide unit 11 and protrudes from an inside of the lower case 10 or the tray 20 . A protrusion 14 is formed in a portion of one of the guide rails 13 catches the stopper 12 to restrict a moving distance of the tray 20 when the tray 20 is moved out of the lower case 10 . A spacing portion 15 is placed between the lower case 10 and the guide unit 11 . The spacing portion 15 is a necessary portion to assist in inserting the guide rails 13 in the lower case 10 during assembly.
[0012] However, as shown in FIG. 3 , when the tray 20 is moved out of the lower case 10 , the protrusion 14 collides with the stopper 12 and the stopper 12 may be cut by a collision shock. Specifically, when an external force is applied to the tray 20 in an X-direction ( FIG. 1 ), the tray 20 is opened in the X-direction, the protrusion 14 collides with the stopper 12 and does not survive the external force, and damage occurs in the guide unit 11 in the direction of the spacing portion 15 .
[0013] Meanwhile, referring to FIG. 2 , a distance G 1 is formed between the disk D mounted on the turntable 22 and the upper case 30 . The distance G 1 is optimized for operation of the disk drive, and is difficult to change.
[0014] When an operating shock occurs in a Z-direction ( FIG. 1 ) while the disk drive is in the lower case 10 , the disk D clamped in the turntable 22 does not survive the operating shock and may deviate from the turntable 22 . In this case, an information recording surface may be damaged, information may be lost, and the disk D may be held in the disk drive such that the tray 20 is not easily opened.
SUMMARY OF THE INVENTION
[0015] Accordingly, it is an aspect of the present invention to provide a disk drive capable of preventing a disk from deviating from a turntable by an external force and having a guide unit that endures an external shock when a tray is moved out of a lower case.
[0016] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
[0017] The forgoing and/or other aspects are achieved by providing a disk drive including a lower case; a tray to slide in the lower case, including a turntable on which the disk is seated; and an upper case to cover an upper portion of the lower case and having a deviation-prevention element protruding towards the lower case and preventing the disk from being deviated from the turntable by an external force by reducing a distance between the upper case and the disk.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above and/or other aspects and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:
[0019] FIG. 1 is an exploded perspective view of a conventional disk drive;
[0020] FIG. 2 is a cross-sectional view of the disk drive of FIG. 1 ;
[0021] FIG. 3 is a plan view of a cut stopper of FIG. 1 ;
[0022] FIG. 4 is an exploded perspective view of a disk drive according to an embodiment of the present invention;
[0023] FIG. 5 is a partial enlarged view of a portion of a lower case of FIG. 4 ;
[0024] FIG. 6 is a cross-sectional view of the disk drive of FIG. 4 ;
[0025] FIG. 7 is a plan view of a deviation-prevention element according to an embodiment of the present invention;
[0026] FIG. 8 is a cross-sectional view taken along line I-I′ of FIG. 7 ;
[0027] FIG. 9 is a plan view of a deviation-prevention element according to another embodiment of the present invention; and
[0028] FIG. 10 is a cross-sectional view taken along a line II-II′ of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout. The embodiments are described below to explain the present invention by referring to the figures.
[0030] Referring to FIG. 4 , a disk drive includes a lower case 100 , an upper case 130 which covers the lower case 100 , and a tray 120 which is installed to slides in the lower case 100 and on which a disk D is seated.
[0031] The tray 120 includes a turntable 122 on which the disk D is seated, a spindle motor 124 (see FIG. 6 ) which is installed on the same axis as the turntable 122 and which rotates the turntable 122 , and a base frame 121 having an optical pickup unit 123 which is installed to slides in a radial direction of the disk D and reproduces information stored on the disk D or records the information to the disk D.
[0032] Guide rails 113 are installed at both sides of the tray 120 , and a protrusion 114 is formed in a portion of one of the guide rails 113 and protrudes upwards, that is, toward the upper case 130 .
[0033] Referring to FIG. 5 , a guide unit 111 is installed at both sides of the lower case 100 . The guide rails 113 are inserted into the guide unit 111 , and the guide unit 111 guides the guide rails 113 to slide. A stopper 112 is formed in the guide unit 111 corresponding to the guide rails 113 in which the protrusion 114 is formed. The stopper 112 protrudes from a direction in which the guide rails 113 face each other. A spacing portion 117 is placed between the lower case 100 and the guide unit 111 .
[0034] A portion 111 a of the guide unit 111 having the stopper 112 is thinner than other portions of the guide unit 111 so as to form the spacing portion 117 separated from the lower case 100 by a predetermined distance. Thus, the portion 111 a itself has an elastic force and can be elastically deformed. The portion 111 a is elastically deformed when the guide rails 113 are assembled in the guide unit 111 such that the stopper 112 is prevented from being caught on the protrusion 114 and the spacing portion 117 is formed in the portion 111 a for ease of assembly.
[0035] A reinforcement unit 116 is formed on an opposite side of the portion 111 a having the stopper 112 to protrude from the spacing portion 117 . The length L (the length in which the tray 120 is attached and detached to and from the lower case 100 ) of the reinforcement unit 116 may be larger than the length I of the stopper 112 . In addition, the reinforcement unit 116 may be formed so that the length L of the reinforcement unit 116 is greater than the length I of the stopper 112 and the lengths L and I overlap each other.
[0036] Thus, the stopper 112 alleviates the concentration of stress where it is connected to the guide rails 113 so that the stopper 112 is prevented from being damaged by a shock against the protrusion 114 . The reinforcement unit 116 may have a variety of shapes that maintain its function.
[0037] In the above structure, the tray 120 is attached and detached to and from the lower case 100 as the guide rail 113 slides along the guide unit 111 . When the tray 120 is removed from the lower case 100 , the protrusion 114 collides with the stopper 112 and is stopped.
[0038] Referring to FIGS. 4 and 6 , a deviation-prevention element 131 is formed in the upper case 130 and protrudes from a direction opposite to the lower case 100 , that is, to face the disk D seated on the turntable 122 .
[0039] The deviation-prevention element 131 faces a noninformation area of the disk D, that is, an inside (a circumference of a portion seated on the turntable 122 ) of the disk D. This prevents information stored on the disk D from being damaged by a collision caused by an external shock applied to the deviation-prevention element 131 .
[0040] The deviation-prevention element 131 is not formed in an area in which the tray 120 is attached and detached to and from the lower case 100 and also faces the noninformation area of the disk D, so as not to interfere with an operation of attaching and detaching the tray 120 to and from the lower case 100 . The deviation-prevention element 131 has a U-shape, but is not limited to this shape and may have a variety of shapes in which the deviation-prevention element 131 faces the noninformation area of the disk D, excluding the direction in which the tray 120 is attached and detached to and from the lower case 100 .
[0041] The deviation-prevention element 131 may be formed as one piece with the upper case 130 .
[0042] A distance G 2 between the deviation-prevention element 131 and the disk D is smaller than a distance G 1 (see FIG. 2 ) between the upper case 130 and the disk D so that the deviation-prevention element 131 prevents the disk D from being detached from the turntable 122 by an external shock.
[0043] Referring to FIGS. 7 and 8 , a plurality of deviation-prevention elements 231 protrudes from an upper case 230 (similar to the upper case 130 ) to face the disk D seated on the turntable 122 . In addition, the deviation-prevention elements 131 face a noninformation area of the disk D, that is, an inside of the disk D. The deviation-prevention elements 231 can again be formed as one body with the upper case 230 .
[0044] The operation of the deviation-prevention element 231 is similar to that of the deviation-prevention element 131 of FIGS. 4 and 6 and thus, detailed descriptions thereof will be omitted.
[0045] Referring to FIGS. 9 and 10 , a deviation-prevention element 331 is formed by attaching an adhesion sheet having a predetermined thickness to a bottom surface of an upper case 330 (similar to the upper case 130 ). In this case, even though the deviation-prevention element 331 is not formed as one body with the upper case 330 , the deviation-prevention element 331 may easily be installed in a disk drive for ease of manufacture. The operation of the deviation-prevention element 331 is similar to that of the deviation-prevention element 131 of FIGS. 4 and 6 and thus, detailed descriptions thereof will be omitted.
[0046] As described above, in the disk drive according to the embodiments of the present invention, a disk is prevented from being deviated from a turntable by an external force, and even though an external shock is applied to a direction in which a tray is opened, a guide unit survives the external shock and is not damaged.
[0047] While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention, as defined by the following claims.
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A disk drive including a lower case, a tray to be attached and detached to and from the lower case while sliding in the lower case and having a turntable on which a disk is seated, and an upper case installed to cover an upper portion of the lower case. The upper case has at least one deviation-prevention element extending toward the lower case to prevent the disk from deviating from the turntable by an external force on the disk drive by reducing a distance between the upper case and the disk seated on the turntable.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for forming a chromium oxide film on the surface of stainless steel, and, more particularly, to a method for forming a chromium oxide film, as a passivation layer, on a stainless-steel surface, by which oxidation resistance is markedly increased with reduced moisture adsorption, and diffusion and permeation of hydrogen into the stainless steel can be sharply prevented.
2. Description of the Related Art
The definition of the terms “clean surface” in the vacuum related fields varies according to vacuum exposure environments. In other words, “clean” means much more than scrubbing the sample and handling it with care. For example, in an ultra high vacuum of 1×10 −9 Torr or an extreme high vacuum of 1×10 −12 Torr, a “clean surface” is defined as a surface at which outgassing due to thermal effects does not occur beyond a particular level. For the reduction of outgassing, any ultra high vacuum chamber and the compartments thereof must be subjected to pretreatment, such as chemical cleaning or electrolytic polishing.
Stainless steels are the preferred materials for ultra high vacuum or extreme high vacuum processing conditions because of their superior oxidation resistance, low outgassing rate, and easy welding properties.
Stainless steels have a native passivation oxide layer. Although the surface of stainless steel is protected by the native passivation oxide layer, it still has a strong affinity for gases, so that when exposed to air, the surface is prone to absorb gases such as water vapor. Water molecules are adsorbed onto the surface or into the near surface region of stainless steel, and the porous surface oxide layer serves as a reservoir for water. This weakness of stainless steel against moisture sorption and subsequent outgassing has been a problem in unbaked stainless steel vacuum systems.
The conventional surface treatment technique can create an ultra high vacuum condition to a certain extent. However, since the hydrophilic porous surface absorbs excess water, it takes a long time to evacuate the chamber and the degree of vacuum is also lowered.
SUMMARY OF THE INVENTION
To solve the above problems, it is an objective of the present invention to provide a method for processing the surface of stainless steel, by which moisture sorption, and diffusion and permeation of hydrogen can be suppressed, so that evacuation time can be sharply reduced with an improved degree of vacuum.
To achieve the above objective of the present invention, there is provided a method for forming a chromium oxide film on a stainless steel surface, comprising: (a) placing a sample having the stainless steel surface into a vacuum furnace, evacuating the vacuum furnace to a pressure of 2×10 −7 to 3×10 −7 Torr, and heating the vacuum furnace to 450 to 600° C. at a rate of 5 to 10° C./min; (b) maintaining the pressure in the vacuum furnace for 10 to 20 minutes at a temperature of 450 to 600° C. to remove foreign materials from the surface of the stainless steel and to diffuse chromium atoms from the interior of the stainless steel; and (c) supplying oxygen into the vacuum furnace while maintaining the pressure and temperature until an oxygen partial pressure reaches 1×10 −9 to 2.5×10 −7 Torr, to cause the diffused chromium atoms to react with oxygen, resulting in the chromium oxide (Cr 2 O 3 ) film on the surface of the stainless steel.
Preferably, step (c) is carried out for 50 seconds to 28 hours.
Preferably, when the temperature of the vacuum furnace is 450° C., step (c) is carried out at a pressure of 1×10 −9 to 2×10 −9 Torr for 14 to 28 hours.
Preferably, when the temperature of the vacuum furnace is 500° C., step (c) is carried out at a pressure of 8×10 −9 to 9×10 −9 Torr for 3 to 3.5 hours.
Preferably, when the temperature of the vacuum furnace is 550° C., step (c) is carried out at a pressure of 5×10 −8 to 6×10 −8 Torr for 1,600 to 2,000 seconds. Preferably, when the temperature of the vacuum furnace is 600° C., step (c) is carried out at a pressure of 2.5×10 −7 to 3.5×10 −7 Torr for 300 to 400 seconds.
Preferably, the stainless steel includes 304, 304L, 316, 316L and 316LN stainless steels.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objective and advantages of the present invention will become more apparent by describing in detail a preferred embodiment thereof with reference to the attached drawings in which:
FIGS. 1A and 1B are graphs illustrating changes of the surface composition of a 304 stainless steel surface at partial pressures of 1×10 −9 and 1×10 −7 Torr of oxygen; and
FIG. 2 is a graph showing relative amounts of water per unit area desorbed from the unoxidized and oxidized surfaces of 304 stainless steel.
DETAILED DESCRIPTION OF THE INVENTION
A method for processing the surface of stainless steel according to the present invention wherein a stainless steel sample is heated at an appropriate temperature at an appropriate oxygen partial pressure in a high vacuum environment such that chromium (Cr) comes out of the surface of the stainless steel from the inside, which allows a chemical reaction with oxygen.
The novel feature of the present invention is based on the fact that a chromium oxide film formed on the stainless steel surface has a hydrophobic property. In other words, if the porous oxide film on the stainless steel surface is replaced with a dense chromium oxide film, the outgassing from the stainless steel surface can be greatly reduced.
The formation of the chromium oxide film may be carried out by a vacuum thermal oxidation method (G. Hultquist, C. Leygraf, Mater. Sci. Eng ., 42(1980), p. 99). The chromium oxide film on the stainless steel surface serves as a diffusion barrier for hydrogen, reduces surface roughness, and causes a sharp reduction in outgassing at ambient conditions.
To create a chromium oxide film with a smooth surface, the present inventors slowed down the growth rate of the oxide film. Also, formation of the perfect chromium oxide film was evidenced using surface-sensitive synchrotron radiation photoemission and temperature programmed desorption (TPD) techniques. As a result, it has been shown that the oxide film present on the surface is almost pure Cr 2 O 3 . Also, it was found that the formed Cr 2 O 3 thin film shows a marked sorption resistance.
When the inventive method is applied to the manufacture of a vacuum furnace, moisture sorption in the vacuum furnace can be sharply lowered, which allows the vacuum level of the chamber to reach ultra high vacuum after preventilation. In addition, the thin film formed on the stainless steel surface, which acts as a barrier, suppresses the diffusion and permeation of hydrogen, and thus extreme high vacuum as well as ultra high vacuum can be easily attained.
Hereinafter, a method for forming a chromium oxide film on the surface of a stainless steel according to the present invention will be described in greater detail with reference to the appended drawings.
The surface processing on the stainless steel sample according to the present invention is preferably performed at the final step in the manufacture of a stainless steel vacuum furnace. First, the components which will constitute the vacuum furnace are placed into a vacuum furnace and then evacuated to a pressure of 2×10 −7 to 3×10 −7 Torr or less.
Then, the temperature of the vacuum furnace is raised slowly to 450° C. at a rate of 5° C./min, and heated at this temperature for 10 to 20 minutes to remove foreign materials from the surface of the stainless steel sample and to simultaneously diffuse chromium from the stainless steel substrate. While keeping the temperature of the chamber at the same level, oxygen is allowed to flow into the vacuum furnace until the partial pressure of oxygen reaches about 1×10 −9 Torr, which allows a chemical reaction between the diffused chromium and the supplied oxygen, so that a chromium oxide film is formed on the surface of the stainless steel substrate.
In the formation of the chromium oxide film, the partial pressure and the reaction temperature are correlated. For example, the pressure in the vacuum furnace is maintained at 8×10 −9 Torr for a temperature of 500° C., at 5×10 −8 Torr for 550° C., and at 2.5×10 −7 Torr for 600° C. After the formation of the oxide film is completed, the heater of the vacuum furnace is turned off and then cooled slowly to room temperature.
The stainless steel substrate formed by the inventive method has a smooth, dense and thin chromium oxide film over its surface, so that the moisture sorption rate sharply drops to 1/100 or less. Also, the diffusion and permeation of hydrogen is prevented, so that the vacuum furnace can reach a desired vacuum level within a short period of time with an improved degree of vacuum.
It is assumed that a turbo-molecular pump is used for evacuating the vacuum furnace. For a vacuum furnace manufactured by a conventional method, the pressure of the vacuum furnace remains near 1×10 −8 Torr. Meanwhile, the stainless steel vacuum furnace processed by the inventive method can reach 1×10 −10 Torr, which is 100 times lower than the vacuum level of the conventional vacuum furnace, within merely 5 hours. In addition, while the pressure of the conventional vacuum furnace reaches 2×10 −10 Torr at the lowest, the pressure of the vacuum furnace manufactured by the inventive method can drop to 1×10 −11 Torr or less, which is close to the extreme high vacuum region.
The present invention will be described in greater detail by means of the following examples. The following examples are for illustrative purposes and not intended to limit the scope of the invention.
In the present embodiment, commercial-grade 304-stainless steel foil was used as a sample. Photoemission measurements were performed at the 2B1 spherical grating monochromator beamline at the Pohang light Source (PLS) in the Pohang Accelerator Laboratory. The overall instrument resolution was about 0.4 eV at a photon energy hv=143 eV, which was chosen to measure the surface-sensitive Cr 3p and Fe 3p spectra. During the measurements, the base pressure was maintained at 1×10 −10 Torr or more, and the oxidation temperature was maintained at 450° C.
FIGS. 1A and 1B show the changes of the surface composition of the 304 stainless steel at 450° C. exposed to oxygen partial pressures of 1×10 −9 and 1×10 −7 Torr, respectively. In FIGS. 1 A and FIG. 1B, the relative amounts of trivalent Cr (•), metallic Cr , hexavalent Cr (♦), and iron (▪) are plotted. Also, the intensity of the Cr 2 O 3 satellite peaks (*) is also shown in FIG. 1 A. Also, the inset in FIG. 1A shows the wide-scan photoemission spectrum at an oxygen exposure of 3.6L.
Referring to FIGS. 1A and 1B, the plots show that an iron oxide film is replaced by a chromium oxide film. The chromium oxide is then easily characterized by photoemission spectra. In effect, the chromium is mostly in the form Cr 2 O 3 , as evidenced by the binding energy, spin-orbit and multiplet splittings of the Cr 3p as well as its satellite feature at 13 eV binding energy.
Referring to FIG. 1A, as the oxygen exposure increases, the trivalent Cr concentration continues to increase, whereas the metallic Cr and trace iron oxides steadily decrease. At above 100L, there will remain only a chromium-oxide film that has a stoichiometry of Cr 2 O 3 . The thickness of the Cr 2 O 3 film, deduced from photonenergy dependence studies, appears to be ˜10A. This thickness corresponds to about 1.5λ, where λ is the electron escape depth (λ≈6A). No measurable chromium-depleted zone was found.
By contrast, the plots in FIG. 1B, which were measured at an oxygen partial pressure of 1×10 −7 Torr, show that an initial increase (decrease) in the surface chromium (iron) content is followed by a steady decrease (increase) with an increase in oxygen exposure. Here, the critical pressure p c is defined as the oxygen pressure at which the supply of oxygen starts to exceed the volume diffusion of Cr. The critical pressure p c at 450° C. is about 1×10 −8 Torr. If the oxygen partial pressure is higher than the critical pressure p c , for example, at 1×10 −7 Torr, the amount of Cr atoms diffusing to the surface is limited and prevents all oxygen from reacting only with Cr. Thus, iron segregates there during further oxidation, and the film becomes more enriched in iron. Meanwhile, at an oxygen partial pressure of 1×10 −9 Torr, there is a larger supply of Cr than of oxygen, and thus a pure Cr 2 O 3 film is developed.
The thermal desorption characteristics of the, thin Cr 2 O 3 film surface were investigated by TPD. For comparison, the venting condition was kept the same by using an extremely dry nitrogen venting system. FIG. 2 shows the relative amounts of water per unit area desorbed from the unoxidized and oxidized surfaces of the 304 stainless steel surface at 450° C. at three oxygen partial pressures, namely, at 1×10 −4 Torr for 1 hour, at 1×10 −8 Torr for 12 hours and at 1×10 −9 Torr for 24 hours. The surface oxidation, even at 1×10 −4 Torr, which is much higher than the critical pressure p c , greatly reduces the quantity of H 2 O released. At an oxygen partial pressure of 1×10 −9 Torr, which is lower than the critical pressure p c , the amount of water desorbed from the oxidized stainless steel surface is three times lower than that at 1×10 −6 Torr. As a result, the total amount of H 2 O desorbed from the Cr 2 O 3 film surface is about two times smaller than that from the unoxidized surface.
The inset in FIG. 2 shows thermal desorption spectra of water for the unoxidized surface (solid line) and the oxidized surface at 1×10 −9 Torr (dotted line). As shown in the TPD spectra of H 2 O, the unoxidized surface shows a large peak around 650 K, whereas a distinct peak is not detected from the Cr 2 O 3 (oxidized at 1×10 −9 Torr for 24 hours) over the temperature range. This result indicates that there is a remarkable improvement in terms of sorption-resistant properties.
The outgassing rate of an oxidized extreme high vacuum furnace is about 100 times lower than that of an unoxidized ultra high vacuum furnace. This superior adsorption resistance of the oxidized stainless steel surface in such a high vacuum condition is regarded as a result of the compact rhombohedral structure of the Cr 2 O 3 film. Also, the extremely smooth surface of the Cr 2 O 3 film contributes to reducing the adsorption of water. In other words, the sorption resistance of the stainless steel is enhanced by forming the smooth and dense Cr 2 O 3 film.
As described above, the method for processing the surface of a stainless steel substrate according to the present invention provides a dense and smooth Cr 2 O 3 film to the surface, which sharply suppresses the adsorption of moisture and the diffusion and transmission of hydrogen. Thus, the degree of vacuum can be raised to a higher level, for example, to the extreme high vacuum level of 1×10 −11 Torr or less, and the time required for reaching a desired vacuum level can be reduced. Furthermore, the formation of the new Cr 2 O 3 film on the stainless steel surface according to the present invention can provide ultra high or extreme high vacuum with excellent cleanliness and superior performance. The stainless steel surface processing technique according to the present invention is applicable in fabricating more advanced semiconductor devices, which need an extreme high vacuum environment.
While this invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made thereto without departing from the spirit and scope of the invention as defined by the appended claims.
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A method for forming a chromium oxide film on the surface of a stainless steel sample. The method includes: (a) placing a sample having stainless a steel surface into a vacuum furnace, evacuating the vacuum furnace to a pressure of 2×10 −7 to 3×10 −7 Torr, and heating the vacuum furnace to 450 to 600° C. at a rate of 5 to 10° C./min; (b) maintaining the vacuum furnace for 10 to 20 minutes at a temperature of 450 to 600° C. to remove foreign materials from the surface of the stainless steel sample and to extract chromium atoms from the stainless steel substrate; and (c) supplying oxygen to the vacuum furnace while maintaining the temperature until oxygen partial pressure reaches 1×10 −9 to 2.5×10 −7 Torr, so the extracted chromium atoms react with oxygen, producing a chromium oxide (Cr 2 O 3 ) film on the surface of the stainless steel. The dense and smooth Cr 2 O 3 film improves oxidation resistance and sorption resistance, and suppresses diffusion and permeation of hydrogen.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. application Ser. No. 13/090,889, filed on Apr. 20, 2011, which claims the benefit of U.S. Provisional Application No. 61/326,294, filed on Apr. 21, 2010, the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates to a coordinate measuring device. One set of coordinate measurement devices belongs to a class of instruments that measure the three-dimensional (3D) coordinates of a point by sending a laser beam to the point, where it is intercepted by a retroreflector target. The instrument finds the coordinates of the point by measuring the distance and the two angles to the target. The distance is measured with a distance-measuring device such as an absolute distance meter (ADM) or an interferometer. The angles are measured with an angle-measuring device such as an angular encoder. A gimbaled beam-steering mechanism within the instrument directs the laser beam to the point of interest. An example of such a device is a laser tracker. Exemplary laser tracker systems are described by U.S. Pat. No. 4,790,651 to Brown et al., incorporated by reference herein, and U.S. Pat. No. 4,714,339 to Lau et al.
[0003] A coordinate-measuring device closely related to the laser tracker is the total station. The total station, which is most often used in surveying applications, may be used to measure the coordinates of diffusely scattering or retroreflective targets. Hereinafter, the term laser tracker is used in a broad sense to include total stations.
[0004] Ordinarily the laser tracker sends a laser beam to a retroreflector target. A common type of retroreflector target is the spherically mounted retroreflector (SMR), which comprises a cube-corner retroreflector embedded within a metal sphere. The cube-corner retroreflector comprises three mutually perpendicular mirrors. The apex of the cube corner, which is the common point of intersection of the three mirrors, is located at the center of the sphere. It is common practice to place the spherical surface of the SMR in contact with an object under test and then move the SMR over the surface being measured. Because of this placement of the cube corner within the sphere, the perpendicular distance from the apex of the cube corner to the surface of the object under test remains constant despite rotation of the SMR. Consequently, the 3D coordinates of a surface can be found by having a tracker follow the 3D coordinates of an SMR moved over the surface. It is possible to place a glass window on the top of the SMR to prevent dust or dirt from contaminating the glass surfaces. An example of such a glass surface is shown in U.S. Pat. No. 7,388,654 to Raab et al., incorporated by reference herein.
[0005] A gimbal mechanism within the laser tracker may be used to direct a laser beam from the tracker to the SMR. Part of the light retroreflected by the SMR enters the laser tracker and passes onto a position detector. The position of the light that hits the position detector is used by a tracker control system to adjust the rotation angles of the mechanical azimuth and zenith axes of the laser tracker to keep the laser beam centered on the SMR. In this way, the tracker is able to follow (track) the SMR.
[0006] Angular encoders attached to the mechanical azimuth and zenith axes of the tracker may measure the azimuth and zenith angles of the laser beam (with respect to the tracker frame of reference). The one distance measurement and two angle measurements performed by the laser tracker are sufficient to completely specify the three-dimensional location of the SMR.
[0007] As mentioned previously, two types of distance meters may be found in laser trackers: interferometers and absolute distance meters (ADMs). In the laser tracker, an interferometer (if present) may determine the distance from a starting point to a finishing point by counting the number of increments of known length (usually the half-wavelength of the laser light) that pass as a retroreflector target is moved between the two points. If the beam is broken during the measurement, the number of counts cannot be accurately known, causing the distance information to be lost. By comparison, the ADM in a laser tracker determines the absolute distance to a retroreflector target without regard to beam breaks, which also allows switching between targets. Because of this, the ADM is said to be capable of “point-and-shoot” measurement. Initially, absolute distance meters were only able to measure stationary targets and for this reason were always used together with an interferometer. However, some modern absolute distance meters can make rapid measurements, thereby eliminating the need for an interferometer. Such an ADM is described in U.S. Pat. No. 7,352,446 to Bridges et al., incorporated by reference herein.
[0008] In its tracking mode, the laser tracker will automatically follow movements of the SMR when the SMR is in the capture range of the tracker. If the laser beam is broken, tracking will stop. The beam may be broken by any of several means: (1) an obstruction between the instrument and SMR; (2) rapid movements of the SMR that are too fast for the instrument to follow; or (3) the direction of the SMR being turned beyond the acceptance angle of the SMR. By default, following the beam break, the beam remains fixed at the point of the beam break or at the last commanded position. It may be necessary for an operator to visually search for the tracking beam and place the SMR in the beam in order to lock the instrument onto the SMR and continue tracking.
[0009] Some laser trackers include one or more cameras. A camera axis may be coaxial with the measurement beam or offset from the measurement beam by a fixed distance or angle. A camera may be used to provide a wide field of view to locate retroreflectors. A modulated light source placed near the camera optical axis may illuminate retroreflectors, thereby making them easier to identify. In this case, the retroreflectors flash in phase with the illumination, whereas background objects do not. One application for such a camera is to detect multiple retroreflectors in the field of view and measure each in an automated sequence. Exemplary systems are described in U.S. Pat. No. 6,166,809 to Pettersen et al., and U.S. Pat. No. 7,800,758 to Bridges et al., incorporated by reference herein.
[0010] Some laser trackers have the ability to measure with six degrees of freedom (DOF), which may include three coordinates, such as x, y, and z, and three rotations, such as pitch, roll, and yaw. Several systems based on laser trackers are available or have been proposed for measuring six degrees of freedom. Exemplary systems are described in U.S. Published Patent Application No. 2010/0128259 to Bridges, incorporated by reference herein; U.S. Pat. No. 7,800,758 to Bridges et al., U.S. Pat. No. 5,973,788 to Pettersen et al.; and U.S. Pat. No. 7,230,689 to Lau.
User Control of Laser Tracker Functionality
[0011] Two common modes of operation of the laser tracker are tracking mode and profiling mode. In tracking mode, the laser beam from the tracker follows the retroreflector as the operator moves it around. In profiling mode, the laser beam from the tracker goes in the direction given by the operator, either through computer commands or manual action.
[0012] Besides these modes of operation that control the basic tracking and pointing behavior of the tracker, there are also special option modes that enable the tracker to respond in a manner selected by the operator ahead of time. The desired option mode is typically selected in software that controls the laser tracker. Such software may reside in an external computer attached to the tracker (possibly through a network cable) or within the tracker itself. In the latter case, the software may be accessed through console functionality built into the tracker.
[0013] An example of an option mode is the Auto Reset mode in which the laser beam is driven to a preset reference point whenever the laser beam is broken. One popular reference point for the Auto Reset option mode is the tracker Home Position, which is the position of a magnetic nest mounted on the tracker body. The alternative to Auto Reset is the No Reset option mode. In this case, the laser beam continues pointing in the original direction whenever the laser beam is broken. A description of the tracker home position is given in U.S. Pat. No. 7,327,446 to Cramer et al., incorporated by reference herein.
[0014] Another example of a special option mode is PowerLock, a feature offered by Leica Geosystems on their Leica Absolute Tracker™. In the PowerLock option mode, the location of the retroreflector is found by a tracker camera whenever the tracker laser beam is broken. The camera immediately sends the angular coordinates of the retroreflector to the tracker control system, thereby causing the tracker to point the laser beam back at the retroreflector. Methods involving automatic acquisition of a retroreflector are given in international application WO 2007/079601 to Dold et al. and U.S. Pat. No. 7,055,253 to Kaneko.
[0015] Some option modes are slightly more complex in their operation. An example is the Stability Criterion mode, which may be invoked whenever an SMR is stationary for a given period of time. The operator may track an SMR to a magnetic nest and set it down. If a stability criterion is active, the software will begin to look at the stability of the three-dimensional coordinate readings of the tracker. For instance, the user may decide to judge the SMR to be stable if the peak-to-peak deviation in the distance reading of the SMR is less than two micrometers over a one second interval. After the stability criterion is satisfied, the tracker measures the 3D coordinates and the software records the data.
[0016] More complex modes of operation are possible through computer programs. For example, software is available to measure part surfaces and fit these to geometrical shapes. Software will instruct the operator to move the SMR over the surface and then, when finished collecting data points, to raise the SMR off the surface of the object to end the measurement. Moving the SMR off the surface not only indicates that the measurement is completed; it also indicates the position of the SMR in relation to the object surface. This position information is needed by the application software to properly account for the offset caused by the SMR radius.
[0017] A second example of complex computer control is a tracker survey. In the survey, the tracker is driven sequentially to each of several target locations according to a prearranged schedule. The operator may teach these positions prior to the survey by carrying the SMR to each of the desired positions.
[0018] A third example of complex software control is tracker directed measurement. The software directs the operator to move the SMR to a desired location. It does this using a graphic display to show the direction and distance to the desired location. When the operator is at the desired position, the color on the computer monitor might, for example, turn from red to green.
[0019] The element common to all tracker actions described above is that the operator is limited in his ability to control the behavior of the tracker. On the one hand, option modes selected in the software may enable the operator to preset certain behaviors of the tracker. However, once the option modes have been selected by the user, the behavior of the tracker is established and cannot be changed unless the operator returns to the computer console. On the other hand, the computer program may direct the operator to carry out complicated operations that the software analyzes in a sophisticated way. In either case, the operator is limited in his ability to control the tracker and the data collected by the tracker.
Need for Remote Tracker Commands
[0020] A laser tracker operator performs two fundamental functions. He positions an SMR during a measurement, and he sends commands through the control computer to the tracker. However, it is not easy for one operator to perform both of these measurement functions because the computer is usually far away from the measurement location. Various methods have been tried to get around this limitation, but none is completely satisfactory.
[0021] One method sometimes used is for a single operator to set the retroreflector in place and walk back to the instrument control keyboard to execute a measurement instruction. However, this is an inefficient use of operator and instrument time. In cases where the operator must hold the retroreflector for the measurement, single operator control is only possible when the operator is very close to the keyboard.
[0022] A second method is to add a second operator. One operator stands by the computer and a second operator moves the SMR. This is obviously an expensive method and verbal communication over large distances can be a problem.
[0023] A third method is to equip a laser tracker with a remote control. However, remote controls have several limitations. Many facilities do not allow the use of remote controls for safety or security reasons. Even if remote controls are allowed, interference among wireless channels may be a problem. Some remote control signals do not reach the full range of the laser tracker. In some situations, such as working from a ladder, the second hand may not be free to operate the remote control. Before a remote control can be used, it is usually necessary to set up the computer and remote control to work together, and then only a small subset of tracker commands can ordinarily be accessed at any given time. An example of a system based on this idea is given in U.S. Pat. No. 7,233,316 to Smith et al.
[0024] A fourth method is to interface a cell phone to a laser tracker. Commands are entered remotely by calling the instrument from the cell phone and entering numbers from the cell phone keypad or by means of voice recognition. This method also has many shortcomings. Some facilities do not allow cell phones to be used, and cell phones may not be available in rural areas. Service requires a monthly service provider fee. A cell phone interface requires additional hardware interfacing to the computer or laser tracker. Cell phone technology changes fast and may require upgrades. As in the case of remote controls, the computer and remote control must be set up to work together, and only a small subset of tracker commands can ordinarily be accessed at a given time.
[0025] A fifth method is to equip a laser tracker with internet or wireless network capabilities and use a wireless portable computer or personal digital assistant (PDA) to communicate commands to the laser tracker. However, this method has limitations similar to a cell phone. This method is often used with total stations. Examples of systems that use this method include U.S. Published Patent Application No. 2009/017618 to Kumagai et al., U.S. Pat. No. 6,034,722 to Viney et al., U.S. Pat. No. 7,423,742 to Gatsios et al., U.S. Pat. No. 7,307,710 to Gatsios et al., U.S. Pat. No. 7,552,539 to Piekutowski, and U.S. Pat. No. 6,133,998 to Monz et al. This method has also been used to control appliances by a method described in U.S. Pat. No. 7,541,965 to Ouchi et al.
[0026] A sixth method is to use a pointer to indicate a particular location in which a measurement is to be made. An example of this method is given in U.S. Pat. No. 7,022,971 to Ura et al. It might be possible to adapt this method to give commands to a laser tracker, but it is not usually very easy to find a suitable surface upon which to project the pointer beam pattern.
[0027] A seventh method is to devise a complex target structure containing at least a retroreflector, transmitter, and receiver. Such systems may be used with total stations to transmit precise target information to the operator and also to transmit global positioning system (GPS) information to the total station. An example of such a system is given in U.S. Published Patent Application No. 2008/0229592 to Hinderling et al. In this case, no method is provided to enable the operator to send commands to the measurement device (total station).
[0028] An eighth method is to devise a complex target structure containing at least a retroreflector, transmitter and receiver, where the transmitter has the ability to send modulated light signals to a total station. A keypad can be used to send commands to the total station by means of the modulated light. These commands are decoded by the total station. Examples of such systems are given in U.S. Pat. No. 6,023,326 to Katayama et al., U.S. Pat. No. 6,462,810 to Muraoka et al., U.S. Pat. No. 6,295,174 to Ishinabe et al., and U.S. Pat. No. 6,587,244 to Ishinabe et al. This method is particularly appropriate for surveying applications in which the complex target and keypad are mounted on a large staff. Such a method is not suitable for use with a laser tracker, where it is advantageous to use a small target not tethered to a large control pad. Also it is desirable to have the ability to send commands even when the tracker is not locked onto a retroreflector target.
[0029] A ninth method is to include both a wireless transmitter and a modulated light source on the target to send information to a total station. The wireless transmitter primarily sends information on the angular pose of the target so that the total station can turn in the proper direction to send its laser beam to the target retroreflector. The modulated light source is placed near the retroreflector so that it will be picked up by the detector in the total station. In this way, the operator can be assured that the total station is pointed in the right direction, thereby avoiding false reflections that do not come from the target retroreflector. An exemplary system based on this approach is given in U.S. Pat. No. 5,313,409 to Wiklund et al. This method does not offer the ability to send general purpose commands to a laser tracker.
[0030] A tenth method is to include a combination of wireless transmitter, compass assembly in both target and total station, and guide light transmitter. The compass assembly in the target and total station are used to enable alignment of the azimuth angle of the total station to the target. The guide light transmitter is a horizontal fan of light that the target can pan in the vertical direction until a signal is received on the detector within the total station. Once the guide light has been centered on the detector, the total station adjusts its orientation slightly to maximize the retroreflected signal. The wireless transmitter communicates information entered by the operator on a keypad located at the target. An exemplary system based on this method is given in U.S. Pat. No. 7,304,729 to Wasutomi et al. This method does not offer the ability to send general purpose commands to a laser tracker.
[0031] An eleventh method is to modify the retroreflector to enable temporal modulation to be imposed on the retroreflected light, thereby transmitting data. The inventive retroreflector comprises a cube corner having a truncated apex, an optical switch attached to the front face of the cube corner, and electronics to transmit or receive data. An exemplary system of this type is given in U.S. Pat. No. 5,121,242 to Kennedy. This type of retroreflector is complex and expensive. It degrades the quality of the retroreflected light because of the switch (which might be a ferro-electric light crystal material) and because of the truncated apex. Also, the light returned to a laser tracker is already modulated for use in measuring the ADM beam, and switching the light on and off would be a problem, not only for the ADM, but also for the tracker interferometer and position detector.
[0032] A twelfth method is to use a measuring device that contains a bidirectional transmitter for communicating with a target and an active retroreflector to assist in identifying the retroreflector. The bidirectional transmitter may be wireless or optical and is part of a complex target staff that includes the retroreflector, transmitter, and control unit. An exemplary system of this type is described in U.S. Pat. No. 5,828,057 to Hertzman et al. Such a method is not suitable for use with a laser tracker, where it is advantageous to use a small target not tethered to a large control pad. Also the method of identifying the retroreflector target of interest is complicated and expensive.
[0033] There is a need for a simple method for an operator to communicate commands to a laser tracker from a distance. It is desirable that the method be: (1) useable without a second operator; (2) useable over the entire range of the laser tracker; (3) useable without additional hardware interfacing; (4) functional in all locations; (5) free of service provider fees; (6) free of security restrictions; (7) easy to use without additional setup or programming; (8) capable of initiating a wide range of simple and complex tracker commands; (9) useable to call a tracker to a particular target among a plurality of targets; and (10) useable with a minimum of additional equipment for the operator to carry.
SUMMARY
[0034] According to an embodiment of the present invention, a method for optically communicating, from a user to a laser tracker, a command to control operation of the laser tracker includes the steps of providing a rule of correspondence between each of a plurality of commands and each of a plurality of positions, each position being a three-dimensional coordinate; selecting by the user a first command from among the plurality of commands and moving by the user a retroreflector to a first position from among the plurality of positions, wherein the first position corresponds to the first command. The method further includes projecting a first light from the laser tracker to the retroreflector; reflecting a second light from the retroreflector, the second light being a portion of the first light and obtaining first sensed data by sensing a third light, the third light being a portion of the second light. The method further includes determining the first command based at least in part on processing the first sensed data according to the rule of correspondence and executing the first command with the laser tracker.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] Referring now to the drawings, wherein like elements are numbered alike in the several FIGURES:
[0036] FIG. 1 shows a perspective view of an exemplary laser tracker;
[0037] FIG. 2 shows computing and power supply elements attached to exemplary laser tracker;
[0038] FIGS. 3A-3E illustrate ways in which a passive target can be used to convey gestural information through the tracking and measuring systems of the laser tracker;
[0039] FIGS. 4A-4C illustrate ways in which a passive target can be used to convey gestural information through the camera system of a laser tracker;
[0040] FIGS. 5A-5D illustrate ways in which an active target can be used to convey gestural information through the camera system of a laser tracker;
[0041] FIG. 6 is a flow chart showing the steps carried out by the operator and laser tracker in issuing and carrying out a gestural command;
[0042] FIG. 7 is a flow chart showing the optional and required parts of a gestural command;
[0043] FIGS. 8-10 show a selection of laser tracker commands and corresponding gestures that might be used by the operator to convey these commands to the laser tracker;
[0044] FIGS. 11A-11F show alternative types of gestures that might be used;
[0045] FIG. 12 shows an exemplary command tablet for transmitting commands to a laser tracker by means of gestures;
[0046] FIG. 13 shows an exemplary method for using gestures to set a tracker reference point;
[0047] FIG. 14 shows an exemplary method for using gestures to initialize the exemplary command tablet;
[0048] FIG. 15 shows an exemplary method for using gestures to measure a circle;
[0049] FIG. 16 shows an exemplary method for using gestures to acquire a retroreflector with a laser beam from a laser tracker;
[0050] FIG. 17 shows an exemplary electronics and processing system associated with a laser tracker;
[0051] FIG. 18 shows an exemplary geometry that enables finding of three dimensional coordinates of a target using a camera located off the optical axis of a laser tracker;
[0052] FIG. 19 shows an exemplary method for communicating a command to a laser tracker by gesturing with a retroreflector in a spatial pattern;
[0053] FIG. 20 shows an exemplary method for communicating a command to a laser tracker by indicating a position with a retroreflector;
[0054] FIG. 21 shows an exemplary method for communicating a command to a laser tracker by gesturing with a retroreflector in a temporal pattern;
[0055] FIG. 22 shows an exemplary method for communicating a command to a laser tracker by measuring a change in the pose of a six DOF target with a six DOF laser tracker;
[0056] FIG. 23 shows an exemplary method for communicating a command to point the laser beam from the laser tracker to a retroreflector and lock onto the retroreflector, the communication based on a gesture involving a spatial pattern created with the retroreflector;
[0057] FIG. 24 shows an exemplary method for communicating a command to point the laser beam from the laser tracker to a retroreflector and lock onto the retroreflector, the communication based on a gesture involving a temporal pattern in the optical power received by the laser tracker; and
[0058] FIG. 25 shows an exemplary method for communicating a command to point the laser beam from the laser tracker to a retroreflector and lock onto the retroreflector, the communication based on a gesture involving a change in the pose of a six DOF probe.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0059] An exemplary laser tracker 10 is illustrated in FIG. 1 . An exemplary gimbaled beam-steering mechanism 12 of laser tracker 10 comprises zenith carriage 14 mounted on azimuth base 16 and rotated about azimuth axis 20 . Payload 15 is mounted on zenith carriage 14 and rotated about zenith axis 18 . Zenith mechanical rotation axis 18 and azimuth mechanical rotation axis 20 intersect orthogonally, internally to tracker 10 , at gimbal point 22 , which is typically the origin for distance measurements. Laser beam 46 virtually passes through gimbal point 22 and is pointed orthogonal to zenith axis 18 . In other words, laser beam 46 is in the plane normal to zenith axis 18 . Laser beam 46 is pointed in the desired direction by motors within the tracker (not shown) that rotate payload 15 about zenith axis 18 and azimuth axis 20 . Zenith and azimuth angular encoders, internal to the tracker (not shown), are attached to zenith mechanical axis 18 and azimuth mechanical axis 20 and indicate, to high accuracy, the angles of rotation. Laser beam 46 travels to external retroreflector 26 such as the spherically mounted retroreflector (SMR) described above. By measuring the radial distance between gimbal point 22 and retroreflector 26 and the rotation angles about the zenith and azimuth axes 18 , 20 , the position of retroreflector 26 is found within the spherical coordinate system of the tracker.
[0060] Laser beam 46 may comprise one or more laser wavelengths. For the sake of clarity and simplicity, a steering mechanism of the sort shown in FIG. 1 is assumed in the following discussion. However, other types of steering mechanisms are possible. For example, it would be possible to reflect a laser beam off a mirror rotated about the azimuth and zenith axes. An example of the use of a mirror in this way is given in U.S. Pat. No. 4,714,339 to Lau et al. The techniques described here are applicable, regardless of the type of steering mechanism.
[0061] In exemplary laser tracker 10 , cameras 52 and light sources 54 are located on payload 15 . Light sources 54 illuminate one or more retroreflector targets 26 . Light sources 54 may be LEDs electrically driven to repetitively emit pulsed light. Each camera 52 comprises a photosensitive array and a lens placed in front of the photosensitive array. The photosensitive array may be a CMOS or CCD array. The lens may have a relatively wide field of view, say thirty or forty degrees. The purpose of the lens is to form an image on the photosensitive array of objects within the field of view of the lens. Each light source 54 is placed near camera 52 so that light from light source 54 is reflected off each retroreflector target 26 onto camera 52 . In this way, retroreflector images are readily distinguished from the background on the photosensitive array as their image spots are brighter than background objects and are pulsed. There may be two cameras 52 and two light sources 54 placed about the line of laser beam 46 . By using two cameras in this way, the principle of triangulation can be used to find the three-dimensional coordinates of any SMR within the field of view of the camera. In addition, the three-dimensional coordinates of the SMR can be monitored as the SMR is moved from point to point. A use of two cameras for this purpose is described in U.S. Published Patent Application No. 2010/0128259 to Bridges.
[0062] Other arrangements of one or more cameras and light sources are possible. For example, a light source and camera can be coaxial or nearly coaxial with the laser beams emitted by the tracker. In this case, it may be necessary to use optical filtering or similar methods to avoid saturating the photosensitive array of the camera with the laser beam from the tracker.
[0063] Another possible arrangement is to use a single camera located on the payload or base of the tracker. A single camera, if located off the optical axis of the laser tracker, provides information about the two angles that define the direction to the retroreflector but not the distance to the retroreflector. In many cases, this information may be sufficient. If the 3D coordinates of the retroreflector are needed when using a single camera, one possibility is to rotate the tracker in the azimuth direction by 180 degrees and then to flip the zenith axis to point back at the retroreflector. In this way, the target can be viewed from two different directions and the 3D position of the retroreflector can be found using triangulation.
[0064] A more general approach to finding the distance to a retroreflector with a single camera is to rotate the laser tracker about either the azimuth axis or the zenith axis and observe the retroreflector with a camera located on the tracker for each of the two angles of rotation. The retroreflector may be illuminated, for example, by an LED located close to the camera. FIG. 18 shows how this procedure can be used to find the distance to the retroreflector. The test setup 900 includes a laser tracker 910 , a camera 920 in a first position, a camera 930 in a second position, and a retroreflector in a first position 940 and a second position 950 . The camera is moved from the first position to the second position by rotating the laser tracker 910 about the tracker gimbal point 912 about the azimuth axis, the zenith axis, or both the azimuth axis and the zenith axis. The camera 920 includes a lens system 922 and a photosensitive array 924 . The lens system 922 has a perspective center 926 through which rays of light from the retroreflectors 940 , 950 pass. The camera 930 is the same as the camera 920 except rotated into a different position. The distance from the surface of the laser tracker 910 to the retroreflector 940 is L 1 and the distance from the surface of the laser tracker to the retroreflector 950 is L 2 . The path from the gimbal point 912 to the perspective center 926 of the lens 922 is drawn along the line 914 . The path from the gimbal point 916 to the perspective center 936 of the lens 932 is drawn along the line 916 . The distances corresponding to the lines 914 and 916 have the same numerical value. As can be seen from FIG. 18 , the nearer position of the retroreflector 940 places an image spot 942 farther from the center of the photosensitive array than the image spot 952 corresponding to the photosensitive array 950 at the distance farther from the laser tracker. This same pattern holds true for the camera 930 located following the rotation. As a result, the distance between the image points of a nearby retroreflector 940 before and after rotation is larger than the distance between the image points of a far away retroreflector 950 before and after rotation. By rotating the laser tracker and noting the resulting change in position of the image spots on the photosensitive array, the distance to the retroreflector can be found. The method for finding this distance is easily found using trigonometry, as will be obvious to one of ordinary skill in the art.
[0065] Another possibility is to switch between measuring and imaging of the target. An example of such a method is described in U.S. Pat. No. 7,800,758 to Bridges et al. Other camera arrangements are possible and can be used with the methods described herein.
[0066] As shown in FIG. 2 , auxiliary unit 70 is usually a part of laser tracker 10 . The purpose of auxiliary unit 70 is to supply electrical power to the laser tracker body and in some cases to also supply computing and clocking capability to the system. It is possible to eliminate auxiliary unit 70 altogether by moving the functionality of auxiliary unit 70 into the tracker body. In most cases, auxiliary unit 70 is attached to general purpose computer 80 . Application software loaded onto general purpose computer 80 may provide application capabilities such as reverse engineering. It is also possible to eliminate general purpose computer 80 by building its computing capability directly into laser tracker 10 . In this case, a user interface, possibly providing keyboard and mouse functionality is built into laser tracker 10 . The connection between auxiliary unit 70 and computer 80 may be wireless or through a cable of electrical wires. Computer 80 may be connected to a network, and auxiliary unit 70 may also be connected to a network. Plural instruments, for example, multiple measurement instruments or actuators, may be connected together, either through computer 80 or auxiliary unit 70 .
[0067] The laser tracker 10 may be rotated on its side, rotated upside down, or placed in an arbitrary orientation. In these situations, the terms azimuth axis and zenith axis have the same direction relative to the laser tracker as the directions shown in FIG. 1 regardless of the orientation of the laser tracker 10 .
[0068] In another embodiment, the payload 15 is replaced by a mirror that rotates about the azimuth axis 20 and the zenith axis 18 . A laser beam is directed upward and strikes the mirror, from which it launches toward a retroreflector 26 .
[0000] Sending Commands to the Laser Tracker from a Distance
[0069] FIGS. 3A-3E , 4 A- 4 C, and 5 A- 5 D demonstrate sensing means by which the operator may communicate gestural patterns that are interpreted and executed as commands by exemplary laser tracker 10 . FIGS. 3A-3E demonstrate sensing means by which the operator communicates gestural patterns that exemplary laser tracker 10 interprets using its tracking and measuring systems. FIG. 3A shows laser tracker 10 emitting laser beam 46 intercepted by retroreflector target 26 . As target 26 is moved side to side, the laser beam from the tracker follows the movement. At the same time, the angular encoders in tracker 10 measure the angular position of the target in the side-to-side and up-down directions. The angular encoder readings form a two dimensional map of angles that can be recorded by the tracker as a function of time and analyzed to look for patterns of movement.
[0070] FIG. 3B shows laser beam 46 tracking retroreflector target 26 . In this case, the distance from tracker 10 to target 26 is measured. The ADM or interferometer readings form a one-dimensional map of distances that can be recorded by tracker 10 as a function of time and analyzed to look for patterns of movement. The combined movements of FIGS. 3A and 3B can also be evaluated by laser tracker 10 to look for a pattern in three-dimensional space.
[0071] The variations in angle, distance, or three-dimensional space may all be considered as examples of spatial patterns. Spatial patterns are continually observed during routine laser tracker measurements. Within the possible range of observed patterns, some patterns may have associated laser tracker commands. There is one type of spatial pattern in use today that may be considered a command. This pattern is a movement away from the surface of an object following a measurement. For example, if an operator measures a number of points on an object with an SMR to obtain the outer diameter of the object and then moves the SMR away from the surface of the object, it is clear that an outer diameter was being measured. If an operator moves the SMR away from the surface after measuring an inner diameter, it is clear that the inner diameter was being measured. Similarly, if an operator moves an SMR upward after measuring a plate, it is understood that the upper surface of the plate was being measured. It is important to know which side of an object is measured because it is necessary to remove the offset of the SMR, which is the distance from the center to the outer surface of the SMR. If this action of moving the SMR away from an object is automatically interpreted by software associated with the laser tracker measurement, then the movement of the SMR may be considered to be a command that indicates “subtract the SMR offset away from the direction of movement.” Therefore, after including this first command in addition to other commands based on the spatial patterns, as described herein, there is a plurality of commands. In other words, there is a correspondence between a plurality of tracker commands and a plurality of spatial patterns.
[0072] With all of the discussions in the present application, it should be understood that the concept of a command for a laser tracker is to be taken within the context of the particular measurement. For example, in the above situation in which a movement of the retroreflector was said to indicate whether the retroreflector target was measuring an inner or outer diameter, this statement would only be accurate in the context of a tracker measuring an object having a circular profile.
[0073] FIG. 3C shows laser beam 46 tracking retroreflector target 26 . In this case, retroreflector target 26 is held fixed, and tracker 10 measures the three-dimensional coordinates. Certain locations within the measurement volume may be assigned special meanings, as for example when a command tablet, described later, is located at a particular three-dimensional position.
[0074] FIG. 3D shows laser beam 46 being blocked from reaching retroreflector target 26 . By alternately blocking and unblocking laser beam 46 , the pattern of optical power returned to tracker 10 is seen by the tracker measurement systems, including the position detector and the distance meters. The variation in this returned pattern forms a pattern as a function of time that can be recorded by the tracker and analyzed to look for patterns.
[0075] A pattern in the optical power returned to the laser tracker is often seen during routine measurements. For example, it is common to block a laser beam from reaching a retroreflector and then to recapture the laser beam with the retroreflector at a later time, possibly after moving the retroreflector to a new distance from the tracker. This action of breaking the laser beam and then recapturing the laser beam may be considered to be a simple type of user command that indicates that the retroreflector is to be recaptured after it is moved to a new position. Therefore, after including this first simple command in addition to other commands based on the temporal variation in optical power, as described herein, there is a plurality of commands. In other words, there is a correspondence between a plurality of tracker commands and a plurality of patterns based on variations in optical power received by a sensor disposed on the laser tracker.
[0076] A change in optical power is often seen during routine measurements when the laser beam is blocked from returning to the laser tracker. Such an action may be interpreted as a command that indicates “stop tracking” or “stop measuring.” Similarly, a retroreflector may be moved to intercept a laser beam. Such simple actions might be interpreted as commands that indicates “start tracking” These simple commands are not of interest in the present patent application. For this reason, commands discussed herein involve changes in optical power that include at least a decrease in optical power followed by an increase in optical power.
[0077] FIG. 3E shows laser beam 46 tracking retroreflector 26 with a six degree-of-freedom (DOF) probe 110 . Many types of six-DOF probes are possible, and the six-DOF probe 110 shown in FIG. 3E is merely representative, and not limiting in its design. Tracker 10 is able to find the angle of angular tilt of the probe. For example, the tracker may find and record the roll, pitch, and yaw angles of probe 110 as a function of time. The collection of angles can be analyzed to look for patterns.
[0078] FIGS. 4A-4C demonstrate sensing means by which the operator may communicate gestural patterns that exemplary laser tracker 10 interprets using its camera systems. FIG. 4A shows cameras 52 observing the movement of retroreflector target 26 . Cameras 52 record the angular position of target 26 as a function of time. These angles are analyzed later to look for patterns. It is only necessary to have one camera to follow the angular movement of retroreflector target 26 , but the second camera enables calculation of the distance to the target. Optional light sources 54 illuminate target 26 , thereby making it easier to identify in the midst of background images. In addition, light sources 54 may be pulsed to further simplify target identification.
[0079] FIG. 4B shows cameras 52 observing the movement of retroreflector target 26 . Cameras 52 record the angular positions of target 26 and, using triangulation, calculate the distance to target 26 as a function of time. These distances are analyzed later to look for patterns. Optional light sources 54 illuminate target 26 .
[0080] FIG. 4C shows cameras 52 observing the position of retroreflector target 26 , which is held fixed. Tracker 10 measures the three-dimensional coordinates of target 26 . Certain locations within the measurement volume may be assigned special meanings, as for example when a command tablet, described later, is located at a particular three-dimensional position.
[0081] FIGS. 5A-5D demonstrate sensing means by which the operator may communicate gestural patterns that exemplary laser tracker 10 interprets by using its camera systems in combination with an active light source. FIG. 5A shows cameras 52 observing active retroreflector target 120 . Active retroreflector target comprises retroreflector target 126 onto which are mounted light source 122 and control button 124 that turns light source 122 on and off. The operator presses control button 124 on and off in a prescribed pattern to illuminate light source 122 in a pattern that is seen by cameras 52 and analyzed by tracker 10 .
[0082] An alternative mode of operation for FIG. 5A is for the operator to hold down control button 124 only while gesturing a command, which might be given, for example, using side-to-side and up-down movements. By holding down control button 124 only during this time, parsing and analysis is simplified for tracker 10 . There are several ways that the tracker can obtain the pattern of movement, whether control button 124 is held down or not: (1) cameras 52 can follow the movement of light source 122 ; (2) cameras 52 can follow the movement of retroreflector 126 , which is optionally illuminated by light sources 54 ; or (3) tracking and measurement systems of laser tracker 10 can follow the movement of retroreflector 126 . In addition, it is possible for the tracker to follow retroreflector 126 in order to collect measurement data while the operator is at the same time pressing control button 124 up and down to produce a temporal pattern in the emitted LED light to issue a command to the tracker.
[0083] FIG. 5B shows cameras 52 observing light source 132 on six DOF probe 130 . Six-DOF probe 130 comprises retroreflector 136 , light source 132 , and control button 134 . The operator presses control button 134 on and off in a prescribed manner to illuminate light source 132 in a pattern seen by cameras 54 and analyzed by tracker 10 .
[0084] An alternative mode of operation for FIG. 5B is for the operator to hold down control button 134 only while gesturing a command, which might be given, for example, using side-to-side and up-down movements or rotations. By holding down control button 134 only during this time, parsing and analysis is simplified for tracker 10 . In this case, there are several ways that the tracker can obtain the pattern of movement: (1) cameras 52 can follow the movement of light source 132 ; (2) cameras 52 can follow the movement of retroreflector 136 , which is optionally illuminated by light sources 54 ; or (3) tracking and measurement systems of laser tracker 10 can follow the movement or rotation of six-DOF target 130 .
[0085] FIGS. 5A , 5 B can also be used to indicate a particular position. For example, a point on the spherical surface of the active retroreflector target 120 or a point on the spherical surface of the six-DOF probe 130 can be held against an object to provide a location that can be determined by the cameras 52 . Certain locations within the measurement volume may be assigned special meanings, as for example when a command tablet, described in reference to FIG. 12 , is located at a particular three-dimensional position.
[0086] FIG. 5C shows cameras 52 observing light source 142 on wand 140 . Wand 140 comprises light source 142 and control button 144 . The operator presses control button 144 on and off in a prescribed manner to illuminate light source 142 in a temporal pattern seen by cameras 54 and analyzed by tracker 10 .
[0087] FIG. 5D shows cameras 52 observing light source 142 on wand 140 . The operator presses control button 144 on wand 140 to continuously illuminate light source 142 . As the operator moves wand 140 in any direction, cameras 52 record the motion of wand 140 , the pattern of which is analyzed by tracker 10 . It is possible to use a single camera 52 if only the pattern of the transverse (side-to-side, up-down) movement and not the radial movement is important.
[0088] As explained above, tracker 10 has the ability to detect spatial positions, spatial patterns, and temporal patterns created by the operator through the use of retroreflector target 26 , six-DOF target 110 or 130 , active retroreflector target 120 , or wand 140 . These spatial or temporal patterns are collectively referred to as gestures. The particular devices and modes of sensing depicted in FIGS. 3A-3E , 4 A- 4 C, 5 A- 5 D are specific examples and should not be understood to limit the scope of the invention.
[0089] FIG. 6 shows flow chart 200 , which lists steps carried out by the operator and laser tracker 10 in issuing and carrying out gestural commands. In step 210 , laser tracker 10 scans continuously for commands. In other words, the tracker uses one or more of the modes of sensing shown in FIGS. 3A-3E , 4 A- 4 C, 5 A- 5 D to record positions, spatial patterns, and temporal patterns. In step 220 , the operator signals a command. This means that the operator creates a gesture by taking a suitable action on an object such as retroreflector target 26 , six-DOF target 110 or 130 , active retroreflector target 120 , or wand 140 . An appropriate action might involve movement to a particular absolute coordinate or movement to create a particular spatial or temporal pattern.
[0090] In step 230 , tracker 10 intercepts and parses the command just signaled by the operator. It intercepts the command by sensing and recording spatial and temporal information from the moving objects. It parses the command by using computing power, possibly within the tracker, to break the stream of data into appropriate subunits and identify the patterns formed by the subunits according to an algorithm. Types of algorithms that might be used are discussed hereinafter.
[0091] In step 240 , the tracker acknowledges that a command has been received. The acknowledgement might be in the form of a flashing light located on the tracker, for example. The acknowledgement might take several forms depending on whether the command was clearly received, garbled or incomplete, or impossible to carry out for some reason. The signal for each of these different conditions could be given in a variety of different ways. For example, different colors of lights, or different patterns or durations of flashes might be possible. Audible tones could also be used as feedback.
[0092] In step 250 , tracker 10 checks whether the command is garbled. In other words, is the meaning of the received command unclear? If the command is garbled, the flow returns to step 210 , where tracker 10 continues to scan for commands. Otherwise the flow continues to step 260 , where tracker 10 checks whether the command is incomplete. In other words, is more information needed to fully define the command? If the command is incomplete, the flow returns to step 210 , where tracker 10 continues to scan for commands. Otherwise the flow continues to step 270 .
[0093] In step 270 , tracker 10 executes whatever actions are required by the command. In some cases, the actions require multiple steps both on the part of the tracker and the operator. Examples of such cases are discussed below. In step 280 , tracker 10 signals that the measurement is complete. The flow then returns to step 210 , where the tracker continues to scan for commands.
[0094] FIG. 7 shows that step 220 , in which the operator signals a command, comprises three steps: step 222 —prologue, step 224 —directive, and step 226 —epilogue. The prologue and epilogue steps are optional. The directive part of the command is that part of the command that conveys the instructions to be followed. The prologue part of the command indicates to the tracker that the command is starting and the directive will soon be given. The epilogue part of the command indicates to the tracker that the command is over.
[0095] FIGS. 8-10 show two exemplary sets of gestures (“Example 1 gesture” and “Example 2” gesture) that correspond to an exemplary set of commands. The leftmost columns of FIGS. 8-10 show the exemplary set of commands. Some of these commands are taken from FARO CAM2 software. Other commands are taken from other software such as SMX Insight software or the Utilities software shipped with the FARO laser tracker. Besides these examples, commands may be taken from other software or simply created for a particular need. In each of FIGS. 8-10 , the second column shows a software shortcut in the CAM2 software, if available. An operator may press this software shortcut on the keyboard to execute the corresponding command. The third and fourth columns of FIGS. 8-10 show some spatial patterns that might be used to represent a certain command. The two dimensional spatial patterns might be sensed using methods shown in FIG. 3A , 4 A, or 5 D, for example.
[0096] For each of the gestures in the third and fourth columns in FIGS. 8-10 , the starting position is indicated with a small circle and the ending position is indicated with an arrow. The gestures in the third column of FIGS. 8-10 are simple shapes—circles, triangles, or squares. The 28 shapes shown in this column are distinguished from one another by their orientations and starting positions. In contrast, the shapes in the fourth column of FIGS. 8-10 are suggestive of the command to be carried out. The main advantage of the shapes in the third columns is that these are easier for the computer to recognize and interpret as commands. This aspect is discussed in more detail below. The main advantage of the shapes in the fourth columns is that these may be easier for the operator to remember.
[0097] FIGS. 11A-11F show some alternative spatial patterns that might be used in gestures. FIG. 11A shows single strokes; FIG. 11B shows alphanumeric characters; FIG. 11C shows simple shapes; FIG. 11D shows a simple path with the path retraced or repeated once; FIG. 11E shows a compound path formed of two or more simpler patterns; and FIG. 11F shows patterns formed of two or more letters.
[0098] FIG. 12 shows an exemplary command tablet 300 . The operator carries command tablet 300 to a convenient location near the position where the measurement is being made. Command tablet 300 may be made of stiff material having the size of a sheet of notebook paper or larger. The operator places command tablet 300 on a suitable surface and may use a variety of means to hold the target in place. Such means may include tape, magnets, hot glue, tacks, or Velcro. The operator establishes the location of command tablet 300 with the frame of reference of laser tracker 10 by touching fiducial positions 310 , 312 , and 314 with retroreflector 26 . It would be possible to use multiple command tablets in a given environment. An exemplary procedure for finding the command tablet location is discussed below.
[0099] Command tablet 300 may be divided into a number of squares. In addition to the squares for fiducial positions 310 , 312 , and 314 , there are squares for commands in FIGS. 8-10 , and other squares corresponding to target type, nest type, direction, and number. The layout and contents of exemplary command tablet 300 is merely suggestive, and the command tablet may be effectively designed in a wide variety of ways. A custom command tablet may also be designed for a particular job.
[0100] To gesture a command to laser tracker 10 , the operator touches the retroreflector to the desired square on command tablet 300 . This action by the operator corresponds to step 220 in FIG. 200 . Sensing of the action may be carried out by methods shown in FIG. 3C or 4 C, for example. If a sequence involving multiple numbers is to be entered—for example, the number 3.50—then the squares 3, point, 5, and 0 would be touched in order. As is discussed below, there are various ways of indicating to the tracker that a square is to be read. One possibility is to wait a preset time—say, for at least two seconds. The tracker will then give a signal, which might be a flashing light, for example, indicating that it has read the contents of the square. When the entire sequence of numbers has been entered, the operator may terminate the sequence in a predetermined way. For example, the agreed upon terminator might be to touch one of the fiducial points.
[0101] Command tablet 300 may also be used with an articulated arm CMM instead of a laser tracker. An articulated arm CMM comprises a number of jointed segments attached to a stationary base on one end and a probe, scanner, or sensor on the other end. Exemplary articulated arm CMMs are described in U.S. Pat. No. 6,935,036 to Raab et al., which is incorporated by reference herein, and U.S. Pat. No. 6,965,843 to Raab et al., which is incorporated by reference herein. The probe tip is brought into contact with the squares of command tablet 300 in the same way as the retroreflector target is brought into contact with the squares of command tablet 300 when using a laser tracker. An articulated arm CMM typically makes measurement over a much smaller measurement volume than does a laser tracker. For this reason, it is usually easy to find a convenient place to mount command tablet 300 when using an articulated arm CMM. The particular commands included in command tablet 300 would be adapted to commands appropriate for the articulated arm CMM, which are different than commands for the laser tracker. The advantage of using a command tablet with an articulated arm CMM is that it saves the operator the inconvenience and lost time of setting down the probe, moving to the computer, and entering a command before returning to the articulated arm CMM.
[0102] We now give four examples in FIGS. 13-16 of how gestures may be used. FIG. 13 shows gestures being used to set a reference point for exemplary laser tracker 10 . Recall from the earlier discussion that Auto Reset is a possible option mode of a laser tracker. If the laser tracker is set to the Auto Reset option, then whenever the beam path is broken, the laser beam will be directed to the reference position. A popular reference position is the home position of the tracker, which corresponds to the position of a magnetic nest permanently mounted on the body of the laser tracker. Alternatively, a reference point close to the work volume may be chosen to eliminate the need for the operator to walk back to the tracker when the beam is broken. (Usually this capability is most important when the tracker is using an interferometer rather than an ADM to make the measurement.)
[0103] In FIG. 13 , the actions shown in flow chart 400 are carried out to set a reference point through the use of gestures. In step 420 , the operator moves the target in the pattern shown for “Set Reference Point” in FIG. 10 . The target in this case may be retroreflector 26 , for example, as shown in FIG. 3A . In step 430 , laser tracker 10 intercepts and parses the command and acknowledges that the command has been received. In this case, the form of acknowledgement is two flashes of the red light on the tracker front panel. However, other feedback such as a different color or pattern, or an audible tone may be used. In step 440 , the operator places SMR 26 into the magnetic nest that defines the reference position. Laser tracker 10 continually monitors position data of SMR 26 and notes when it is stationary. If the SMR is stationary for five seconds, tracker 10 recognizes that the operator has intentionally placed the SMR in the nest, and the tracker begins to measure. A red light on the tracker panel, for example, may be illuminated while the measurement is taking place. The red light goes out when the measurement is completed.
[0104] In FIG. 14 , the actions shown in flow chart 500 are carried out to establish the position of exemplary command tablet 300 in three-dimensional space. Recall from the earlier discussion that command tablet 300 has three fiducial positions 310 , 312 , and 314 . By touching a retroreflector target to these three positions, the position of command tablet 300 in three-dimensional space can be found. In step 510 , the operator moves the target in the pattern shown for “Initialize Command Tablet” in FIG. 9 . The target in this case may be retroreflector 26 , for example, as shown in FIG. 3A . In step 520 , laser tracker 10 intercepts and parses the command and acknowledges that the command has been received by flashing the red light twice. In step 530 , the operator holds SMR 26 against one of the three fiducial points. Laser tracker 10 continually monitors position data of SMR 26 and notes when the SMR is stationary. In step 540 , if SMR 26 is stationary for five seconds, tracker 10 measures the position of SMR 26 . In step 550 , the operator holds SMR 26 against a second of the three fiducial points. In step 560 , if SMR 26 is stationary for five seconds, tracker 10 measures the position of SMR 26 . In step 570 , the operator holds SMR 26 against the third of the three fiducial points. In step 580 , if SMR 26 is stationary for five seconds, tracker 10 measures the position of SMR 26 . Now tracker 10 knows the three-dimensional positions of each of the three fiducial points, and it can calculate the distance between these three pairs of points from these three points. In step 590 , tracker 10 searches for an error by comparing the known distances between the points to the calculated distances between the points. If the differences are too large, a signal error is indicated in step 590 by a suitable indication, which might be flashing of the red light for five seconds.
[0105] In FIG. 15 , the actions shown in flow chart 600 are carried out to measure a circle through the use of gestures. In step 610 , the operator moves the target in the pattern shown for “Measure a Circle” in FIG. 8 . The target in this case may be retroreflector 26 , for example, as shown in FIG. 3A . In step 620 , laser tracker 10 intercepts and parses the command and acknowledges that the command has been received by flashing the red light twice. In step 630 , the operator holds retroreflector 26 against the workpiece. For example, if the operator is measuring the inside of a circular hole, he will place the SMR against the part on the inside of the hole. Laser tracker 10 continually monitors position data of retroreflector 26 and notes when the SMR is stationary. In step 640 , after retroreflector 26 is stationary for five seconds, the red light comes on and tracker 10 commences continuous measurement of the position of retroreflector 26 . In step 650 , the operator moves retroreflector 10 along the circle of interest. In step 660 , when enough points have been collected, the operator moves retroreflector 26 away from the surface of the object being measured. The movement of retroreflector 26 indicates that the measurement is complete. It also indicates whether retroreflector target 26 is measuring an inner diameter or outer diameter and enables the application software to remove an offset distance to account for the radius of retroreflector 26 . In step 670 , tracker 10 flashes the red light twice to indicate that the required measurement data has been collected.
[0106] In FIG. 16 , the actions shown in flow chart 700 are carried out to acquire a retroreflector after the laser beam from laser tracker 10 has been broken. In step 710 , the operator moves the retroreflector in the pattern shown for “Acquire SMR” in FIG. 10 . The target in this case may be retroreflector 26 , for example, as shown in FIG. 4A . At the beginning of this procedure, the SMR has not acquired the SMR and hence the modes shown in FIGS. 3A-3E cannot be used. Instead cameras 52 and light sources 54 are used to locate retroreflector 26 . In step 720 , laser tracker 10 intercepts and parses the command and acknowledges that the command has been received by flashing the red light twice. At the same time, it drives the laser beam 46 toward the center of retroreflector 26 . In step 730 , tracker 10 checks whether the laser beam has been captured by retroreflector 26 . In most cases, the laser beam is driven close enough to the center of retroreflector 26 that it lands within the active area of the position detector within the tracker. In this case, the tracker servo system drives the laser beam in a direction that moves the laser beam toward the center of the position detector, which also causes the laser beam to move to the center of retroreflector 26 . Normal tracking occurs thereafter. If the laser beam is not driven close enough to the center of retroreflector 26 to land on the position detector within the tracker, then one possibility is to perform a spiral search, as shown in step 740 . Laser tracker 10 carries out a spiral search by aiming the laser beam in a starting direction and then directing the beam in an ever widening spiral. Whether or not to perform a spiral search can be set as an option with the laser tracker or the application software used with the laser tracker. Another option, which might be appropriate for a rapidly moving target, is to repeat step 720 repeatedly until the laser beam is captured by the retroreflector or until there is a timeout.
[0107] As discussed previously with reference to FIG. 7 , the operator signals a command through the use of three steps: an optional prologue, a directive, and an optional epilogue. If tracker 10 is constantly parsing data and can quickly respond when the desired pattern has been produced, then it may be possible to use the directive alone without the prologue or epilogue. Similarly, if the operator touches a position on command tablet 300 , the command should be clear to the tracker without the need for a prologue or epilogue. On the other hand, if the tracker cannot parse quickly enough to respond immediately to the patterns created by the operator, or if there is a chance that the operator might create a command pattern unintentionally, then use of a prologue, epilogue, or both may be needed.
[0108] An example of a simple prologue or epilogue is simply a pause in the movement of the target, which might be any of the targets shown in FIGS. 3A-3E , 4 A- 4 C, and 5 A- 5 D. For example, the operator may pause for one or two seconds before the start of a pattern and one or two seconds at the end of the pattern. By pausing in this way, the starting and ending positions of each gesture, indicated by circles and arrows, respectively, in FIGS. 8-10 and by circles and squares, respectively, in FIG. 11 will be more easily understood by the parsing software within the tracker or computer.
[0109] Another example of a simple prologue or epilogue is rapid blocking and unblocking of the laser beam from the tracker. For example, the operator may splay his fingers so that there is a space between each of the four digits. Then by moving his fingers rapidly across the laser beam, the beam will be broken and unbroken four times in rapid succession. Such a temporal pattern, which might be referred to as the “four finger salute”, is readily recognized by the laser tracker. The modes of sensing based on temporal variations in returned laser power are shown in FIG. 3D with a passive target and in FIGS. 5A-5C with active targets.
[0110] Besides the use of a prologue or epilogue in the gestural command, a type of prologue is also sometimes needed at the start of an action by the laser tracker. For example, in the examples of FIGS. 13-15 , there is a wait of five seconds after a command is given before the tracker measurement is made. The purpose of this wait is to give the operator time to get the retroreflector target into position before beginning the measurement. Of course, the time of five seconds is arbitrary and could be set to any desired value. In addition, it would be possible to use other indicators that the measurement should begin. For example, it would be possible to use a four-finger salute rather than a time delay to indicate readiness for measurement.
[0111] Active targets such as those shown in FIGS. 5A-D are useful in applications such as tool building and device assembly. A tool is a type of apparatus made to assist in the manufacture of other devices. In fields such as automotive and aerospace manufacturing, tools are constructed to exacting specifications. The laser tracker helps both in assembling and in checking such tools. In many cases, it is necessary to align the component elements of a tool with respect to one another. A single retroreflector target, such as retroreflector 26 , can be used to establish a coordinate system to which each element in the tool can be properly aligned. In a complicated tool, however, this can involve a lot of iterative measuring. An alternative is to mount multiple retroreflector targets on the tooling elements and then measure all of these in rapid succession. Such rapid measurement is made possible today by modern tracker technologies such as absolute distance meters and camera systems (such as components 42 , 44 ). If multiple retroreflectors are mounted directly on tooling, then it may be difficult or inefficient for an operator to use one of these retroreflectors to create gestural commands. It may be more convenient to use a wand such as 140 shown in FIG. 5C or 5 D. The operator can quickly give commands using a wand without disturbing the retroreflectors mounted on the tooling. Such a wand may be mounted on the end of a hammer or similar device to leave the operator's hands free to perform assembly and adjustment. In some cases, a separate retroreflector or six-DOF probe, like those shown in FIGS. 5A and 5B , respectively, may be needed during tool building. By adding a light source and control button to the basic SMR or six-DOF probe, the operator can issue commands in a very flexible way.
[0112] Active targets such as those shown in FIGS. 5A-D are also useful in device assembly. A modern trend is flexible assembly using laser trackers rather than automated tooling assembly. An important advantage of the tracker approach is that little advance preparation is required. One thing that makes such assembly practical today is the availability of software that matches CAD software drawings to measurements made by laser trackers. By placing retroreflectors on the parts to be assembled and then sequentially measuring the retroreflectors with a laser tracker, the closeness of assembly can be shown on a computer display using colors such as red to indicate “far away”, yellow to indicate “getting closer”, and green to indicate “close enough”. Using an active target, the operator can give commands to measure selected targets or groups of targets in ways to optimize the assembly process.
[0113] Multiple retroreflectors are often located in a single measurement volume. Examples for tool building and device assembly with multiple retroreflectors were described above. These examples showed that an active target can be particularly useful. In other cases, the ability of the laser tracker to recognize movements of multiple passive retroreflectors can be useful. For example, suppose that multiple retroreflectors have been placed on a tooling fixture such as a sheet metal stamping press and the operator wants to perform a target survey after each operation of the fixture. The survey will sequentially measure the coordinates of each target to check the repeatability of the tooling fixture. An easy way for the operator to set up the initial survey coordinates is to sequentially lift each retroreflector out of its nest and move it around according to a prescribed gestural pattern. When the tracker recognizes the pattern, it measures the coordinates of the retroreflector in its nest. It is the ability of the tracker cameras to recognize gestural patterns over a wide field of view that enables the operator to conveniently switch among retroreflectors.
[0114] As mentioned previously, there are several different types of methods or algorithms that can be used to identify gestural patterns and interpret these as commands. Here we suggest a few methods, while recognizing that a wide variety of methods or algorithms could be used and would work equally well. As explained earlier, there are three main types of patterns of interest: (1) single-point absolute position, (2) temporal patterns, and (3) movement patterns. Recognizing single-point absolute position is arguably the easiest of these three categories. In this case, the tracker simply needs to compare measured coordinates to see whether these agree to within a specified tolerance to a coordinate on the surface of command tablet 300 .
[0115] Temporal patterns are also relatively easy to identify. A particular pattern might consist of a certain number of on-off repetitions, for example, and additional constraints may be placed on the allowable on and off times. In this case, tracker 10 simply needs to record the on and off times and periodically check whether there is a match with a pre-established pattern. It would of course be possible to reduce the power level rather than completely extinguishing the light to send a signal to the tracker. Reduction in the level of retroreflected laser power could be obtained by many means such as using a neutral density filter, polarizer, or iris.
[0116] Movement patterns may be parsed in one, two, or three dimensions. A change in radial distance is an example of a one-dimensional movement. A change in transverse (up-down, side-to-side) movement is an example of two-dimensional measurement. A change in radial and transverse dimensions is an example of three-dimensional measurement. Of course, the dimensions of interest are those currently monitored by the laser tracker system. One way to help simplify the parsing and recognition task is to require that it occur within certain bounds of time and space. For example, the pattern may be required to be between 200 mm and 800 mm (eight inches and 32 inches) in extent and to be completed in between one and three seconds. In the case of transverse movements, the tracker will note the movements as changes in angles, and these angles in radians must be multiplied by the distance to the target to get the size of the pattern. By restricting the allowable patterns to certain bounds of time and space, many movements can be eliminated from further consideration as gestural commands. Those that remain may be evaluated in many different ways. For example, data may be temporarily stored in a buffer that is evaluated periodically to see whether a potential match exists to any of the recognized gestural patterns. A special case of a gestural movement pattern that is particularly easy to identify is when the command button 124 in FIG. 5A is pushed to illuminate light 122 to indicate that a gesture is taking place. The computer then simply needs to record the pattern that has taken place when light 122 was illuminated and then evaluate that pattern to see whether a valid gesture has been generated. A similar approach can be taken when the operator presses command button 134 to illuminate light 132 in FIG. 5B or presses command button 144 to illuminate light 142 in FIG. 5D .
[0117] Besides these three main patterns, it is also possible to create patterns made using a passive object or a passive object in combination with a retroreflector. For example, the cameras on the tracker might recognize that a particular command is given whenever a passive red square of a certain size is brought within one inch of the SMR.
[0118] It would also be possible to combine two of the three main patterns. For example, it would be possible to combine both the speed of movement with a particular spatial pattern, thereby combining pattern types two and three. As another example, the operator may signal a particular command with a saw tooth pattern comprising a rapid movement up, followed by a slow return. Similarly acceleration might be used. For example, a flick motion might be used to “toss” a laser beam away in a particular direction around an object.
[0119] Variations are also possible within types of patterns. For example, within the category of spatial patterns, it would be possible to distinguish between small squares (say, three-inches on a side) and large squares (say, 24 inches on a side).
[0120] The methods of algorithms discussed above are implemented by means of processing system 800 shown in FIG. 17 . Processing system 800 comprises tracker processing unit 810 and optionally computer 80 . Processing unit 810 includes at least one processor, which may be a microprocessor, digital signal processor (DSP), field programmable gate array (FPGA), or similar device. Processing capability is provided to process information and issue commands to internal tracker processors. Such processors may include position detector processor 812 , azimuth encoder processor 814 , zenith encoder processor 816 , indicator lights processor 818 , ADM processor 820 , interferometer (IFM) processor 822 , and camera processor 824 . It may include gestures preprocessor 826 to assist in evaluating or parsing of gestures patterns. Auxiliary unit processor 870 optionally provides timing and microprocessor support for other processors within tracker processor unit 810 . It may communicate with other processors by means of device bus 830 , which may transfer information throughout the tracker by means of data packets, as is well known in the art. Computing capability may be distributed throughout tracker processing unit 810 , with DSPs and FPGAs performing intermediate calculations on data collected by tracker sensors. The results of these intermediate calculations are returned to auxiliary unit processor 870 . As explained previously, auxiliary unit 70 may be attached to the main body of laser tracker 10 through a long cable, or it may be pulled within the main body of the laser tracker so that the tracker attaches directly (and optionally) to computer 80 . Auxiliary unit 870 may be connected to computer 80 by connection 840 , which may be an Ethernet cable or wireless connection, for example. Auxiliary unit 870 and computer 80 may be connected to the network through connections 842 , 844 , which may be Ethernet cables or wireless connections, for example.
[0121] Preprocessing of sensor data may be evaluated for gestures content by any of processors 812 - 824 , but there may also be a processor 826 specifically designated to carry out gestures preprocessing. Gestures preprocessor 826 may be a microprocessor, DSP, FPGA, or similar device. It may contain a buffer that stores data to be evaluated for gestures content. Preprocessed data may be sent to auxiliary unit for final evaluation, or final evaluation of gestures content may be carried out by gestures preprocessor 826 . Alternatively, raw or preprocessed data may be sent to computer 80 for analysis.
[0122] Although the use of gestures described above has mostly concentrated on their use with a single laser tracker, it is also beneficial to use gestures with collections of laser trackers or with laser trackers combined with other instruments. One possibility is to designate one laser tracker as the master that then sends commands to other instruments. For example, a set of four laser trackers might be used in a multilateration measurement in which three-dimensional coordinates are calculated using only the distances measured by each tracker. Commands could be given to a single tracker, which would relay commands to the other trackers. Another possibility is to allow multiple instruments to respond to gestures. For example, suppose that a laser tracker were used to relocate an articulated arm CMM. An example of such a system is given in U.S. Pat. No. 7,804,602 to Raab, which is incorporated by reference herein. In this case, the laser tracker might be designated as the master in the relocation procedure. The operator would give gestural commands to the tracker, which would in turn send appropriate commands to the articulated arm CMM. After the relocation procedure was completed, the operator could use a command tablet to give gestural commands to the articulated arm CMM, as described above.
[0123] FIG. 19 shows steps 1900 that are carried out in giving a gesture to communicate a command to the laser tracker according to the discussions that referenced FIGS. 3A-B , 4 A-B, and 5 A. Step 1910 is to provide a rule of correspondence between commands and spatial patterns. Step 1920 is for the user to select a command from among the possible commands. Step 1930 is for the user to move the retroreflector in a spatial pattern corresponding to the desired command. The spatial pattern might be in transverse or radial directions. Step 1940 is to project a light from the laser tracker to the retroreflector. This light may be a beam of light emitted along the optical axis of the laser tracker or it may be light emitted by an LED near a camera disposed on the laser tracker. Step 1950 is to reflect light from the retroreflector back to the laser tracker. Step 1960 is to sense the reflected light. The sensing may be done by a photosensitive array within a camera disposed on the tracker; by a position detector in the tracker, or by a distance meter within the tracker. Step 1970 is to determine the command based on the rule of correspondence. Step 1980 is to execute the command.
[0124] FIG. 20 shows steps 2000 that are carried out in giving a gesture to communicate a command to the laser tracker according to the discussions that referenced FIGS. 3C , 4 C, and 5 A. Step 2010 is to provide a rule of correspondence between commands and three-dimensional positions. Step 2020 is for the user to select a command from among the possible commands. Step 2030 is for the user to move the retroreflector to a position corresponding to the desired command, possibly by bringing the retroreflector target in contact with a command tablet. Step 2040 is to project a light from the laser tracker to the retroreflector. This light may be a beam of light emitted along the optical axis of the laser tracker or it may be light emitted by an LED near a camera disposed on the laser tracker. Step 2050 is to reflect light from the retroreflector back to the laser tracker. Step 2060 is to sense the reflected light. The sensing may be done by a photosensitive array within a camera disposed on the tracker; by a position detector in the tracker, or by a distance meter within the tracker. Step 2070 is to determine the command based on the rule of correspondence. Step 2080 is to execute the command.
[0125] FIG. 21 shows steps 2100 that are carried out in giving a gesture to communicate a command to the laser tracker according to the discussions that referenced FIGS. 3D and 5A . Step 2110 is to provide a rule of correspondence between commands and temporal patterns. Step 2120 is for the user to select a command from among the possible commands. Step 2130 is to project a light from the laser tracker to the retroreflector. This light may be a beam of light emitted along the optical axis of the laser tracker or it may be light emitted by an LED near a camera disposed on the laser tracker. Step 2140 is to reflect light from the retroreflector back to the laser tracker. Step 2150 is to sense the reflected light. The sensing may be done by a photosensitive array within a camera disposed on the tracker; by a position detector in the tracker, or by a distance meter within the tracker. Step 2160 is for the user to create a temporal pattern in the optical power received by the sensors on the laser tracker. Such a temporal pattern is easily done by blocking and unblocking a beam of light as discussed hereinbelow. Step 2170 is to determine the command based on the rule of correspondence. Step 2180 is to execute the command.
[0126] FIG. 22 shows steps 2200 that are carried out in giving a gesture to communicate a command to a six DOF laser tracker according to the discussions that referenced FIGS. 3E and 5B . Step 2210 is to provide a rule of correspondence between commands and pose of a six DOF target. Step 2220 is for the user to select a command from among the possible commands. Step 2230 is to use the six DOF laser tracker to measure at least one coordinate of a six DOF target in a first pose. A pose includes three translational coordinates (e.g., x, y, z) and three orientational coordinates (e.g., roll, pitch, yaw). Step 2240 is for the user to change at least one of the six dimensions of the pose of the six DOF target. Step 2250 is to measure the at least one coordinate of a second pose, which is the pose that results after the user has completed step 2240 . Step 2260 is to determine the command based on the rule of correspondence. Step 2270 is to execute the command.
[0127] FIG. 23 shows steps 2300 that are carried out in giving a gesture to communicate a command to the laser tracker to point the laser beam from the laser tracker to the target and lock onto the target. Step 2310 is to project light onto the retroreflector. This light may be light emitted by an LED near a camera disposed on the laser tracker. Step 2320 is for the user to move the retroreflector in a predefined spatial pattern. Step 2330 is to reflect light from the retroreflector to the laser tracker. Step 2340 is to sense the reflected light. The sensing may be done, for example, by a photosensitive array within a camera disposed on the tracker. Step 2350 is to determine the command based on the rule of correspondence. Step 2360 is to point the beam of light from the tracker to the retroreflector. Step 2370 is to lock onto the retroreflector with the laser beam from the tracker.
[0128] FIG. 24 shows steps 2400 that are carried out in giving a gesture to communicate a command to the laser tracker to point the laser beam from the laser tracker to the target and lock onto the target. Step 2410 is to project light onto the retroreflector. This light may be light emitted by an LED near a camera disposed on the laser tracker. Step 2420 is to reflect light from the retroreflector to the laser tracker. Step 2430 is to sense the reflected light. The sensing may be done, for example, by a photosensitive array within a camera disposed on the tracker. Step 2440 is to generate a predefined temporal pattern, as discussed hereinabove. Step 2450 is to determine the command based on the rule of correspondence. Step 2460 is to point the beam of light from the tracker to the retroreflector. Step 2470 is to lock onto the retroreflector with the laser beam from the tracker.
[0129] FIG. 25 shows steps 2500 that are carried out in giving a gesture to communicate a command to the laser tracker to point the laser beam from the laser tracker to the target and lock onto the target. Step 2510 is to project light onto the retroreflector. This light may be light emitted by an LED near a camera disposed on the laser tracker. Step 2520 is to measure at least one coordinate of a first pose of a six DOF target. As discussed hereinabove, the pose includes three translational and three orientational degrees of freedom. Step 2530 is to change at least one coordinate of a first pose. Step 2540 is to measure the at least one coordinate of a second pose, which is the pose that results after the at least one coordinate of the six DOF probe has been changed. Step 2550 is to determine the rule of correspondence has been satisfied. Step 2560 is to point the beam of light from the tracker to the retroreflector. Step 2570 is to lock onto the retroreflector with the laser beam from the tracker.
[0130] While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation.
[0131] The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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A method for optically communicating, from a user to a laser tracker, a command to control operation of the tracker includes providing a rule of correspondence between a plurality of commands and a plurality of positions, each position being a 3-D coordinate; selecting by the user a first command from among the commands and moving by the user a retroreflector to a first position wherein the first position corresponds to the first command. Also, projecting a first light from the tracker to the retroreflector, reflecting a second light from the retroreflector, the second light being a portion of the first light and obtaining first sensed data by sensing a third light, the third light being a portion of the second light. Further, determining the first command based on processing the first sensed data according to the rule of correspondence and executing the first command with the tracker.
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CROSS REFERENCE TO RELATED PATENT APPLICATIONS
This application is a continuation-in-part of our co-pending U.S. Pat. Application Ser. No. 318,656 filed Mar. 3, 1989. The disclosure of U.S. Pat. Application Ser. No. 318,656 is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
This invention relates to drive assemblies for seam-forming apparatus of systems for automatic or computer-controlled manipulation of sheet material during processing, e.g., fabric or other limp material to be assembled at a sewing station.
During the construction of a useful item from raw stock of flat goods (e.g., cloth, paper, plastic, and film), it is often necessary to precisely position and guide the flat goods through a work station. Typical work stations perform assembly operations such as joining, cutting or folding. For example, such work stations can be equipped with sewing machines for joining multiple layers of limp fabric, such as may be from separate limp material segments, or from several regions of the same (folded) limp material segment.
Conventionally, the positioning and guiding of the fabric-to-be-joined is accomplished by skilled human operators. The operators manually feed or advance the fabric-to-be-joined through the stitch forming mechanism of the sewing machine along predetermined seam trajectories on the fabric. The resultant seams can be straight or curved, or a combination of both as is often required in the assembly of fabric panels to form articles of clothing, for example. Typically, the fabric-to-be-joined must be precisely positioned and accurately directed to the sewing head to achieve the desired seam. The human operator must therefore function not only as a "manipulator" of the fabric but also as a real-time "sensing and feedback medium", making small adjustments, e.g., in orientation, fit-up and seam trajectory, to obtain quality finished goods. The adjustments are required, for example, due to variations in seam type, geometry, location and fit-up.
In the prior art, to assist in the formation of such a seam, an operator manually presents and feeds two limp material segments to be joined to a fold assembly coupled to a sewing machine. The fold assembly, for example, a Simanco USA model 230056, is adapted to receive the presented segments and to guide the edges so that at the output end of the fold assembly, the two segments emerge with their lateral edges interlocked and ready for joining. The fold assembly is positioned so that the emerging segments are driven by the feed dogs of the sewing machine to the needle and bobbin assembly of the sewing head of the machine.
One drawback of this technique is that it is labor intensive; that is, a large portion of the cost for manufacture is attributable to manual labor. An additional drawback is introduced when the material is being fed on off-the-arm sewing machines, such as those used for sewing seams in pant legs or sleaves. The fold assemblies in the prior art do not accommodate the special situation of feeding material to be sewn into a tube shape. In that situation, the material and construction of the sewing machine often makes it difficult and awkward for the human operator to maintain an even feed of fabric.
To reduce labor cost in the clothing assembly industry, automated or computer-controlled manufacturing techniques have been developed for many of the desired assembly operations. However, even the manual assisted techniques have limited effectiveness due to the required degree of human intervention and are limited in their ability to accommodate curved seams and seams forming a tube, such as pant legs or sleaves.
Accordingly, it is an object of the invention to provide an improved drive assembly for positioning and guiding sheet material, e.g., fabric or other limp material to be processed, in the formation of seams with off-the-arm machines.
It is another object of the present invention to provide an improved drive assembly suitable for automatic or computer-controlled seam forming operations on an off-the-arm sewing machine, which is of simple, rugged, versatile, and economical design.
SUMMARY OF THE INVENTION
These and other objects of the invention are accomplished by an improved drive assembly for controlling the position of sheet material, e.g., fabric or other flat goods, slidingly supported on a work surface with a relatively low coefficient of friction, with an off-the-arm sewing machine.
The present invention is a seam forming apparatus for forming a seam at one lateral edge of one limp material segment (e.g., an edge finishing seam, such as a hem), or at one lateral edge of each of two limp material segments.
The apparatus includes a fold assembly extending along a reference axis from an input end to an output end. The fold assembly establishes a first segment guide channel adapted to receive a first of the limp material segments. That first segment guide channel extends from the input end to the output end, and is open at the input end and at one lateral side.
In some forms of the invention adapted for joining two limp material segments, the fold assembly also establishes a second segment guide channel adapted to receive the second of the limp material segments. That second segment guide channel also extends from the input end to the output end, and is open at the input end and at one lateral side.
The first and second segment guide channels each extend about an associated channel axis extending substantially parallel to the reference axis near the output end of the fold assembly.
For a full felled seam, the two segment guide channels of the fold assembly have substantially V- (or C--) shaped cross sections, and the first and second channels are oppositely directed and interleaved near the output end. As used herein, the terms "V-" and "C-" ar used interchangeably to define a shape which curves about a central point, either in a continuous or piecewise continuous manner.
In one form, the invention further includes two feed plane support members. That first feed plane support member has a segment support surface extending substantially to the lower surface of the portion of the first segment guide channel above its associated channel axis at the input end of the fold assembly. The second feed plane support member has a material support surface extending substantially to the lower surface of the portion of the second segment guide channel at the input end of the fold assembly.
A position controller controls the position of the lateral edges of the segments in the channels to be at associated predetermined positions measured with respect to the reference axis at a point along that axis between the input and output ends of the fold assembly. Generally, the controlled edges are laterally spaced apart from the reference axis by an associated predetermined distance near the input end of the fold assembly. The segment edge positions are controlled bidirectionally, and pursuant to a closed loop control system.
In various forms of the invention, the position controller includes segment edge sensors between the input end and output end of the fold assembly. Those edge sensors are adapted to generate position signals representative of the positions with respect to the reference axis of the lateral edges of the limp material segments in their respective channels. Segment drivers are responsive to the position signals for controlling the lateral edges of the segments to be at their associated predetermined positions.
Preferably, the edge sensors are positioned between the segment drivers and the output end of the fold assembly, although in some forms, this configuration may be reversed.
The segment drivers each include a rotatable drive wheel adapted for rotation about an axis substantially parallel to the reference axis. The wheels have their respective lateral surfaces opposite to a platen substantially coincident with a surface of a respective one of the segment guide channels near the input end of the fold assembly.
Preferably, at least one of the platens and the drive wheel surface opposite thereto is positioned within the respective one of the segment guide channels.
The preferred form of the invention is further adapted to selectively bias the outer surfaces of the drive wheels toward their respective platens. By differentially biasing the drive wheels toward their respective platens, differing drags may be established in the two segments, so that a desired relative stretching may be achieved. The lateral surfaces of the drive wheels may selectively be positioned away from their respective platens to permit easy loading of segments to the fold assembly. With the wheels biased toward their respective platens, drive motors coupled to the wheels control the rotational motion of the wheels, together or independently, to establish control of the limp material segment positions within the fold assembly.
In forms of the present invention adapted for off-the-arm sewing machines, the segment drivers are an integral part of a drive assembly. The drive assembly may include drive shafts which couple each of the drive wheels to an associated, selectively operable motor. In one form, the drive shafts are coupled to an actuator for selective pivotal movement between two positions, whereby at one position the drive wheels are biased towards and adjacent each respective platen, and at another position the drive wheels are biased away from each respective platen. In an alternate form, the drive shafts are each coupled to a drive arm assembly, each of which is slidable along a second axis, substantially perpendicular to the reference axis, for moving the drive shafts between the two positions. In a first position for each arm, its drive wheel is biased toward its platen, and in a second position its drive wheel is biased away from that platen.
The above-described seam forming apparatus may be integrated with the sewing head and feed dog assembly of a sewing machine to form an automated full felled seam forming system. With this configuration, two segments-to-be-joined may be readily loaded in separate (and overlapping) feed planes to the fold assembly. Then, the sewing head may be actuated so that the feed dog assembly draws the two segments through the fold assembly to the needles of the sewing head. As the segments are drawn through the fold assembly, the position of the lateral edges are dynamically controlled to establish a high quality seam.
While particularly adapted for use with an off-the-arm sewing machine, these forms may also be used with other machine configurations.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the features, advantages, and objects of the invention, reference should be made to the following detailed description and the accompanying drawings, in which:
FIG. 1 is a perspective view of an apparatus for forming a full felled seam in accordance with the present invention;
FIG. 2A is a top view of the fold assembly of the system of FIG. 1;
FIG. 2B is a side elevation view from the input end of the fold assembly of FIG. 1;
FIG. 3A is an exploded view of the light source of the optical detector of the system of FIG. 1;
FIG. 3B is a sectional view of the reflector assembly of FIG. 3A;
FIG. 4 is a perspective view of the fold assembly and segment position controller of the system of FIG. 1;
FIG. 5 shows an embodiment of the invention adapted for a feed-off-the-arm sewing machine;
FIG. 6A shows a plan view of the fold assembly of the system of FIG. 5;
FIG. 6B shows an exploded perspective view of the fold assembly and sensor assembly of the system of FIG. 5;
FIG. 6C shows a sectional view along lines 6C--6C of the sensor assembly of the system of FIG. 6A;
FIG. 7A shows a front plan view of an alternative drive wheel biasing assembly;
FIG. 7B shows a sectional view along lines 7B--7B of the drive wheel biasing assembly of FIG. 7A;
FIG. 7C shows a rear plan view of the drive wheel biasing assembly of FIG. 7A;
FIG. 8A is a top plan view of an alternative fold assembly for use in the system of FIG. 1;
FIG. 8B is a perspective view of the fold assembly of FIG. 8A;
FIG. 8C is a side elevation view from the output end of the fold assembly of FIG. 8A;
FIG. 9A shows a representation of the cross-sections of limp material segments in the fold assembly of FIGS. 8A, 8B and 8C along lines A--A through F--F;
FIG. 9B shows a representation of the cross-sections of limp material segments in the fold assembly of FIGS. 6A, 6B and 6C along lines A--A through F--F;
FIG. 10 shows two curved edge limp material segments as positioned in the fold assembly of FIGS. 8A, 8B and 8C;
FIG. 11 is a perspective view of an alternative form of the apparatus of FIG. 1; and
FIG. 12 shows an embodiment of another alternative form of the apparatus of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A seam forming system 10 embodying the invention is shown in FIG. 1. System 10 includes a conventional dual needle sewing head 12 of a flat bed sewing machine. Sewing head 12 is positioned over a work support surface 14 which overlies a conventional dual bobbin assembly (not shown). A pair of conventionally operative feed dog assemblies are positioned with their drive elements, one of which is shown as reference number 20, extending through the top of work surface 14. The presser foot 13 of head 12 biases the segments against the feed dogs 20 and 22 so that the feed dog assemblies selectively drive a limp material workpiece along a reference axis 26 toward the needles of the sewing head 12.
The system 10 further includes a fold assembly 30 positioned on the work surface 14. The fold assembly 30 defines two limp material segment guide channels 34 and 36 extending laterally into the fold assembly 30, and includes an optical position detection system 37, described in detail below in conjunction with FIG. 4. The workpiece support surface 14 provides a limp material segment support surface leading to the channel 34 and a support element 38 provides a limp material segment support surface leading to channel 36. The channels 34 and 36 are open at the input end of fold assembly 30 and along one lateral side, permitting positioning therein of the lead edges of limp material segments on surfaces 14 and 38.
A first segment drive wheel 40 is positioned with its central axis substantially parallel to axis 26 and its lateral surface adjacent to an effective platen established by the support surface 14. A second segment drive wheel 42 is positioned with its central axis substantially parallel to axis 26 and with its lateral surface adjacent to a platen 44 (shown with broken lines) which overlies the extended plane of support surface 38. The wheels 40 and 42 include axially directed ridges on their lateral surfaces.
The drive wheels 40 and 42 are coupled by respective ones of flexible drive shafts 50, 52 and belts 54, 56 to a respective one of stepper motors 60 and 62.
The drive wheels 40 and 42 are generally biased away from each other, i.e. so that wheel 40 is biased toward surface 14 and wheel 42 is biased toward surface 38. A drive wheel biasing assembly 66, including an associated actuator (not shown), is coupled to the shafts 50 and 52. That assembly 66 is selectively operative to establish the above-noted bias to wheels 40 and 42, or to remove that bias and withdraw wheel 40 from surface 14 and wheel 42 from platen 44. When the wheels 40 and 42 are biased toward surfaces 14 and 38, respectively, limp material segments in the guide channels may be controlled by movement of the wheels. When the wheels 40 and 42 are displaced from the surfaces, segments may be easily loaded or removed from the channels.
In the embodiment of FIG. 1, a linear actuator is used to selectively drive a wedge-shaped element, or cam 68, in the direction of axis 26 to either push apart (in the forward position, as shown in FIG. 1) the shafts 50 and 52, or permit a biasing spring, not shown, to push the wheels together (i.e. away from their respective platens).
A controller 100 is selectively operable to control the operation of the sewing head 12 and its associated feed dog assembly, the optical detection system 37 and the position and rotary motion of the drive wheels 40 and 42.
In the system 10 of FIG. 1, the fold assembly 30 is similar to a Simanco USA model 230056 folder, which has been modified to include an optical position detection system 37. Fold assembly 30, shown in FIGS. 2A and 2B extends from an input end 30a to an output end 30b along a principal axis 30A. Assembly 30 defines two segment guide channels (having cross-sections indicated by the broken lines in FIG. 2B) which extend laterally into assembly 30 and curl around the principal axis 30A of assembly 30. Axis 30A effectively provides a reference (or channel) axis about which the cross-section of the channels extend. While offset somewhat from axis 26, axis 30A is "substantially" parallel to axis 26 near the output end of assembly 30.
The assembly 30 includes the optical source and reflector portions of the optical detection system 37. As shown in FIG. 3A, these portions include a light emitting diode (LED) 70 and a dual beam forming reflector assembly 72. The assembly 72, shown in assembled form in FIG. 3B, includes a housing 74, a reflector 76 and a collimator 78. With this configuration, light from LED 70 is split by reflector 76 to form two laterally (with respect to axis 30A) directed beams. As shown in FIG. 4, the beams from reflector 76 are directed across the respective segment guide channels of assembly 30 along propagation paths 79a and 79b to be incident upon the input ends of respective pairs of optical fibers 80 and 82 leading to corresponding pairs of optical detectors 84 and 86 (illustrated in block diagram form in FIG. 4). The optical fiber pairs 80 and 82 are mounted in a housing (not shown) affixed to assembly 30. The optical detectors are operative in conjunction with the controller 100 to identify when a limp material segment in one of the channels 34, 36 blocks the beam from LED 70 from none, one or both of the input ends of the optical fiber pairs.
In operation of the system of FIG. 1, the actuator for assembly 66 is initially positioned so that the wheels 40 and 42 are drawn back from the respective surfaces of surface 14 and platen 44. Then a first limp material segment 101 is positioned between wheels 40 and surface 14 and a second limp material segment 102 is positioned between wheel 42 and platen 44. The two segments are then pushed through the fold assembly 30 to overlie the feed dogs 20 and 22. Then the actuator of assembly 66 is positioned to bias wheels 40 and 42 against surface 14 and platen 44 respectively to engage the respective limp material segments 101 and 102.
Then the feed dogs 20 and 22 and sewing head 12 are actuated to draw the limp material segments 101 and 102 through the fold assembly 30. As the segments are drawn through the assembly 30, the controller determines the position of the lateral edge of those segments by monitoring the optical detectors 84 and 86. Under closed loop control, the wheels 40 and 42 are selectively driven bidirectionally, as necessary, so that the lateral edges of the segments cover just one fiber of the fiber pairs 80 and 82 as the segments 101 and 102 are drawn through assembly 30. The axially extending grooves in the lateral surfaces of wheels 40 and 42 permit axial motion of the segments, while resisting lateral movement, except in response to rotary motion of the wheels.
With this configuration, where the position of the lateral edges of the segments is automatically controlled between the drive wheels and the feed dogs, a highly accurate full felled seam may be established, on a continuous basis and without manual intervention. In alternative configurations, the relative positions of the wheels and the optical detectors may be reversed. In some embodiments of the invention, the bias pressure of the wheels 40 and 42 toward their respective platens may be independently varied to provide desired drag forces to the respective material segments passing in the direction of axis 26. With such control, selective stretching of one segment with respect to the other may be attained in a seam.
An alternative configuration embodying the invention is shown generally in FIG. 5. In that configuration, a feed-off-the-arm sewing machine 106 is fitted with a fold assembly 110 and a drive wheel/bias assembly 112. The fold assembly 110 is described below in conjunction with FIGS. 6A, 6B and 6C, and the drive wheel/bias assembly 112 is described below in conjunction with FIGS. 7A, 7B and 7C. In those figures, elements which correspond to elements in FIGS. 1-4 are denoted with identical reference numerals. In operation, limp material segments are folded in assembly 110 and drawn along an axis 114 toward the needles of machine 106.
The fold assembly 110 is shown in detailed form in FIGS. 6A, 6B and 6C. Assembly 110 includes a folder 120 and a sensor assembly 122 of the optical detection system 37. In the illustrated form, folder 120 includes two curved metal elements 123 and 124 that define a pair of oppositely directed V- (or C-) shaped segment guide channels 126, 128 extending along an axis 130' from an input end 120a to an output end 120b. The folder 120 is similar to a type 152-D folder, manufactured by Atlanta Attachment Company, Inc., in which the element 123 has been partially cut away, and a slot 125 has been placed in element 124, in order to accommodate the sensor assembly 122 that is affixed to folder 120 by a screw 127.
The sensor assembly 122 includes a housing 130 and a pair of internally positioned, oppositely directed light emitting diodes 132, 134 and associated pairs of photodetectors 132a, 134a. The housing 130 defines extensions to the segment guide channels 126, 128, and also includes a surface 122a which establishes an extension to the top surface of element 123. The diode/detector pair 132/132a are positioned to detect a limp material segment 142 in the extension to channel 126. The diode/detector pair 134/134a (positioned along a sensing axis passing through the slot 125) are positioned to detect a limp material segment 140 in the extension to channel 128.
A pair of drive wheels 40 and 4 from drive wheel/bias assembly 112, described below in conjunction with FIGS. 7A, 7B and 7C, are adapted to be selectively biased toward or away from the upper surface of element 124 and surface 122a which function as platens.
The drive/wheel bias assembly 112 is shown in FIGS. 7A, 7B and 7C. The assembly 112 includes a support member 148 which is affixed to the sewing machine 106. Assembly 112 also includes drive wheels 40 and 42 (rotatable about axes 40a and 42a, respectively), drive belts 54 and 56, drive shafts 50 and 52, and drive motors 60 and 62, all of which correspond in function to the similarly referenced elements in the configuration of FIG. 1.
The shaft 50 and wheel 40 are positioned on an arm 150 which is pivoted about a first pivot axis 150a and the shaft 52 and wheel 42 are positioned on an arm 152 which is pivoted about a second pivot axis 152a. Linear actuators 160 and 162 are selectively operable to shift the positions of arms 150 and 152 so that the wheels 40 and 42 are biased toward (as illustrated with solid lines in FIG. 7C) or withdrawn (as illustrated in phantom in FIG. 7C) from their respective platens. When the wheels are biased toward their respective platens, positional control of segments 140 and 142 is attained. When the wheels are displaced from their respective platens, the segments 140 and 142 may readily be loaded into or removed from the fold assembly 110.
A controller 100' functions in a similar manner to controller 100 in the configuration of FIGS. 1-4 to control the operation of the sewing head of machine 106 (including sewing head 12 and its associated feed dog assembly), the optical detection system 37 and the position and rotary motion of drive wheels 40 and 42.
FIGS. 8A, 8B and 8C illustrate another alternate form 30' for the fold assembly 30 in the system of FIG. 1. Elements in FIGS. 8A, 8B and 8C which correspond to elements in FIG. 1 are identified by the same reference designations.
The fold assembly 30' includes a rigid central member 210 extending along reference axis 26 from the input end 30a' to the output end 30b". The 30a' of member 210 has a substantially I-shaped cross-section and the output end 30b' has a substantially Z-shaped cross-section. As used herein, the term "1-shaped" refers to a substantially straight line shape, and the term "Z-shaped" refers to a substantially third order curve or piece-wise linear equivalent where the regions at and near the maximum/minimum points are referred to as vertices. The intermediate portions of member 210 have a substantially continuously decreasing Z-shaped cross-section along axis 26 from the output end to the input end. As used herein, the term "continuously decreasing Z-shaped" refers to a shape that substantially continuously changes from Z-shaped to I-shaped.
A rigid upper guide member 212 (shown in broken lines in FIG. 8B), having an inner surface V-shaped cross-section, is positioned above member 210 to establish an upper segment guide channel 36. Similarly, a rigid lower guide member 214, having an inner surface with a V-shaped cross-section, is positioned below member 210 to establish a lower segment guide channel 34. As used herein, the term "V-shaped" refers to a second order curve, or piecewise continuous equivalent where the region at or near the maximum/minimum point is referred to as a vertex.
Optical sensors in members 210, 212 and 214 provide signals representative of the limp material segment position within channels 34 and 36. With the illustrated configuration, the sensors may be positioned between lines D-D and E-E (i.e. near the output end 30b') to permit near-needle segment control. Drive wheels, 40 and 42 (shown in phantom in FIG. 813) are affixed to central member 210. The bottom and top surfaces, respectively, of members 212 and 214 are selectively biased toward or away from the wheels. When biased toward the wheels, in a related sense in response to the sensed position of limp material segments in channels 34 and 36, the wheels are driven to achieve positional control of the limp material segments.
With the configuration of FIGS. 8A, 8B and 8C, the segment guide channels 34 and 36 have adjacent Z-shaped cross-sections near the output end 30b' of fold assembly 30'. As a result, limp material segments positioned in channels 34 and 36 are successively transferred from having adjacent substantially planar cross-sections near the input end 30a', to have adjacent Z-shaped cross-sections at intermediate points between input end 30a' and output end 30b', and to have oppositely-directed, interleaved V-shaped cross-sections near output end 30b'. The control of the limp material segment geometry in this manner permits particularly effective formation of a full-felled seam. For comparison purposes, the segment geometry for limp material segments S1 and S2 in the fold assembly 30' and for fold assembly 110 is shown (along lines A--A through F--F viewed from the input end) in FIGS. 9A and 9B, respectively.
With the illustrated fold assembly 30', material segments bearing relatively high curvature lateral edges (such as a 3-inch radius, 45° arc length, curved edge) may be fed into channels 34 and 36, for example, as illustrated for curved segments S1 and S2 of FIG. 10. Such segments may be drawn through the fold assembly 30' readily and presented to the sewing head to establish a curved full felled seam.
FIG. 11 shows a drive assembly 112' for use with an off-the-arm sewing machine 106. In this configuration, an off-the arm sewing machine 106 is fitted with a fold assembly 11, which assembly 110 is described above in conjunction with FIGS. 6A, 6B and 6C. In those figures, elements which correspond to elements in FIGS. 1-4 are denoted with identical reference numerals. The drive assembly 112' includes a support member (not shown) which is affixed to the sewing machine 106. Assembly 112' also includes drive wheels 40 and 42 rotatable about intersecting axes.
Shaft 52 and wheel 42 are positioned on drive motor 62, which in turn is rigidly attached to pivot arm 174. Pivot arm 174 is, in turn, pivotally (about axis 174b) attached to a pneumatic linear actuator 162. Actuator 162 is selectively operable to shift the position of pivot arm 174 and drive motor 62 in a range of motion where in a first position wheel 42 is biased against its platen (as illustrated), and in a second position, wheel 42 is biased away from its platen.
Pivot arm 174 may include a slot 190 near its point of joinder with actuator 162 for slidably engaging the actuator 162. Thus, actuator 162 moves along longitudinal axis 162a to a first, forward position in which it exerts downward pressure on pivot arm 174, causing the motor 62 and attached shaft 52 and wheel 42 to pivot about axis 174a to move wheel 42 to its first position. Conversely, actuator 162 moves along longitudinal axis 162a to a second, rearward position in which it exerts upward pressure on pivot arm 174 to raise up along slot 190, causing the motor 62 to pivot about axis 174a to move wheel 42 to its second position.
Similarly, shaft 50 and wheel 40 are positioned on drive motor 60, which is pivotally (about axis 180a) attached to mounting assembly 180. Mounting assembly 180 is rigidly attached to sewing machine 106. The drive motor 60 is adapted to receive input drive signal from a controller (not shown) for rotating the rigid drive shaft 50 and drive wheel 40 about axis 40a. The drive shaft 50 and drive wheel 40 may be pivoted about axis 180a in a range of motion where, in a first position, wheel 40 is biased against its platen, and in a second poSition, wheel 40 is biased away from its platen.
When the wheels are biased toward their respective platens, positional control of segments 140 and 142 may be attained when the wheels are displaced from their respective platens, the segments 140 and 142 may readily be loaded into or removed from the fold assembly 110.
An important aspect of the embodiment shown in FIG. 11 is the independent pivotal movement of drive sub-assemblies 240 and 242, described above, for loading segments into fold assembly 110. The independent mounting of drive sub-assembly 242, having a pivotal rigid drive shaft 52 which may be lifted upward away from drive sub-assembly 240 independent of movement of drive sub-assembly 240, enables a human operator to more easily manipulate material segments in the fold assembly 110.
FIG. 12 shows another embodiment of the drive assembly of the present invention. In that configuration, also designed for use in an off-the-arm sewing machine 106, the entire drive assembly is mounted such that by lifting the drive wheel/bias assembly 112' upward, an operator may readily access the fold assembly 110 for loading segments. The fold assembly 110 is described above in conjunction with FIGS. 6A, 6B and 6C. In those figures, elements which correspond to elements in FIGS. 1-4 are denoted with identical reference numerals.
The drive assembly 112" is generally described above in conjunction with FIGS. 7A, 7B, 7C, and 11. The assembly 112" includes a support member 148 which is affixed to the sewing machine 106. Assembly 112" also includes drive wheels 40 and 42, rotatable about axes 40a and 42a respectively, drive belts 54 and 56, rigid drive shafts (not shown), and drive motors 60 and 62, all of which correspond in function to the similarly referenced elements in the configuration of FIGS. 1 and 11,
In the illustrated embodiment of FIG. 12, a pair of drive shafts (not shown), and wheels 40 and 42 are associated with a drive assembly. The drive assembly includes first drive arms 150 and 152, which are substantially "L"-shaped and extend upward to form second drive arms, For example, and as shown inn FIG. 12, first drive arm 152 extends upward to form second drive arm 156. The second drive arms are substantially perpendicular to the axes of rotation 40a and 42a for drive wheel 40 and 42 reSpectively and substantially parallel to axis 163a. The second drive arms are adapted to slidably engage with linear actuators enabling the entire drive assembly to be lifted away from fold assembly 110. For example, and as shown in FIG. 12, drive arm 156 slidably engages with linear actuator 162. In the illustrated embodiment, first drive arm 152 and second drive arm 156 are integrally formed, as are .first drive arm 150 and second drive arm 154. In other forms, the first and second drive arms of the drive assembly may be separate pieces which are mechanically or otherwise connected. The drive wheel/bias assembly 112' further includes a pair of biasing axial springs 260, 262 against which pressure platforms 264, 266, protruding out from the second drive arms 154, 156, respectively, exert upward pressure.
In operation, drive motor 62 engages drive belt 56 in a manner similar to that described above with respect to FIG. 1, to rotate drive wheel 42 about axis 42a. Actuator 162 is selectively operable to shift the position of second drive arm 156, and related pressure platform 266, along axis 163a in a range of motion where in a first position, wheel 42 is biased against its platen, and in a second position, wheel 42 is biased away from its platen. Pressure platform 266 acts against spring 262 to moderate upward movement of drive sub-assembly 242. In a similar manner, the drive sub-assembly 240 operates to selectively position wheel 40 in a range of motion from a first position to a second position comparable to the first and second positions of sub-assembly 242.
Thus, in the manner described above with respect to FIG. 12, drive sub-assemblies 240, 242 may selectively be lifted up and out of the way of the fold assembly 110 during introduction and removal of material. The sub-assemblies 240, 242 may be independently operable, or may operate in tandem, depending upon the specific application.
The preferred embodiments of the present invention have been described above in a form adapted for forming a full felled seam at the lateral edges of two limp material segments, and for forming a seam on an off-the-arm machine. In alternate forms, different seam configurations may be attained. For example, a fold assembly may be used which provides only a single segment guide channel and drive wheel, wherein a drive wheel may be used to bidirectionally control the segment position to establish segment position for a high quality hem. Alternatively, still different fold assemblies may be used to form folded segment geometries for other seams.
The invention can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The described embodiments of the invention are to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than the foregoing description, and all changes which come within the meaning and range of equivalence of the claims are therefore intended to be embraced therein.
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Drive assemblies for seam forming apparatus used to form a seam in one or more limp material segments include a fold assembly and a driver for positioning the segments within guide channels in the fold assembly prior to presentation to a seam joining device. The driver controls the segments to be at associated predetermined positions within the fold assembly. The drive assemblies include actuator means for moving drive wheels of the driver between two positions relative to the guide channels.
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BACKGROUND OF THE INVENTION
This invention relates to the control of the delicate tissue paper web during its production and, more particularly, to the control of the conveyance of high bulk paper tissue of the type commonly used as facial and toilet tissue. Still more particularly, it relates to a pickup and drying arrangement for preserving and enhancing the high bulk properties, which are initially a part of a tissue web but which are usually lost or diminished during its passage through a papermaking machine, all the while controlling the conveyance of the web.
Illustrations of prior types of high bulk tissue, processes and machines for its manufacture are shown in U.S. Pat. Nos. 3,301,746 and 3,812,000. The apparatus disclosed in these patents for manufacturing such tissue have one common deficiency in their structural configurations. Specifically, at some point during the conveyance of the tissue web from its formation until it is removed from the last dryer, it is not carried by a felt, fabric or dryer roll surface. By "not carried," it is meant that the web, at some point along its path of travel, is either totally unsupported or must adhere to the bottom of the felt, fabric or dryer surface from which it can drop off or be temporarily separated from the felt, fabric or dryer surface. This is a situation which usually occurs between successive rolls along the web's serpentine path of travel in the papermaking machine.
Web support, and positive control of its movement, is important in the manufacture of all types of paper, but it is especially critical in the manufacture of tissue paper grades because of the comparatively high speeds involved (commonly about 3,000 fpm, but often up to about 4,000 fpm and, sometimes, over 5,000 fpm) and the relatively light weight of the tissue web itself (about 12-15 lbs. per 3,000 ft 2 ). By contrast, a typical newsprint machine for example might run about 2,000 fpm with a web basis weight of about 32 lbs. per 3,000 ft 2 .
If the sheet is not supported and controlled during its manufacture, it might break or billow away from its carrier surface and become wrinkled as it passes through a roll nip or over a roll beneath the felt or fabric. Any such interruption in the papermaking process is very disruptive and expensive in terms of lost time. In addition, any wrinkled paper must be rejected and recycled.
The production of high bulk tissue is especially sensitive to web control since there is no press section in the papermachine configuration to compress the tissue web and thus tend to increase its stability and ease in handling.
SUMMARY OF THE INVENTION
This invention provides maximum web stability by carrying the web on top of the fabric or dryer surface from the point where it is removed from the forming wire to the point where it is doctored off the last drying roll to be wound on the reel. The web is never passed across an open gap or adhered to the bottom of a fabric or dryer surface as it travels through the paper-making machine.
Accordingly, it is an object of the invention to provide a high bulk tissue papermaking machine configuration which positively controls the web during its travel through the machine.
Another object of the invention is to provide a high bulk tissue papermaking machine and configuration wherein the web is carried on a fabric, felt or dryer surface for its entire path of travel through the machine from its pickup on the forming wire through the last dryer.
A feature of the invention is a papermaking machine configuration having maximum web support and control without utilizing two separate fabrics to hold the web therebetween.
These and other objects, features and advantages of the invention will be readily apparent to those skilled in the art when the description of the preferred embodiment is read in conjunction with the attached drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevational view in somewhat schematic form, showing the preferred embodiment of the papermaking machine configuration from the stock former to the reel.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in the drawing, a hydraulic former 8 is movably positioned by a jack screw 5 to discharge a dilute aqueous slurry of tissue paper stock fibers 13 through its slice 11 into the converging gap defined by upper and lower forming wires 12, 10, respectively.
Upper looped forming wire 12 is guided about its path of travel by guide rolls 20 and forming roll 14 which are mounted to cross beams which in turn are mounted to side framework (both of which are not shown for clarity, but which are well known to those in the paper industry). Similarly, lower forming wire 10 is guided about its path of travel by guide rolls 16 which are mounted to cross beams (not shown). For guiding purposes, one or more rolls 20, 16 are adjustably mounted for lateral movement indicated by double-headed arrows 15, 17. A pan 21 is positioned to receive excess water thrown from wire 12 as it travels downwardly to begin the web formation process.
The mat of stock fibers forming web W travels between forming wires 10, 12 to a point where lower wire 10 is guided away from one side by turning roll 18. Web W remains on wire 12 by virtue of a pressure differential created when a slight gap 23 is formed over one side of the web W as wire 10 is guided away from it just prior to being turned around roll 18. The atmospheric pressure between web W and top wire 12 is less than that in a gap between the web and lower wire 10. This, in combination with the surface tension of the water in the interstices of wire 12, causes web W to adhere to wire 12 from which it is picked off to be carried on fabric 30 by pickup roll 22 having a suction gland 19 therein.
A suction flat box 28 is mounted to be positioned against the inside surface of looped fabric 30 to assist in removing water from the newly formed web W. Fabric 30 is any of a variety of commercially available foraminous configurations, usually of a woven construction, which are commonly made of plastic filaments, but which can also be made of metallic wires. Such a fabric is lightweight, flexible and may contain a pattern to impart a desired surface design or texture to the web.
Fabric 30 is guided in a looped path by a plurality of guide rolls 32, one or more of which is laterally movable, as indicated by arrows 33, to adjust tension in the fabric as desired. Two of the guide rolls 32 train fabric 30 over the surface of dryer roll 34 which is of the thru-air, or transpiration, type. A transpiration dryer functions by projecting heated gas (in this case, air) through the web material (in this case, tissue paper) whereby the exposure of the web fibers to the evaporative effects of the air is increased and moisture is physically blown out and removed from the web. The dryer surface 37 is foraminous, or perforated, to distribute the heated air uniformly through the web. Typically, it is constructed of fine wire mesh. A hot air plenum 36 is mounted over a portion of the upper periphery of dryer 34 to blow hot air through its foraminous bottom wall 39, into the interior of roll 34 through its foraminous surface and out through the remainder of the peripheral roll surface to dry the web. The direction of this discharged hot air is indicated by arrows 31 as it enters a receiving plenum 38 for discharge from the machine.
Downstream, in the direction of web W travel, a transfer roll 46, having a suction chamber 35, is positioned to contact both the web W on fabric 30 and the surface of a large rotatable dryer roll drum 48 having a smooth, non-foraminous surface 42. Actually, contact is made by a second fabric 40, which may be similar to the first fabric 30 or comprised of a felted construction such as commonly used in a papermaking machine dryer section, which is looped about guide rolls 44, one or more of which are adjustably movable, as shown by arrows 45, to vary the tension.
Roll 48 is commonly known in the paper industry as a Yankee dryer and is usually between about 12 feet and about 18 feet in diameter. It functions by conducting heat into the web and water entrained therein through contact of web W with its surface 42. An air cap 50 is mounted above the upper peripheral surface of dryer 48 to direct heated air downwardly against the web W on the dryer surface to promote faster drying.
On the lower downstream side of dryer drum 48, a doctor 52 engages web W to remove it for transfer to reel 54 where it is wound into a roll 56. Guide rolls 58, 64 assist in this transfer.
In operation, the formed web W is picked off wire 12 by suction pickup roll 22 and carried on fabric 30 which holds it against the surface of transpiration dryer roll 34 and carries it to suction transfer roll 46 which urges the second fabric, or felt, 40 to pick it off fabric 30 and place it on the surface 42 of Yankee dryer drum 48 where it is carried to the point where it is doctored off and wound into a roll. The direction of rotation of dryers 34 and 48 are shown by arrows 66 and 67, respectively.
It is important to note that the web is not merely guided by a fabric/felt (i.e. placed in contact therewith), but it is carried (i.e. physically held on the fabric/felt or dryer roll surface by gravity or vacuum pressure) for its entire travel through the papermaking machine from pickup off the forming wire to where it is doctored off. Thus, there is no opportunity for the web to leave the surface of a fabric, felt or dryer and the chances of its breaking while being carried by these components are very low and certainly less than if it was adhering to the bottom or lower surface of a fabric, felt or dryer. This is especially important in the production of high bulk tissue which might broadly be defined as tissue which is not subjected to a pressing operation as it is passed through a papermaking machine during its production, at least prior to being dried. As such, the high bulk tissue remains very soft, delicate and susceptible to tearing so any situation requiring it to support itself from pickup through drying should be avoided, which is precisely what this invention achieves.
While the preferred embodiment has been described in detail, variations are contemplated. For example, the heated air supplied to transpiration dryer 34 could be supplied through its rotatable axles, in which case the bottom wall 39 of plenum 36 would be a continuous baffle instead of being foraminous. The transpiration dryer itself could comprise a flat, horizontal box over which the web carrying fabric would travel as shown in U.S. Pat. No. 3,447,247 which is assigned to the assignee of this invention. Also, first fabric 30 could carry the web W about more than one transpiration dryer 34, in which case Yankee dryer 48 might not be used, or Yankee dryer 48 might then be of a smaller diameter. Finally, the web W might be formed with a more traditional single wire Fourdrinier type arrangement.
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A web pickup and drying apparatus in a papermaking machine for producing a high bulk paper tissue web while carrying the web throughout its travel from pickup off the forming wire through the drying stages on the surface of a fabric, felt or dryer roll. After pickup, the web is first subjected to a thru-air (transpiration) dryer from which it is applied to the surface of a large diameter dryer roll. There is no conventional press section to reduce bulk before the web is dry.
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This is a continuation of application Ser. No. 801,935, filed Nov. 26, 1985, which was abandoned upon the filing hereof.
This invention relates to a process for improving the properties of textile materials which consist of or contain natural vegetable or animal fibres.
BACKGROUND OF THE INVENTION
Many processes are known for the treatment of textile materials in which either one somehow influences or changes the structure of the textile fibres themselves, or one treats the textile fibres with chemicals which will be more or less strongly absorbed thereon. All the well-known processes of this kind do no doubt improve one or other of the properties of the textile materials thus treated, but these treatments seem inevitably to cause other properties to deteriorate.
It is thus known for instance in the permanent-waving or crimping of straight hair, to treat either human hair or even wool with keratolytic agents, then to shape the hair or wool and finally to fix or oxidize the shaped hair, as is described for example in GB-PS No. 453 700.
It is also known, as described in DE-OS No. 26 53 958, to impart so-called permanent trouser creases to trousers made from keratin-containing fibres by treating the relevant areas with reducing agents so as to open the disulphide linkages, the desired creases being then pressed in and set or hardened. Unfortunately however it is not possible by this procedure to achieve a really permanent shaping, in the sense of a pleating or crease formation which is maintained even after wetting or actual washing.
Attempts have been made, for example as described in DE-OS No. 20 25 454, to polymerize vinyl polymers onto wool fibres or the hair; or, as described in DE-AS No. 16 15 166, to polymerise N-vinylpyrrolidone onto wool fibres or the hair. Similarly, in order to make wool shrink-proof, the polymerization thereon of other synthetics such as acrylamide has been proposed, as described in U.S. Pat. No. 3,005,730. These procedures, however, yield woollen materials which have a "hard" feel to them and which will drape only stiffly--they are quite unsuitable for use on softly draping silk.
It is furthermore also known, for example from DE-AS No. 1 106 725, to treat cellulosic woven fabrics with thiodiglycols and an acid catalyst so as to improve their crease resistance, and after drying to heat them to about 170° C. in order to harden the cellulose by exchange between the sulphide residue and the OH-groups of the cellulose in the fibres; and in polyurethane finishing it is possible to replace the thiodiglycols according to DE-AS Nos. 1 146 029 and 1 110 606 with polyepoxides or other polymerisation products, or according to DE-PS No. 9 67 641, DE-OS No. 24 21 888, DE-OS No. 28 37 081 and DE-AS No. 19 16 331, with isocyanate polyaddition products with an amine compound. These procedures however are at best only suitable for cellulosic fibres, and are not at all suitable for wool and silk; while even the cellulosic materials thus treated have a bad "feel" to them.
Broadly similar processes have been proposed, and recommended also for polyurethane finishing, in which a permanent pleating effect is achieved by means of treatment with an urethane emulsion as described in DE-OS Nos. 23 60 050, 24 30 508, 25 51 436 or 19 09 095; and the procedure can be further improved according to DE-OS No. 25 38 020 by the use of a reducing agent of the bisulphide type. However, all these procedures, which depend on the use of polymerisates, tend to spoil the soft "feel" of woollen textiles treated in this way.
Finely-divided metal oxides, particularly aluminum oxide, have been used to improve the abrasion-resistance of textile materials, as described in DE-OS No. 16 19 088, DE-AS No. 1 127 861 and 1 138 371, but polyethylene or another film-former is then needed to be present to ensure fixation of the metal oxide. Metal oxides have also been used in suspension, according to DE-PS Nos. 679 465 and 905,967, to impart a matt finish to textiles. These proposals however have given no improvement in shape-retention, to the textile materials.
SUMMARY OF THE INVENTION
It is the object of this invention to provide a process for the treatment of textiles which will result in an improvement of practically all of the desired properties of the textile material; and which will in particular improve the shape-retention of preformed textiles, such for example as pleated silk material, and their temperature resistance. It is a subsidiary object of the process of the present invention to make it easier to care for the textile material, and in particular to render it colour-fast on boiling, to impart resistance to fading and to protect textile materials, in particular, such as wool, against shrinking and felting.
According to the invention there is provided a process for improving the properties of textile materials which consist of or contain natural vegetable or animal fibres, in which the textile material is subjected to the steps of:
(a) treatment with a keratolytic liquid of the kind used for the permanent-waving of human hair, which after it has acted on the textile material is then washed out thereof;
(b) impregnation with a suspension of a finely-divided glazing powder of the kind used in ceramics as a glazing material; and
(c) heat-treatment of the thus-treated textile material at a temperature of above 180° C.
The term "textile materials" is used herein to embrace threads, yarns or fleeces as well as knitted and woven fabrics, which consist of or contain natural vegetable or animal fibres, such as especially silk, wool and cotton.
Textile materials which have been treated by the process of the invention can find use in many obvious ways, for instance in the fashion or other clothing trades and as furnishing or other decorative materials, but they are also suitable for many industrial purposes. In the fashion and other clothing trade there has been a long-felt but largely unfulfilled need to be able to shape preformed materials, for example ironed and pleated materials, in such a way that the shaping would remain unaffected by water, whether in washing or when splashed with water, and also by chemical cleaning. This need arises particularly in connection with pleated silk and pleated woollen materials. It is therefore a notable feature of this invention that pleated or otherwise shaped materials treated by the process of this invention maintain their shape-retention even on washing at higher temperatures or upon chemical cleaning. Another remarkable consequence of the process of the invention is that it seems to prevent felting or woollen materials; and equally with mixed weaves, the process seems to prevent any differential shrinkage.
The industrial uses of textile materials treated by the process of the invention spring in particular from their exceptionally high temperature-resistance, which can extend up to temperatures of 300° C. or even higher, and as a result of which quite surprisingly it becomes possible to use textile materials treated by the process of the invention as filter materials or catalyst supports even under difficult conditions of temperature and pressure. It is a further advantage of textile materials treated by the process of the invention, especially but not only for industrial purposes, that they are much more resistant to fungus attack and rotting; and that the colour-fastness of the thus-treated textile materials is also improved.
Moreover, because of the excellent shape-retention exhibited by them, pile weave textile materials, such as for example velvet, when treated by the process of the invention will keep their structure unchanged and thus retain their natural appearance even after limited loading, without "pressure places" making an appearance.
As already indicated above, the process of this invention involves at least three fundamental treatment stages or process steps.
In the first of these fundamental process steps, the textile material is treated with a keratolytic liquid which is subsequently washed out; in the second fundamental process step, the textile material is impregnated with a suspension of a finely-divided glazing or frit powder; and in the third fundamental process step the textile material is submitted to heat-treatment at a temperature above 180° C. There are however certain preferred additional process steps beyond those three fundamental ones, as will be described below. It is especially preferred that after the first fundamental process step the textile material should be treated with an oxidizing agent, which is subsequently washed out, before the material is subjected to the second fundamental process step.
The keratolytic liquids employed in the process are those of the kind which may be used for the treatment of human hair as permanent-waving preparations. Particularly preferred such keratolytic liquids are alkali-metal sulphite solutions which have been adjusted to an alkaline pH value, or those which contain alkaline additives such as monoethanolamine, ammonia or urea; the pH-value of these keratolytic solutions will ordinarily lie above 8, for example between 9 and 10. Instead of thioglycol acids, solutions with ethanolamineammoniumthioglycolate or similarly-acting compounds such as guanidinethioglycolate can be used. In addition to can be used. In addition to glycerin-monomercaptan there can be used also glycolesters of the di- and tri-thiocarbonic acids in about 10% solutions, derivatives of thioacetic acids, formamidinsulphin acids and the like.
In the first fundamental step of the process the treatment of the textile fibres with keratolytic liquid must take place for a time sufficient to allow it to act thereon, and thus will vary in duration according to the type of keratolytic liquid employed and the type of fibre under treatment. In general the textile material should be left in contact with the keratolytic liquid for a period of from 10 to 40 minutes, e.g. for "Batist" for 25 minutes or longer up to a period of 1.5 to 3 hours after this liquid has been applied. Shorter periods of treatment can however be used with more highly concentrated keratolytic liquids, while equally it may be necessary to extend the period of treatment with less concentrated keratolytic liquids.
After the treatment with the keratolytic liquid, the latter is preferably squeezed off or otherwise physically removed from the textile material, and is finally washed out therefrom.
As previously indicated, the first step of the process is preferably followed by an additional step in which the textile material is treated with an oxidizing agent. At its simplest, this can be done by air, particularly if small quantities of metal salts, such as for example manganese salts, are added to the rinsing water. The most useful and therefore important oxidizing agents for use in this step are hydrogen peroxide, perborate and bromate; but others can also be used, such as urea peroxide and other per-compounds such as amino-1,3,5-triazinperhydrate or melaninperhydrate. In general it is possible to use as oxidizing or neutralizing agents in the process of this invention any of the solutions which are known as so-called fixing agents for the permanent-waving of human hair. After this oxidizing agent treatment, the resulting neutralized or fixed textile material should be freed from this oxidizing or neutralizing agent, conveniently by washing it out.
In the second fundamental step of the process of this invention, the textile material must be impregnated with a suspension of a finely-divided glazing or frit powder. Suitable frits or glazing powders are those generally known from the ceramic industry, which are premolten glazing compositions that have been choquecooled and pulverized. The suspensions will normally contain 0.5-10% of clay or bentonite acting as suspending agent. The softening point of such frits or glazing materials can be considerably reduced by including borates or alkali metal oxides therein. For further information about suitable frits and glazes reference is made to "Keramik Lexikon" or Gustav Weiss, Ullstein Verlag (1984) Berlin, the contents of which are incorporated herein.
The premier choice of frits and glazes for use in the process of the invention must fall on the metal oxides which are used in ceramics as glazing material, and certainly in the most varied compositions of basic, amphoteric or acid oxides, in which desirably there will also be included fluxing agents such as borates. It is advantageous to use glazing or frit powders based on basic oxides, in order to avoid excessively high melting temperatures. One class of preferred frits are the so-called lead frits, containing from about 70 to 80% of PbO, the remainder being SiO 2 and preferably up to 40% by weight of sodium borate in the form of borax crystals or calcined borax. Frits containing additions of zinc borate and calcium borate may also be used with advantage. Particularly suitable frits, because of their low melting point, are boron frits with a formula made up of PbO, 0.5 SiO 2 , 1.5 B 2 O 2 . An equally preferred lead-free frit has the formula:
0.35 K 2 O
0.35 Al 2 O 3
0.28 CaO
0.28 ZnO
3.16 SiO 2
0.16 B 2 O 3
0.09 Li 2 O
The glazing or frit powder is incorporated in the suspension as a fine powder with a particle size of preferably from 10 to 400 μm, although finely divided powder with an average particle size below 10 μm can be used. The aqueous suspensions of the glazing or frit powder employed will preferably have a weight ratio in the range of 1:2 to 2:1, the optimum ratio being selected primarily to ensure that the suspension can be applied evenly to the textile material by whatever wiping-on or immersion method is to be used in the impregnation step.
The amount of glazing or frit powder applied can vary considerably. Suitable application rates will for example be from 0.5 to 5 g per m 2 for lengths of textiles, calculated in terms of the dry substance of the total metal oxides; or, if calculated on the basis of the weight of the textile materials, suitable application rates will range from 0.5 to 10% by weight. When the textile material is to be used for fashion or other clothing purposes or as furnishing or other decorative material, the amount applied should be at the lower end of those ranges, but when the textiles are to be used as temperature-resistant industrial cloth, it is then recommended to apply the suspension at the upper end of these ranges.
In the third fundamental step of the process of this invention the textile materials thus impregnated are submitted to heat-treatment at a temperature above 180° C. The impregnated textile material is preferably aid-dried before heat-treatment. The heat-treatment may advantageously be performed in a rotating oven, preferably at 250° to 350° C., or by drawing the textile material over an appropriately heated surface. In any given case the optimum heat-treatment will depend on the nature of the glazing or frit suspension and upon the intended end-use of the product. Thus, for example, when a silk weave is to be treated for an industrial end-use, higher proportions of glazing or frit powder can be employed and higher heat-temperatures can be used--and one then obtains a silk which is only slightly soft or smooth in character but which has a considerable temperature-resistance of above 300° C. For other end-uses, it is however possible to use a smaller amount of glazing or frit powder, and thus to get a soft and smooth silk material, which is still heat resistant up to 300° C. The heat treatment is preferably carried out by infra red heating.
It is an interesting and surprising fact that the impregnated textile materials can withstand the heat-treatment. Apparently the application of the frit has the effect of protecting the textile fibres against the heat-treatment, presumably because the frit material protects the fibres from decomposition both by heat-absorption and by its insulating effect.
After the the heat treatment the textile material will preferably be washed, particularly if it is to be used for fashion or other clothing applications or as furnishing or other decorative material.
All the washing steps, thus those undertaken after the treatment with the keratolytic liquid, and after the neutralizing or oxidizing step, and finally also after the heat treatment, can conveniently be carried out with water containing the usual anionic, cationic, amphoteric or non-ionic surface active agents, as well as other usual treatment additives.
A particularly attractive way of carrying out the process of the invention involves the use of glazing or frit powder which contains colouring metal oxides, such as, for example antimony oxide to impart yellow colours, manganese oxide to impart brown colours, copper oxide or iron oxide to impart red colours, cobalt oxide to impart blue colours, and chromium oxide or higher concentrations of manganese oxide to impart black colours. When using coloured suspensions of this sort it is also possible either to treat different areas of the textile materials with different suspensions or even just to squeeze out the suspension to a different extent in different places, and thus to secure correspondingly coloured or correspondingly shaded lengths of material, the resultant patterns of colour or shade being surprisingly good, fast and fade-resistant.
The reason for the improved properties imparted to textile materials by the process of this invention is not fully understood, and it is not wished to be here limited by any theoretical considerations; but it is assumed that the treatment with the keratolytic liquid makes the textile fibres receptive to the deposition in their micro-structure of small metal oxide and/or other frit or glazing particles, which during the subsequent heat-treatment melt and afterwards re-solidify to fix the textile fibres relative to each other and thus impart the observed improvement in the properties of the whole textile material.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order that the invention shall be well understood it will now be further explained with reference to the following examples:
EXAMPLE 1
In order to produce permanent pleating, a length of silk material was mechanically pleated with a 2 mm wide standing pleat, tacked through across the folds at 2 cm spacing, drawn closely together into a folded length, and fastened. The folded length was pre-wetted by dipping in water, after which it was wrung out. The folded length was then soaked in a keratolytic liquid having the following composition:
Keratolytic Liquid
Thioglycolic acid: 7.5% by weight
Ammonia (35%): 5.0% by weight
Wetting Agent: 0.1% by weight
Water, to make: 100.0%
[Note: The pH value of the keratolytic liquid was adjusted to 9.4 by means of monoethanolamine].
The textile material was left in contact with the keratolytic liquid at room temperature for 2.5 hours, after which the liquid was first squeezed out, and then washed out of the textile material with an anionic washing agent, for example one based on alkylarylsulphonate.
The folded length was then treated repeatedly with a suspension of a frit powder containing 78% PbO and the remainder SiO 2 , and having a particle size in the region of 50 to 150 μm.
The folded length was then air-dried for about 1 hour, and thereafter drawn over ceramic rods heated to a temperature of about 300° C.; this heat-treatment was repeatedly carried out, alternately on the two sides of the folded length, until the folded length was quite dry.
The heat-treated material finally was vigorously washed out and dried in a drier, after which the tacking threads were removed.
The silk material thus treated was found to possess pleated folds which remained quite unaffected after chemical cleaning, and also practically unaffected even after washing at 60° C.; and it did not change its appearance even when splashed with water.
EXAMPLE 2
A woollen material was treated in essentially the same manner as in Example 1, except that after the first step and before the second step of the process the material was neutralized or oxidized with a bromate solution, and then again washed out as before.
The woollen material was impregnated in the second step of the process with about 3.8 g (calculated on the basis of the textile material after treatment had been completed) per m 2 of a finely divided PbO frit powder; and subsequently in the third stage it was heat-treated at 280° C. in an oven.
The resultant pleated woollen material showed absolutely no change on chemical cleaning; and showed practically no deterioration of the pleating after washing at 60° C. and subsequent drying in a drum drier.
EXAMPLE 3
An ultramarine-blue woollen material was treated in a manner similar to that described in Example 2. After the treatment with the keratolytic liquid and subsequent oxidation its colour value appeared a little brighter; and, after impregnation with the suspension of glazing or frit powder and the subsequent heat-treatment, this colour tone was maintained even after numerous washes.
EXAMPLE 4
A mixed silk-and-wool fabric was treated with the keratolytic liquid in a manner similar to that described in Example 1; and by thereafter wringing it out or some other mechanical crumpling procedure it was given a smock-like structure, and was subsequently oxidized or neutralized, and washed out. The fabric thus treated was then impregnated with a suspension of glazing or frit powder as in Example 1; and finally was subjected to heat-treatment.
The irregular smocking-structure thus imparted to the fabric was not removed even by numerous washings.
EXAMPLE 5
Mixed wool-and-silk fabrics and mixed cotton-and-wool fabrics were treated in the same manner as described in Example 1. All of these displayed improved properties in terms of shape-retention (especially with pleated goods) and heat-resistance, as well as excellent insensitivity to light.
EXAMPLE 6
An industrial silk similar to that employed in Example 1 was treated with keratolytic liquid, then washed out and oxidized or neutralized. The textile material thus treated was then impregnated several times with an aqueous PbO-frit suspension (having a ratio of 1:1) until about 6 g of frit powder (calculated on a dry basis) was taken up per m 2 of the material. The silk was then heat-treated on a heated roller at a temperature of 320° C.
An exceptionally heat-resistant filter silk was thus obtained, which could be used in industrial applications at temperatures in the region of 300° C. and more, and even in the presence of corrosive substances.
EXAMPLE 7
In a pilot-scale installation, a length of pleated silk material (with the pleats held by tacking threads) having a width of 1300 mm was pre-wetted and then passed at a speed of 15 m/minute through a bath containing a keratolytic liquid having the composition stated in Example 1. The dwell time of the material in the bath was about 15 minutes; but after emerging from the bath the length of material was transferred for a further 15 minutes to a wet-goods store. Finally the thus-treated material, after squeezing out if still necessary, was passed to a conventional washing station.
Thereafter the material was passed at the same speed to a dip-station and there immersed in a bath of frit suspension as described in Example 1. After the dip-station, the length of material was then passed through a squeezer, in order firstly to ensure the complete impregnation of the fabric and also secondly so as roughly to regulate the quantity of the frit suspension taken up.
Finally, the length of material was carried over heated rollers, arranged in a chamber with additional infra-red radiators; the upper surface treatment temperature at this heat-treatment station was about 250° C. The material thus heat-treated was then taken through a dust-extraction station, in order to remove any remaining dust particles; and finally the length was then either rolled-up in the finished pleated form and further processed, or taken to a dyeing station.
A variant of this procedure was also carried out, in which the length of cloth after treatment with the keratolytic liquid but before impregnation with the frit powder was taken through an oxidizing bath containing an oxidizing bromate solution; and a still further variant was also carried out, in which the length of cloth, after it leaves the squeezer station already impregnated with the frit or glazing material is next taken through an oxidizing bath before it undergoes the heat-treatment.
In both these variants, the cloth length, after it left the oxidizing bath, was again taken through a washing station.
In all these procedures, the pleated silk thus obtained showed no change in the folding either after chemical cleaning or after washing at 60° C.
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A process for the treatment of textile materials consisting of or containing natural vegetable or animal fibres, in which (a) ketatolytic liquid is allowed to act on the textile material, and then washed out, then preferably the material is further treated with an oxidizing agent which thereafter is washed out, (b) the textile material is impregnated with a suspension of a finely-divided frit or glazing powder, and (c) the impregnated material is subjected to heat-treatment at a temperature of above 180° C.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to stable hydrolyzed silane aqueous emulsions and their application to various substrates to impart oil and water repellency. More specifically but not by way of limitation, the present invention relates to aqueous emulsions of a fluorocarbon silane and an effective amount of an emulsifier having a hydrophile-lipophile balance, HLB, sufficiently high of retain the fluorocarbon silane in a stable aqueous emulsion in substantially a hydrolyzed state.
2. Description of the Related Art
It is known that hydrolyzable silanes can be formulated as aqueous solutions or emulsions that can be applied to various substrates to impart hydrophobic or water repellency properties. However, for these emulsions to achieve long term storage stability they must be buffered to specific pH ranges to inhibit or prevent the hydrolysis of the silanes in the aqueous medium (see for example, U.S. Pat. No. 4,990,377 and U.S. Pat. No. 4,877,654). It is also known that when hydrolyzable fluorocarbon silanes are applied to various surfaces, they can impart both water repellency and oil repellency to those substrates. However, those hydrolyzable fluorocarbon silanes are applied to the surfaces in the molten state or when dissolved in volatile organic solvents, and must generally be cured by heating with a catalyst to chemically affix the fluorocarbon silane to the substrates (see, U.S. Pat. No. 3,012,006). The use of such volatile solvents are generally harmful to the environment and may be hazardous due to their flammability. Where aqueous solutions or emulsions of the hydrolyzable fluorocarbon silanes are possible, the formulations cannot be stored for long periods of time, especially under a broad range of pH conditions, without undergoing hydrolysis and self-condensation to form insoluble polymeric structures.
It is generally recognized (see, Silane Coupling Agents, E. P Plueddemann, 2 nd. Edition, Plenum Press, NY, 1991; and Silanes And Surfaces, D. E. Leyton, Gordon and Breach Science Publ., NY, 1986) that an important aspect of the durable oil and water repellency that is imparted to surfaces by hydrolyzable fluorocarbon silanes, such as with fluorocarbon alkoxysilanes, is the chemical bonding that occurs between the silane and the active hydrogen functional groups on the substrate. This is achieved by initial hydrolysis of the hydrolyzable groups on the silane to silanol groups, which then undergo condensation with the functionality on the substrate. If there is more than one hydrolyzable group on the silane, multiple silane groups will be formed in the hydrolysis and these silanol groups may condense with the functions on the substrate as well as with adjacent silanol groups attached to the surface. The result is a cross-linked and highly durable fluorocarbon siloxane structure on the surface of the substrate. Accordingly, the highest durability would be expected from the silanes with three hydrolyzable groups on the silicon.
SUMMARY OF THE INVENTION
In view of the above and unlike the solvent based hydrolyzable fluorocarbons and the buffered aqueous trialkoxysilane emulsions of the prior art, it has now been discovered that the aqueous fluorocarbon silane emulsions of this invention contain the silane in an essentially completely hydrolyzed state (measured by NMR as explained more fully later) thus ready for instant bonding to the substrate to provide the repellency properties. Notwithstanding this apparent total hydrolysis and thus highly reactive state of the fluorocarbon silane, the unique aqueous emulsions of the instant invention do not permit the hydrolyzed silanes to self-condense to high molecular weight, water insoluble, polysiloxane structures while in this emulsified state. Thus these emulsions are generally stable to long term storage of one year or more, are stable to broad ranges of pH, typically from about 2.5 to about 11.0, are stable to temperatures of 60° C. or greater, and frequently are stable to repeated freezing and thawing conditions without undergoing coagulation and precipitation of the silane.
In the broadest sense the above observed high reactivity of the emulsion, wherein apparently total hydrolysis of the silane compound in the micelie is achieved simultaneously with long term inhibition of the self-condensation reaction, is felt to be a characteristic of the use of any readily emulsifiable alkoxysilane in combination with an effective amount of an emulsifier of very high HLB value. Thus, the present invention provides for novel aqueous emulsions of unique reactivity and stability comprising: (a) a alkoxysilane compound emulsified in water; and (b) an effective amount of an emulsifier of sufficiently high HLB value to simultaneously retain the alkoxysilane compound in a hydrolyzed state and inhibit the hydrolyzed alkoxysilane compound from appreciable self-condensation.
In one specific embodiment of this invention and consistent with the acknowledged prior art recognition that highest durability is associated with the presence of multiple hydrolyzable groups leading to cross-linked siloxane structures upon condensation on a substrate, the present invention further provides for a perfluoroalkyl substituted trialkoxysilane of the following formula be employed: ##STR1## wherein: R f is a perfluoroalkyl radical of 3 to 18 carbon atoms; R's are the same or different alkyl radicals of 1 to 3 carbon atoms; and p=2 to 4, and n=2 to 10.
The improved method of using the emulsions for surface coating of a substrate according to the instant invention comprises the steps of:
(a) emulsifying in water (i) a fluorocarbon silane represented by the formula: ##STR2## where R f is a perfluoroalkyl radical of 3 to 18 carbon atoms; R's are the same or different alkyl radicals of 1 to 3 carbon atoms; p=2 to 4; and n=2 to 10 and (ii) an effective amount of an emulsifier of sufficiently high HLB value to simultaneously retain said hydrolyzable alkoxysilane compound in a substantially totally hydrolyzed state and inhibit said hydrolyzed alkoxysilane compound from appreciable self-condensation thus forming a reactive aqueous emulsion; and
(b) contacting a substrate with said reactive aqueous emulsion of step (a).
One object of this invention is to produce aqueous emulsions of selected hydrolyzable fluorocarbon silanes that exhibit good stability on storage under a broad range of pH conditions. Another object is to provide such aqueous emulsions wherein the hydrolyzable silane is retained in a highly reactive state by virtue of essentially total hydrolysis of the alkoxy moiety and simultaneously self-condensation is inhibited. Still another object of this invention is to provide an improved process that takes advantage of the highly reactive state of the fluorocarbon silane in the emulsion to render substrates both water repellent and oil repellent by the application of the aqueous emulsions of the hydrolyzed fluorocarbon silanes without the need for special curing operations.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In describing and exemplifying the various features and aspects of the present invention and in explaining how the present invention differs from and is distinguishable over the previously known compositions and methods of use along with their corresponding advantages, it should be appreciated that the novelty of the present invention should be viewed as being the composite of achieving a highly reactive yet stable aqueous emulsion capable of producing a durable, chemically bonded coating as apposed to the specific properties resulting from the simple coating of the substrate. Even though a specifically preferred embodiment of this invention relates to stable aqueous emulsions of hydrolyzable reactive fluorocarbon silanes that are storage stable and that react with substrate surfaces to impart water and oil repellency, in a broader sense the invention relates generically to any desirable property associated with a silane coating. As such, the following description will utilize the preferred fluorocarbon silanes that encompass essentially all of these features with the understanding that certain features of the invention have much broader implications and as such the specific embodiment should not be interpreted as being unduly limiting.
Aqueous emulsions of the compounds of formula (1), in addition to imparting water and oil repellency to surfaces coated therewith, also impart improved lubricity. This is particularly true of those compounds wherein R f contains a greater number of carbon atoms, particularly when R f contains 12-18 carbon atoms. This increased lubricity is of course more readily observed if the substrate coated has a smooth surface. This increased lubricity (i.e., decreased coefficient of friction) renders the surface more scratch resistant.
The fluorocarbon silanes useful in this invention are represented by the following formula: ##STR3## wherein: R f is a perfluoroalkyl radical of 3 to 18 carbon atoms; R's are the same or different alkyl radicals of 1 to 3 carbon atoms; p=2 to 4, and n=2 to 10. The preferred compositions are: R f =mixed perfluoroalkyl groups with an average of 8 to 12 carbons; R'=methyl; and p=2; and n=2 to 4.
When n=2, the preferred composition is perfluoroalkylethyltris(2-(2methoxyethoxy)ethoxy)silane. When n=3, the preferred composition is 2-perfluoroalkylethyltris(2-(2-(2-methoxyethoxy)ethoxy)ethoxy)silane.
The fluorocarbon silanes of this invention are prepared by methods known in the art for hydrocarbon silanes (see, Kirk-Othmer, Encyclopedia of Chemical Technology, third edition, vol. 20, and Mehrota, R. C., Pure Appl. Chem., 13, 111; 1966). The preferred method is by reacting the corresponding perfluoroalkyl trichlorosilane with the proper ether alcohol, such as, diethylene glycol monomethyl ether or triethylene glycol monomethyl ether, for example according to the following equation: ##STR4## Where m is 6-18.
The fluorinated trichloro silane starting materials for the above reaction can be prepared by one of several recognized procedures: for example see, McBee, E. T., J. Am. Chem. Soc., 79, 2329 (1957); Adv. Organomet. Chem, 17, 407 (1979); U.S. Pat. No. 3,012,006; U.S. Pat. No. 4,089,882 or U.S. Pat. No. 4,549,003. The reaction of perfluoroalkylethylene with trichlorosilane, catalyzed by a platinum complex, is preferred for the preparation of perfluoroalkylethyltrichlorosilane because of the mild reaction conditions and the high yields and purity that are achievable.
The mole ratio of perfluoroalkylethyltrichlorosilane to the ether alcohol employed in the preparation of the silanes for this invention is usually stoichiometric (i.e., 1:3); however, a small excess of the alcohol may be used to force the reaction to completion. The value of m is preferably from 6 to 18 and may be composed of pure components, or more economically, of a mixture of components in this range. A mixture containing a distribution of components with an average m of 8 to 12 is most preferred. The yields from this reaction are essentially quantitative. However, small amounts of oligomers may be produced that do not interfere with the use of the reaction product.
An alternate method, also useful for the preparation of the preferred silanes useful for this invention involves the transesterification of 2-perfluoroalkylethyltrimethoxy (or ethoxy) silane with diethylene glycol monomethyl ether or triethylene glycol monomethylether, with removal of the methanol or ethanol by-products. This reaction usually requires an acid or base catalyst, such as p-toluenesulfonic acid or sodium methoxide, to accelerate the reaction.
Any solvent inert to the reactants and products may be used in the reaction to provide the fluorocarbon silane ether ethoxylates of this invention. If the reactants and products are liquid and mutually miscible under the reaction conditions, the solvent may be omitted. Solvents such as hexane, heptane, toluene and cyclohexane are suitable.
The temperatures suitable for these reactions are those that will effect completion within a reasonable length of time. Temperatures ranging from about 0° C. to 160° C., or to the boiling point of the solvent, may be used. Usually temperatures of from about 25° C. to about 120° C. are employed. Reaction times of from about 2 hours up to 24 hours are usually adequate to complete the reaction.
The reactive hydrolyzable fluorocarbon silanes of the compositions described above possess unique properties that enable them to be formulated into stable aqueous emulsions that impart oil and water repellency to surfaces to which they are applied. The use of volatile organic solvents, which increase costs and may degrade the environment, are not required.
The fluorocarbon silanes suitable for preparation of these aqueous emulsions must possess hydrolyzable groups that impart sufficient hydrophilicity to the silane to permit the initial emulsifiability in the aqueous medium, with or with out the emulsifier. In the case of hydrolyzable fluorocarbon silanes represented by formula (1), the preferred compositions have R f as being mixed perfluoroalkyls with an average of 8 to 12 carbons, R' is a --CH 3 , p=2 and n=2 to 4. Corresponding compositions with n=0 or 1 will not produce stable aqueous emulsions by this invention. The preferred compositions with n=2 will produce stable aqueous emulsions only in the presence of the emulsifiers of this invention. The preferred composition with n=3 or greater will initially produce aqueous emulsions without the use of the emulsifiers. However, the usable lifetime (i.e., the time that the aqueous emulsion will retain its stability) will be inversely proportional to the concentration of the silane; e.g., from 1-2 hours for a 10% emulsion to 18-24 hours for a 0.5% emulsion. After which time the emulsion becomes hazy and ultimately results in an unusable mixture due to separation of the hydrolyzed and condensed fluorocarbon polysiloxane. However, during this short usable lifetime, the silane emulsion may be applied to a substrate to impart durable oil and water repellency. Thus in general, the highly stable emulsions of the present invention are prepared from silanes of the above formula or the like, such as poly(ether)alkoxy substituted silanes of sufficient hydrophilicity to achieve .equivalent water emulsifiablity and an appropriately selected emulsifier intimately dispersed in an aqueous mixture.
Emulsifiers usable to prepare the stable aqueous emulsions of the hydrolyzable fluorocarbons silanes of this invention may be chosen from anionic, cationic, nonionic, and amphoteric types. Preferred emulsifiers are those that have an HLB ("The HLB System" published by ICI America's Inc., Wilmington, Del.; Adamson, A. W., "Physical Chemistry of Surfaces", 4th. Ed., John Wily & Sons, N.Y., 1982, p. 475) value greater than 12, and preferably greater than 16. Emulsifiers with HLB values from 12 to 16 may be used, but, usually require significantly greater quantities of the emulsifier to achieve emulsions of adequate stability. Emulsifiers with HLB values below 12 do not form stable emulsions with preferred compositions of this invention. Mixtures of emulsifiers that each meet the above HLB requirements may be used; if they are compatible with one another. Suitable emulsifiers include, but are not limited to, alkylbenzenesulfonates, linear alkyldiphenyletherdisulfonates, alpha-olefin sulfonates, ethoxylated alkyl alcohol ethers, ethoxylated alkyl alcohol ether sulfates, ethoxylated alkylphenols, ethoxylated alkylphenol ether sulfates, ethoxylated perfluoroalkylalkanols, C 8-18 alkyltrimethylammonium salts, C 8-18 alkyldimethylammonium salts, ethoxylated C 8-18 amine salts, alpha-trimethylamino fatty acid betaines and perfluoroalkyl amphoteric surfactants of the type R f --CH 2 CH(OR")CH 2 N(CH 3 ) 2 CH 2 CO 2 (inner salt) where R" is H or acetyl, and quaternary salts of the type R f --CH 2 CH 2 SCH 2 CH(OH)CH 2 N(CH 3 ) 3 + CL--.
The aqueous emulsions of this invention are preferably prepared by dissolving the emulsifier in water and then slowly adding the fluorocarbon silane, employing standard agitation techniques. After the materials are thoroughly blended, the emulsions should stand for up to 72 hours, with or without further agitation, to allow them to fully generate the equilibrium stable composition. However in principle, the emulsifier can be added to an already emulsified water/hydrolyzable silane mixture provided that significant irreversible self-condensation has not taken place.
Analysis of the unique aqueous emulsions of this invention by Nuclear Magnetic Resonance spectroscopy indicates that the alkoxysilanes have undergone hydrolysis to produce hydroxysilanes that are believed to posses the structure: ##STR5## and possibly low molecular weigh oligomers thereof. However, unlike trihydroxysilanes in water mixtures without the emulsifier, these silanes do not undergo condensation to produce insoluble polymeric structures, but remain in a stabilized, emulsified state in the aqueous formulation.
The emulsions normally are essentially colorless, completely clear, water formulations. Particle size measurements by light scattering techniques (Coulter N4MD instrument) show particle sizes of from less than 10 nm to about 300 nm, indicative of true microemulsions or emulsions rather than solutions. Most frequently the particle sizes range from less than 10 nm to 100 nm.
The concentration of the emulsifier in the preferred emulsions is critical and varies with the particular emulsifiers and silanes. The optimum concentration for any given emulsifier/silane system is readily determined by routine procedures. In general, for the silanes of the present invention, the emulsifier may be present at concentrations of from 5 to 100, or more, weight percent based on the silane. The preferred concentrations of emulsifier are in the range of about 10 to 50%. The concentration of the silane may be from 0.01% to 50% by weight, based on the total emulsion, preferably from 0.1 to 25 weight percent for practical reasons.
The clear transparent appearance of an emulsion of this invention is indicative of its stability. Poor stability is recognized by precipitation of the silane as a polymeric species due to condensation to form less soluble siloxane structures which separate from the emulsion.
The preferred fluorocarbon silane emulsions of this invention containing an emulsifier are stable for over 6 months when stored at ambient temperatures. Many are stable at elevated temperatures of up to 60° C. for over two months. Many emulsions, particularly when prepared at emulsifier levels of 30% or greater based on silane weight, are stable to alternate freezing and thawing conditions. Additionally, many of the emulsions are stable at pH levels as high as 11 or as low as 3, if the emulsifier is also unaffected by such conditions. The emulsions of this invention may also be diluted to 0.1% or lower without loss of stability.
The aqueous emulsified fluorocarbon silanes of this invention will interact with functional groups on the surface of the substrate to produce a durable coating of the silane that imparts oil and water repellency to those substrates. The fluorocarbon silane repellent treatment compositions are most useful for imparting repellency to substrates having siliceous, cellulosic or proteinaceous surfaces, and to polymer substrates having pendent active hydrogen groups, such as polyesters and polyamides. Typical of treatable substrates are wood, brick, concrete, masonry, stone, glass, ceramic tile, natural and synthetic fibers, fur and leather.
The substrates are rendered repellent by coating the emulsions on the substrate surface and allowing the coated surface to dry. No curing step is required to achieve the durable repellency properties; however, heat may be applied to accelerate the drying process. The treated surface, after drying, may be washed with water to remove residual emulsifier that may effect the apparent water repellency. The resultant product is a substrate having bonded thereto a surface layer of the hydrolyzed/condensed form of the compound of formula (1) and/or (2).
Various additives such as pigments, biocides, uvabsorbers, and antioxidants may also be advantageously included in the emulsions of the present invention. It is also contemplated mixtures of more than a one silane compound may be used in the emulsions.
The following examples are presented to more fully demonstrate and further illustrate various individual aspects and features of the present invention. In doing so, the preferred perfluoroalkyl trialkoxysilanes are intentionally employed as being generally illustrative of the enhanced reactivity of the hydrolyzed emulsion compositions and generally illustrative of the resulting durable coatings of the process using perfluorocarbon silanes while being specifically illustrative of imparting useful and desirable repellency to substrate surfaces. As such the examples are felt to be non-limiting and are meant to illustrate the invention but are not meant to be unduly limiting in any way particularly with respect to ultimate properties and utility of the coated surfaces.
EXAMPLE 1
Preparation of 2-Perfluoroalkylethyltris[2-(2-methoxyethyoxy)ethoxy]silane:
2-Perfluoroalkylethyltrichlorosilane,-205 g, 0.32 mole, was dissolved in heptane and heated to 75° C. 2-(2-Methoxyethoxy)ethanol, 115.3 g, 0.96 mole, was added slowly to this solution. The hydrogen chloride that evolved was absorbed with a caustic scrubber solution. When the addition was complete, the mixture was heated an additional 24 hours at 75°-80° C. The solvent was removed under vacuum, leaving a clear, colorless liquid product.
EXAMPLE 2
Anionic emulsion:
An aqueous emulsion was prepared from the silane of Example 1 by slowly adding 8.0 g of the alkoxysilane to a stirred solution of 2.4 g of the anionic emulsifier, sodium dodecylbenzenesulfonate, in 89.6 g of water. The emulsion was allowed to stand without agitation for 24 hours to achieve an equilibrium composition, after which it had a pH of 3.65 and appeared clear and colorless. Measurement of particle size with a Coulter N4MD Laser Light Scattering instrument showed an average particle size of 14 nm. The emulsion was stable at ambient temperatures and at 60° C. for more than two months. Freezing and thawing did not affect the stability of the emulsion.
EXAMPLE 3
Cationic Emulsion:
8.0 g of the silane of Example 1 was added slowly to a stirred solution of 2.4 g of hexadecyltrimethylammonium chloride in 89.6 g of water. The emulsion was stirred for 30 minutes after the addition was complete and then allowed to stand for 24 hours to achieve the equilibrium composition. The emulsion had a pH of 5.35 and was clear and colorless, and was stable at ambient temperature and at 60° C. for more than two months. The emulsion was frozen and thawed repeatedly without change in appearance or properties. The emulsion particles were found to have an average particle size of 10 nm. This emulsion was analyzed by quantitative NMR spectroscopy and found to be essentially completely hydrolyzed.
EXAMPLE 4
Nonionic Emulsion:
An aqueous emulsion of the silane of Example 1 was prepared by the method of Example 3, using 8.0 g of the silane, 4.0 g of nonylphenol-50 EO, and 88 g of water. The clear, colorless, aqueous emulsion, with an average particle size of 34 nm, was stable at ambient and elevated temperatures for more than two months, and under repeated freezing and thawing conditions.
EXAMPLE 5
Amphoteric Emulsion:
An aqueous emulsion of the silane of Example 1 was prepared by the method of Example 3, using 8.0 g of the silane, 2.4 g of (2-acetoxy-3-perfluoroalkyl) propylcarboxymethyldimethylammonium inner salt ("ZONYL" FSK of DuPont Co.) and 89.6 g water. The clear, light amber emulsion had a pH of 2.65 and was stable for more than two months at 60° C. and under repeated freeze/thaw cycles. The emulsion particles were found to have an average size of 34 nm.
EXAMPLE 6
Preparation of 2-Perfluoroalkylethyltris[2-(2-(2-methoxyethoxy)ethoxy)ethoxy]silane:
2-Perfluoroalkylethyltrichlorosilane, 205 g, 0.32 mole, was dissolved in heptane. Triethylene glycol monomethyl ether, 157.4 g, 0.96 mole, was added slowly. The reaction temperature was raised to 80° C. and held 24 hours. The hydrogen chloride that was evolved was absorbed in a caustic scrubber solution. The solvent was then removed under vacuum leaving a clear, colorless, slightly viscous liquid product.
EXAMPLE 7
Anionic Emulsion:
An aqueous emulsion of the silane of Example 6 was prepared by the procedure of Example 3, using 9.2 g of the silane, 2.4 g of the anionic surfactant, sodium dodecylbenzenesulfonate, in 88.4 g of water. After standing for 24 hours, the emulsion was clear and colorless and was stable for more than 2 months at 60° C.
EXAMPLE 8
Self-Emulsion:
An aqueous emulsion of the silane of Example 6 was prepared by adding 0.58 g of the silane to 99.4 g of water, without any emulsifiers. The silane became emulsified immediately forming a colorless, clear aqueous mixture. After 18 hours the emulsion became hazy, and after 20 hours a gel and a white precipitate formed in the emulsion, indicating that it had lost its stability and condensed to an insoluble polymeric siloxane. Repellency tests presented in Example 9 were run on this emulsion within the first 8 hours after it was prepared, while it was still colorless and clear.
EXAMPLE 9
Repellency Tests:
The emulsions, prepared in Examples 2-8, were diluted with water to a concentration of 0.50 weight % active ingredient (before hydrolysis) and applied to several substrates. The oil and water repellent properties of these substrates were measured using AATCC (American Association of Textile Chemists and Colorists) Method 118-1978 wherein oil and water ratings of 0 indicate no repellency and ratings of 6 indicate the highest level of repellency. The fluorocarbon silanes were applied at the rate of 1 mg of active ingredient per square inch of substrate, and allowed to dry for 24 hours. The test pieces were then soaked in water for 30 minutes and again air dried for 24 hours before being tested for their repellency by the AATCC Method. The results are listed in Table I. The data illustrate the high levels of oil and water repellency imparted by the emulsion of this invention on a variety of substrates.
TABLE I______________________________________REPELLENCY PERFORMANCE OF HYDROLYZABLESILANE EMULSIONSOil/Water Repellency RatingEx- Ce- "Formica"am- ment Plastic Ceramic Plateple Wood Brick Block Laminate Tile Glass______________________________________Con- 0/0 0/0 0/0 0/5 0/0 0/0trol2 4/4 3/4 3/4 6/6 6/6 1/13 1/2 3/4 5/6 6/6 5/6 5/54 1/3 3/4 3/5 6/6 4/3 6/05 5/4 6/5 5/6 6/6 6/6 6/67 3/3 4/4 3/4 6/6 6/6 6/68 6/4 0/3 0/0 6/6 6/6 6/5______________________________________
EXAMPLE 10
Preparation of 2-Perfluoroalkylethyltris(polyoxyethyleneglycolmonomethylether)silane
2-Perfluoroalkylethyltrichlorosilane, 200 g., 0.30 mole, was dissolved in toluene at 25° C. Polyethyleneglycolmonomethylether having an average molecular weight of 350, 315 g, 0.90 moles, was added slowly to this solution. When the addition was complete, the temperature was raised slowly to 100° C. and held for 24 hours. The solvent was then removed under vacuum leaving a clear viscous liquid.
EXAMPLE 11
Emulsion Preparation:
The product of Example 10 was emulsified in water without added emulsifiers. This emulsion remained clear and colorless for about 1 week. After that time insoluble oligomers formed and precipitated from the emulsion, showing the instability of the aqueous emulsion in the absence of an emulsifier of this invention.
An aqueous emulsion that was stable for more than 2 months was prepared by the method of Example 5, using 2.0 g of the silane and 0.84 g of ("ZONYL" FSK, DUPont Co.) and 97.2 g water. This emulsion was evaluated by the AATCC Test Method of Example 9 and found to give an oil/water repellency ratings on wood of 4/3, and on plate glass of 6/6.
EXAMPLE 12
Repellency Test On Fabrics:
The anionic aqueous emulsion of Example 2 was applied to various fabrics from a bath containing 0.5% of the fluorocarbon silane. The fabrics were dried for 3 minutes at 300° F. The repellency, initially and after one dry cleaning of the fabrics, was determined by the AATCC Test Method 118-1978 where a rating of 6 indicated the highest level of repellency, and compared with the repellency of untreated fabrics. The results are given in Table II.
TABLE II______________________________________REPELLENCY PERFORMANCE ON FABRICSOil/Water Repellency Rating Cotton Poly/cotton NylonExample Init. DC Init. DC Init. DC______________________________________Control(a) 0/0 0/0 0/0 0/0 0/0 0/02(a) 4/5 4/5 2/5 1/5 4/5 4/52(b) 5/5 5/5 4/5 4/5 -- --______________________________________ (a) = Without other bath additives. (b) = With a standard durabilizing finish resin in the bath. Init = Initial repellency DC = After one dry cleaning
EXAMPLE 13
Water Hold-Out Test:
The emulsions of Examples 3 and 5, containing 0.5 weight % of the hydrolyzable fluorocarbon silanes, were applied to masonry bricks and tested for water hold-out according to the procedure of Federal Test Method SS-W-110c. A value for the water absorption of less than 1% weight gain is required to pass this standard test. The emulsion of Example 3 showed a 0.1% weight gain, and the emulsion of Example 5, a 0.2% weight gain. These results demonstrate the excellent water repellency and hold-out achieved by emulsions of this invention.
Having thus described and exemplified the invention with a certain degree of particularity, it should be appreciated that the following claims are not to be so limited but are to be afforded a scope commensurate with the wording of each element of the claim and equivalents thereof.
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Novel and highly reactive hydrolyzed silane emulsions are achieved by emulsifying a hydrolyzable alkoxysilane (e.g., perfluoroalkylethyltris(2-(2-methoxyethoxy)ethoxy)silane, 2-perfluoroalkylethyltris(2-(2-(2-methoxyethoxy)ethoxy)ethoxy) silane, 2-Perfluoroalkylethyltris(polyoxyethyleneglycolmonomethylether)silane or the like) in water in the presence of an effective amount of an emulsifier of sufficiently high HLB value (preferably 14 or greater) to simultaneously retain said hydrolyzable alkoxysilane compound in a substantially totally hydrolyzed state and inhibit said resulting hydrolyzed alkoxysilane compound from self-condensation. Such reactive emulsions containing fluorocarbon silanes are useful to produce durable coatings that impart oil and water repellency to substrates having siliceous, cellulosic or proteinaceous surfaces.
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BACKGROUND OF INVENTION
[0001] The present invention relates generally to an electrically powered vehicle, such as an electric vehicle (EV), a hybrid electric vehicle (HEV) or a fuel cell vehicle (FCV). More specifically the invention relates to a strategy to diagnose a potential fault in an electric motor. The present invention can determine two independent electric motor torque estimates using a plurality of current transducers and optionally a shaft position sensor for the traction motor.
[0002] The need to reduce fossil fuel consumption and emissions in automobiles and other vehicles predominately powered by internal combustion engines (ICEs) is well known. Vehicles powered by electric motors attempt to address these needs. Another alternative solution is to combine a smaller ICE with electric motors into one vehicle. Such vehicles combine the advantages of an ICE vehicle and an electric vehicle and are typically called hybrid electric vehicles (HEVs). See generally, U.S. Pat. No. 5,343,970 to Severinsky.
[0003] The HEV is described in a variety of configurations. Many HEV patents disclose systems where an operator is required to select between electric and internal combustion operation. In other configurations, the electric motor drives one set of wheels and the ICE drives a different set.
[0004] Other, more useful, configurations have developed. For example, a series hybrid electric vehicle (SHEV) configuration is a vehicle with an engine (most typically an ICE) connected to an electric motor called a generator. The generator, in turn, provides electricity to a battery and another motor, called a traction motor. In the SHEV, the traction motor is the sole source of wheel torque. There is no mechanical connection between the engine and the drive wheels. A parallel hybrid electrical vehicle (PHEV) configuration has an engine (most typically an ICE) and an electric motor that work together in varying degrees to provide the necessary wheel torque to drive the vehicle. Additionally, in the PHEV configuration, the motor can be used as a generator to charge the battery from the power produced by the ICE.
[0005] A parallel/series hybrid electric vehicle (PSHEV) has characteristics of both PHEV and SHEV configurations and is sometimes referred to as a “powersplit” configuration. In one of several types of PSHEV configurations, the ICE is mechanically coupled to two electric motors in a planetary gear-set transaxle. A first electric motor, the generator, is connected to a sun gear. The ICE is connected to a carrier gear. A second electric motor, a traction motor, is connected to a ring (output) gear via additional gearing in a transaxle. Engine torque can power the generator to charge the battery. The generator can also contribute to the necessary wheel (output shaft) torque if the system has a one-way clutch. The traction motor is used to contribute wheel torque and to recover braking energy to charge the battery. In this configuration, the generator can selectively provide a reaction torque that may be used to control engine speed. In fact, the engine, generator motor and traction motor can provide a continuous variable transmission (CVT) effect. Further, the HEV presents an opportunity to better control engine idle speed over conventional vehicles by using the generator to control engine speed.
[0006] The desirability of combining an ICE with electric motors is clear. There is great potential for reducing vehicle fuel consumption and emissions with no appreciable loss of vehicle performance or drive-ability. The HEV allows the use of smaller engines, regenerative braking, electric boost, and even operating the vehicle with the engine shutdown. Nevertheless, new ways must be developed to optimize the HEV's potential benefits.
[0007] One such area of development is calculating torque estimates delivered by an electric motor or motors. An effective and successful HEV design (or any vehicle powertrain propelled by electric motors and optionally capturing regenerative braking energy) requires reliable operation. Reliable operation can be improved through careful diagnosis of potential faults within the electric motor or motors. Thus there is a need for a strategy to effectively detect fault in an electric motor propelled vehicle's electrical components and sub-systems, including single subsystem failures, specifically, within the vehicles electric motors. One way to detect fault in an electric motor is to compare two independent calculations of motor torque.
[0008] Previous efforts have used rotor position sensors or estimates as part of the control strategy for an electric motor. For example, Jones et al. (U.S. Pat. No. 6,211,633) discloses an apparatus for detecting an operating condition of a machine synchronizes sampling instants with the machine condition so that reliability data are obtained. The operating condition may be the position of the rotor in which case estimates of the rotor position and rotor velocity at each of the sampling instants are developed.
[0009] Lyons et al. (U.S. Pat. No. 5,864,21 7) discloses an apparatus and method for estimating rotor position in and commutating a switched reluctance motor (SRM), using both flux/current SRM angle estimator and a toothed wheel generating a magnetic pickup. Phase errors can be compensated by adjusting the angle input to the commutator as a function of estimated speed. Alternately, the flux/current SRM angle estimator can be run in background mode to tune the toothed wheel interrupt angle signal at different speeds.
[0010] Drager et al. (U.S. Pat. No. 5,867,004) discloses a control for operating an inverter coupled to a switched reluctance machine that includes a relative angle estimation circuit for estimating rotor angle for a phase in the switched reluctance machine.
[0011] Lyons et al. (U.S. Pat. No. 5,107,195) discloses a method and apparatus for indirectly determining rotor position in a switched reluctance motor that are based on a flux/current model of the machine, which model includes multi-phase saturation, leakage, and mutual coupling effects.
[0012] Lastly, Acarnley (U.S. Pat. No. 6,005,364) discloses a motor monitoring and control circuit that calculates a value parameter for a position of the motor at given instants. The same parameter (which may be position or speed of a rotor) is then measured at subsequent instants. These values are used to compute a future value of the parameter.
[0013] The use of two independent torque estimates to diagnose a potential fault in the electric motor of an electric motor propelled vehicle is unknown in the prior art.
SUMMARY OF INVENTION
[0014] Accordingly, the present invention provides a strategy to effectively detect fault in an electric motor propelled vehicle's electrical components and sub-systems, including single subsystem failures of the electric motor by creating two independent torque estimates of an electric motor for a hybrid electric vehicle (HEV) using a plurality of current transducers and optionally a shaft position sensor. Discrepancies between the two independent torque estimates or the signals used to create the two independent torque estimates can be indicative of a fault or a system or a subsystem failure such as stray current leakage.
[0015] More specifically, the invention provides a strategy to generate two independent torque estimates of a three phase electric motor comprising first and second systems to determine current in each motor phase, first and second systems to generate a first and second estimate of motor shaft position, and first and second systems to generate first and second estimates of motor torque using the first and second systems to determine current in each motor phase and the first and second estimates of motor shaft position.
[0016] The strategy uses four current sensors to generate four measured currents, which are used for the first and second systems to determine current in each motor phase. The first and second systems to estimate motor shaft position can be Kalman filters. Alternatively the second system to estimate motor shaft position can be a resolver.
[0017] Other objects of the present invention will become more apparent to persons having ordinary skill in the art to which the present invention pertains from the following description taken in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF DRAWINGS
[0018] The foregoing objects, advantages, and features, as well as other objects and advantages, will become apparent with reference to the description and figures below, in which like numerals represent like elements and in which:
[0019] [0019]FIG. 1 illustrates a general hybrid electric vehicle (HEV) configuration.
[0020] [0020]FIG. 2 illustrates an electric traction motor for an HEV.
[0021] [0021]FIG. 3 illustrates electric motor stator windings connected in a “wye” configuration.
[0022] [0022]FIG. 4 illustrates an arrangement of four current sensors having two sensors in each of two phases.
[0023] [0023]FIG. 5 illustrates an alternate arrangement of four current sensors.
[0024] [0024]FIG. 6 illustrates the strategy of the present invention in block diagram form.
DETAILED DESCRIPTION
[0025] The present invention relates to electric motors. As the use of electric motors in vehicle applications increases, motor reliability potential fault detection becomes critical. This is especially true in the harsh conditions typically experienced by motors used as vehicle components. For demonstration purposes and to assist in understanding the present invention, it is described in an hybrid electric vehicle (HEV) application. FIG. 1 demonstrates just one possible HEV configuration, specifically a parallel/series hybrid electric vehicle (powersplit) configuration.
[0026] In a basic HEV, a planetary gear set 20 mechanically couples a carrier gear 22 to an engine 24 via a one-way clutch 26 . The planetary gear set 20 also mechanically couples a sun gear 28 to a generator motor 30 and a ring (output) gear 32 . The generator motor 30 also mechanically links to a generator brake 34 and is electrically linked to a battery 36 . A traction motor 38 is mechanically coupled to the ring gear 32 of the planetary gear set 20 via a second gear set 40 and is electrically linked to the battery 36 . The ring gear 32 of the planetary gear set 20 and the traction motor 38 are mechanically coupled to drive wheels 42 via an output shaft 44 .
[0027] The planetary gear set 20 , splits the engine 24 output energy into a series path from the engine 24 to the generator motor 30 and a parallel path from the engine 24 to the drive wheels 42 . Engine 24 speed can be controlled by varying the split to the series path while maintaining the mechanical connection through the parallel path. The traction motor 38 augments the engine 24 power to the drive wheels 42 on the parallel path through the second gear set 40 . The traction motor 38 also provides the opportunity to use energy directly from the series path, essentially running off power created by the generator motor 30 . This reduces losses associated with converting energy into and out of chemical energy in the battery 36 and allows all engine 24 energy, minus conversion losses, to reach the drive wheels 42 .
[0028] A vehicle system controller (VSC) 46 controls many components in this HEV configuration by connecting to each component's controller. An engine control unit (ECU) 48 connects to the engine 24 via a hardwire interface. All vehicle controllers can be physically combined in any combination or can stand as separate units. They are described as separate units here because they each have distinct functionality. The VSC 46 communicates with the ECU 48 , as well as a battery control unit (BCU) 50 and a transaxle management unit (TMU) 52 through a communication network such as a controller area network (CAN) 54 . The BCU 50 connects to the battery 36 via a hardwire interface. The TMU 52 controls the generator motor 30 and traction motor 38 via a hardwire interface.
[0029] A basic diagram of the traction motor 38 is illustrated in FIG. 2. The traction motor 38 has a stator 100 , having slots 104 and teeth 106 . Motor windings 108 carry electric current through the traction motor 38 . The windings are connected in a “wye” configuration, as illustrated in FIG. 3, below. Interior to stator is the rotor 102 . The illustrated rotor 102 has permanent interior magnets 110 . The motor shaft 112 passes through the rotor 102 . A resolver 114 can be connected to the motor shaft 112 .
[0030] The windings 108 of a three phase electric motor can be represented as being arranged in a “wye.” Each of the three phases, commonly referred to as phase a, b, and c are represented by one leg of the “wye.” The “wye” configuration is illustrated in FIG. 3. Phase a 120 would have a corresponding electric current, current a (I a ) 122 , passing through it. Similarly, phases b 124 and c 128 would have corresponding electric currents, current b (I b ) 126 and current c (I c ) 130 , respectively passing through them as well. Measurement or estimation of all three motor phase currents ( 122 , 126 , and 130 ) and the motor shaft 112 position angle is required to calculate the motor torque.
[0031] In the present invention the VSC 46 can detect single system faults generally by two procedures (shown in FIGS. 4 and 5) using alternate types of independent estimations of machine torque. For the embodiments presented, four current sensors per electric motor are used. Many other types of configurations are possible. Sensor output can be sent to the VSC 46 where appropriate actions may be taken such as lighting an indicator lamp or sounding an indicator tone to warn the operator of a potential system fault. Additionally, other hazard mitigation steps, known in the art, could be employed such as cutting power to the motor 38 .
[0032] [0032]FIG. 4 shows a first embodiment of the present invention. FIG. 4, like FIG. 3, shows the “wye” configuration of the three phases of the electric motor. In practice, any individual leg of the “wye” can be any of the individual phases. In FIG. 4, the phases will be referred to as phases x, y, and z, where phases x, y, and z can be any ordering of phases a, b, or c. Phase x 140 would have a corresponding electric current, current x (I x ) 142 , passing through it. Similarly, phases y 144 and z 148 would have corresponding electric currents, current y (I y ) 146 and current z (I z ) 150 , respectively passing through them as well.
[0033] Added to the “wye” configuration are four current sensors. The first current sensor 152 gives a measured current x (i x ). The second current sensor 154 gives a second measured current x (i x ′). The third current sensor 156 gives a measured current y (i y ). The fourth current sensor 158 gives a second measured current y (i y ′). These sensors can be of any type known in the art for measuring motor phase current, such as a resistive shunt or non-contacting current transducers and can be either active or passive.
[0034] [0034]FIG. 5 shows an alternate arrangement of four current sensors on the legs of the “wye” configuration representing the phase s of the electric motor. In this embodiment the first current sensor 152 gives a measured current x (i x ). The second current sensor 154 gives a second measured current x (i x ′). The third current sensor 156 gives a measured current y (i y ). The fourth current sensor 160 gives a measured current z (i x ′).
[0035] [0035]FIG. 6 illustrates a possible strategy using the present invention in block diagram form. An inverter control for operating a switched reluctance machine 178 includes the resolver 114 coupled by a motive power shaft 184 to the rotor 102 of the switched reluctance machine 178 . Excitation is provided by a resolver excitation circuit 188 . The resolver 114 develops first and second signals over lines 192 and 194 that have a phase quadrature relationship (also referred to as sine and cosine signals). A resolver-to-digital converter 190 is responsive to the magnitudes of the signals on the lines 192 and 194 and develops a digital output representing the position of the rotor 102 of the switched reluctance machine 178 . The position signals are supplied along with a signal representing machine rotor 102 velocity to a control and protection circuit 170 . The rotor 102 position signals are also supplied to a commutation circuit 180 and a current control circuit 172 having an input coupled to an output of the control and protection circuit 170 . Circuits 170 and 172 further receive phase current magnitude signals as developed by an inverter 176 . The circuits 170 and 172 develop switch drive signals on lines 174 for the inverter 176 so that the phase currents flowing in the windings of the switched reluctance machine 178 are properly commutated. A position estimation circuit or subsystem 182 is responsive to the phase current magnitudes developed by the inverter 176 , switch control or drive signals for switches in the inverter 176 and DC bus voltage magnitude to develop position and velocity estimate signals for the control and protection circuit 170 . In addition, the position estimate signals are supplied to the commutation circuit 180 . The current control circuit 172 is responsive to the phase current magnitudes developed by the inverter 176 , as well as phase enable output signals developed by the commutation circuit 180 and a reference current signal developed by the control and protection circuit 170 . The current control circuit 172 produces the switch control or drive signals on lines 174 for the inverter 176 . Measurements from these systems allow the development of strategies to estimate normal traction motor 38 torque.
[0036] The resolver 114 , known in the prior art, is a direct measurement of rotor 102 position angle. A Kalman filter based estimation method, also known in the art, can generate a second independent calculation of the rotor 102 position angle in electric and hybrid-electric vehicles.
[0037] Currents a 122 , b 126 , and c 130 in the three phases of the “wye” {a 120 , b 124 , and c 128 } are actively switched at high frequency by the three phase inverter 176 between the motor windings 108 and a direct current voltage source, such as the battery 36 .
[0038] The traction motor 38 has the ideal torque “T” characteristic as follows:
[0039] Equation 1:
T = 3 4 p [ MI f I q + ( L d - L q ) I d I q ]
[0040] where
[0041] p is the number of motor poles (known),
[0042] M is the rotor to stator mutual inductance (known),
[0043] I f is the “equivalent” current corresponding to the permanent magnet magnetic flux (known),
[0044] L d is the direct axis inductance (known),
[0045] L q is the quadrature axis inductance (known),
[0046] I d is the “direct” axis current (estimated from measured and other values), and
[0047] I q is the “quadrature” axis current (estimated from measured and other values).
[0048] To generate relative currents {I d , I q } in a frame that rotates at the rotor velocity, we can write:
[0049] Equation 2:
I d = 2 3 [ I a cos θ + I b cos ( θ - γ ) + I c cos ( θ + γ ) ]
[0050] Equation 3:
I q = - 2 3 [ I a sin θ + I b sin ( θ - γ ) + I c sin ( θ + γ ) ]
[0051] where:
[0052] I a , I b , I c are the stator “wye” coil currents 122 , 126 , and 130 ,
[0053] θ is the rotor position angle, and
[0054] γ is the electrical phase angle between stator coils, and
[0055] where:
γ = 2 3 π = 120 deg .
[0056] To generate two independent estimates of electrical machine torque by using Equation 1, two independent ways to find I d , and I q are required. These currents in turn each depend upon two signals sets:
[0057] 1. the “wye” connected stator phase coil currents {I a 122 , I b 126 , I c 130 }, and
[0058] 2. the motor shaft 112 position angle θ.
[0059] At least two independent strategies are described to independently estimate each of these two signal sets. For the first strategy, assume each of the three legs of the stator coil has current flowing in that leg. The machine winding neutral at the center of the “wye” is not connected, which is true for the case of inverter driven motors. Because Kirchoff's current law, known to those skilled in the art, applies to the “wye” connected circuit, the currents {I a 122 , I b 126 , I c 130 } obey the relationship:
[0060] Equation 4:
I a +I b +I c =0.
[0061] Only two currents need to be known to estimate the third current.
[0062] For example, if {i a , i b , i c } represent current sensor outputs measuring the currents {I a 122 , I b 126 , I c 130 }, by measuring any two, for example {i a , i b }, we can estimate the third i c as Equation 5:
î c =−( i a +i b )
[0063] where î c represents an estimated, not measured, output signal. By using two current sensors, we have estimated the three phase stator currents as {i a , i b , î c }.
[0064] To generate a redundant and completely independent second strategy to estimate stator currents, we cannot rely on either sensor indicating {i a , i b }. Instead we can redundantly measure {i a , i b } with two additional sensors {i a ′, i b ′} as in FIG. 4, and apply Equation 5 to generate the second estimate of i c ′ as:
î c ′=−( i a ′+i c ′),
[0065] Alternatively, we might choose to measure i c ′ directly as in FIG. 5, and either of {i a ′, i b ′} directly, then apply Equation 5 to estimate the remaining current such as:
î b ′=−( i a ′+i c ′),
[0066] or
î a ′=−( i b ′+i c ′).
[0067] This dual stator current estimation is summarized in Table 1, where {x, y, z} are any ordering of the stator coils {a, b, c}.
TABLE 1 Altemate Ways to Estimate One of the Three Stator Currents Independent Independent Strategy Strategy 1: Use 2: Use any column Actual sensors and of sensors Current estimators and estimators I x 142 i x i x ′ i x ′ −(i y ′ + i z ′) I y 146 i y i y ′ −(i x ′ + i z ′) i y ′ I z 150 −(i x 30 i y ) −(i x ′ + i y ′) i z ′ i z ′
[0068] Referring to the table, the far left column of Independent Strategy 2 redundantly measures the same two phase currents {x 142 , y 146 } as does Independent Strategy 1. Putting two current sensors in the same leg may simplify the sensor packaging if two sensors, {x 152 , x′ 154 } for example, can share any of their non-critical components. Such non-critical components can include passive parts such as a sensor housing, mounting fasteners, ferrite core and electrical connector housing. In this case, Equation 4 can be validated as Equation 7 as follows:
i x +i y +−( i x ′+i y ′)=0.
[0069] Furthermore, sensors in the same leg can be cross-checked as Equation 8 as follows:
( i x −i x ′)=0,
( i y −i y ′)=0.
[0070] Any stray current leakage in coil c (due to short circuit faults in wiring to the coil, the coil drivers, and between the coil windings and the stator core) is not explicitly sensed.
[0071] Alternatively, the right two columns of Independent Strategy 2 redundantly measure only one of the two phase currents I x 142 or I y 146 as measured in Independent Strategy 1. The other phase current I z 150 , has a separate sensor 160 to generate signal i z ′, resulting in three unique signals {i x , i y , i z ′} to verify Equation 4 as Equation 9 as follows:
i x i y +i z ′=0.
[0072] If either of the last two columns in the table are selected, any stray current leakage in stator coil c is explicitly sensed, which may enable detection of additional faults causing current leakage in stator coil c.
[0073] In using a total of four current sensors on two or three legs of the traction motor's “wye” windings as in FIGS. 4 and 5, all three current measurements can be generated in two independent ways, and cross-checked to detect whether any one or more measurements should be faulted.
[0074] All present inverter motor control technologies require the rotor 102 position θ according to Equations 2 and 3. Motor shaft 112 angle θ can be measured directly by a sensor called the resolver 114 , or estimated using an observer or Kalman filter based upon the measured motor currents.
[0075] An alternate embodiment of the present invention adds the resolver 114 to the embodiment described above. Traditionally, inverter torque motor controls use the resolver 114 , composed of a “toothed” ring consisting of a plurality of teeth rotating with the motor shaft 112 being measured, and one or more stationery “tooth” sensors of some technology, be it optical, variable reluctance, Hall effect, or other technology known in the art. If one “toothed” ring and one sensor are used, the resolver 114 is also called a “tone wheel.” The tone wheel measures relative position, and it is not capable of sensing direction of travel. Some “tone wheels” omit a tooth as a reference absolute position, but measurement is only relative, so measurement during changes of direction is impossible. If two “tooth” sensors are used, the resolver 114 can sense direction, but it still cannot measure absolute position. If more than two “tooth” sensors are used, the resolver 114 can sense direction and absolute position. Some drawbacks of resolvers are their expense, high failure rates, and requirement of a high speed interface at the microprocessor that receives their output signals.
[0076] Methods have been developed to estimate the motor shaft 112 position. The estimate being derived not from a resolver 114 , but from implicit characteristics of the motor. One such characteristic of an inductance motor is the mutual inductance between the stator coils and the induced current in the rotor 102 , which is dependent upon the relative angle between the two and can be estimated from the motor phase currents {I a 122 , I b 126 , I c 130 }. Another characteristic that can be used to estimate motor shaft 112 position is the back EMF of the motor, known to those skilled in the art as a voltage across the coil that increases with motor speed.
[0077] There are well-documented methods that capitalize on these position dependent motor characteristics to estimate the motor shaft 112 relative position. One method is an observer. Another method is a special case of observer called a Kalman filter. In general the observer will compute by Equation 10:
{circumflex over (θ)}=F( s )(I a , I b , I c )
[0078] where F(s) is the observer transfer function.
[0079] To generate separate and independent estimates a of motor shaft 112 position, generate a first estimate using the stator current estimation approach Independent Strategy 1 given above, and a second estimate using the Independent Strategy 2. The combined current and motor shaft 112 position measuring method can detect all single point failures and is robust in that it can enable safe, if not complete, operation even when a single point fault occurs and is detected.
[0080] Alternatively, one independent motor shaft 112 angle may be measured with a resolver 114 , and a second independent motor shaft 112 angle may be estimated using the proposed observer or Kalman filter and either of the phase current measuring proposals.
[0081] The above-described embodiments of the invention are provided purely for purposes of example. Many other variations, modifications, and applications of the invention may be made.
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The present invention can diagnose a potential fault in an electric motor by generating two independent torque estimates using a plurality of current sensors and optionally a shaft position sensor. The invention provides a strategy to generate two independent torque estimates of a three phase electric motor comprising first and second systems to determine current in each motor phase, first and second systems to generate a first and second estimate of motor shaft position, and first and second systems to generate first and second estimates of motor torque using the first and second systems to determine current in each motor phase and the first and second estimates of motor shaft position. The present invention detects a fault in an electric motor propelled vehicle's electrical components and sub-systems, including single subsystem failures system based on discrepancies between to the two independent torque estimates.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. application Ser. No. 08/878,372 filed Jun. 18, 1997 now abandoned.
FIELD OF THE INVENTION
The present invention relates to chemical or biological reactors generally, and in particular to an apparatus for controlling the temperature within a chemical reactor.
BACKGROUND OF THE INVENTION
Temperature control of a chemical reaction is often the key to obtaining desired products. Where the temperature is controlled, generally the reaction kinetics are controlled. Where the reaction kinetics are controlled, undesired intermediates and byproducts can be diminished or avoided. Traditional temperature control of industrial reactors is generally attained in one of two ways. One method is to control the temperature of the reactants as they enter the reactor. This method fails to address the heat of reaction, which is often responsible for the majority of heat produced or absorbed in a reaction. The heat of reaction can then alter the temperature of the reactants to produce undesirable products. This is especially true for tank reactors.
Conversely, endothermic reactions require the addition of heat during the reaction to maintain the temperature of the reactants. Again, pre-adjustment of the temperature of reactants fails to adequately address this situation. Further, complicated production processes may have exothermic and endothermic reactions taking place (usually at different times) as reactants are added or products withdrawn. Pre-adjustment of reactant temperature is clearly totally inadequate in such situations.
A second method of temperature control of industrial reactors involves the placement of a jacket around the outside of the reaction vessel. In such a case, a fluid of desired temperature is passed through the jacket, thereby cooling or heating the reaction medium. The effectiveness of the jacket is limited by heat transfer properties which are in turn limited by mechanical design characteristics and geometry, including specifically vessel diameter and length. Material of construction, wall thickness, vessel diameter and length are critical design parameters for both strength and heat transfer. Unfortunately, however, heat transfer and mechanical strength are competing values in reactor design. For a given vessel diameter and length, the reactor wall may be thick enough to meet pressure and strength requirements, but too thick for optimal heat transfer between the jacket fluid and the reaction medium, as heat transfer is decreased with increased wall thickness. Where the reactor wall is thinned to improve heat transfer, the structural integrity of the vessel is diminished. This trade-off has historically been the source of design efforts seeking to gain maximum heat transfer efficiency while meeting mechanical strength requirements. If there is an increase in vessel diameter for a given length, the wall becomes weaker under internal pressure and weaker (to a higher order) under external pressure. Increasing vessel diameter, for a given length, also decreases (heat-transfer) surface to reacting medium volume, further inhibiting heat transfer mechanisms.
In the design of reactor cooling systems, two additional concerns arise when low temperatures are needed and cryogenic fluids are being contemplated for use as refrigerants. First, the temperature of the jacket fluid is calculated based on heat transfer requirements for a given reaction medium and reactor design. The required jacket fluid temperature is often below the freezing point of the reactor medium. As a consequence, the reactor contents can freeze along the inside of the reactor wall. The formation of “ice” results in a thicker wall overall and decreased heat transfer efficiency, as well as potentially inconsistent reactor medium composition, and in some cases, destruction of some reactants or products through freezing. Second, when a cryogenic fluid changes phase the vapor generated could occupy as much as 100 times the same volume as the liquid from which it originated. This large increase in specific volume can lead to erratic heat transfer mechanisms and, consequently, poor reactor medium temperature control.
Thus, there is a need for an improved apparatus for controlling the temperature of a reactor during operation that would allow for a (1) thin wall and resultant increased heat transfer to the contents and (2) increase of reactor size (diameter and length) without sacrificing the required mechanical properties of the reactor. Additionally, such an apparatus which prevents the build-up of frozen reactor contents would maintain high heat transfer efficiency and constant reactor medium temperature gradients, resulting in homogeneous and uniform reaction kinetics. The desired reactor would maximize the desired properties of high mechanical strength and high heat transfer efficiency, two qualities which have historically competed, regardless of size (i.e. diameter and length).
SUMMARY OF THE INVENTION
The present invention is an insulated chemical or biological reactor (such as a fermenter) system comprising a reaction vessel, an evacuated insulation shell, a plurality of temperature controlling mixing baffles immersed in the reactor contents and a temperature controlling helical channel coil outside of the reactor but inside the evacuated shell. A device designed to control the separation of phases of the working fluid chosen is required and may be external to the reactor. This device is referred to as the phase separator and has two outlets, one for each phase of the working fluid. The temperature controlling mixing baffles are designed to accept the working fluid in a single phase proceeding from one outlet of the phase separator and to, in turn, cause this fluid to change phase therein without carryover of any of the inlet fluid in the evolved phase. The changing of phase of the working fluid in the temperature controlling mixing baffles takes place at a uniform temperature, the level of which is dictated by the thermodynamic properties of the working fluid selected. The temperature controlling mixing baffles are referred to as isothermal mixing baffles. The channel coil is adapted to accept a circulating fluid, specifically of a single phase evolved by the mixing baffles and the other outlet of the phase separator. The particular working fluid selected depends on the intended temperature control purposes, that is whether heating or cooling is desired and the degree of heating or cooling needed. The channel coil is affixed to the outside wall of the reactor in a helical configuration and adapted to receive the single phase of the working fluid evolved by the mixing baffles and the other outlet of the phase separator which flows spirally upward or downward around the outside of the reactor. The channel coil is shaped to have two straight, parallel sides of the coil in contact with the reactor, normal to the surface of the outside wall of the reactor. This right angle contact between the channel coil and reactor wall increases the section modulus of the vessel wall, and thereby increases the mechanical strength of the reactor wall under external pressure. The wall can thus be made thinner to promote better heat transfer across the wall. The reactor, including the mixing baffles and the affixed coil, are together enclosed within an evacuated jacket.
The separation of the phases of the working fluid is very important for the optimal and predictable operation of the present invention, particularly when cooling of the reactor contents is anticipated. In the cooling mode the isothermal cooling baffles are intended to boil the working fluids which enter as a liquid and evolve only a saturated vapor with no liquid carryover in the form of droplets or mist. The isothermal mixing baffles, therefore, operate in the boiling heat transfer regime exchanging the latent energy of vaporization (at constant temperature) with the reactor contents. The vapor evolved from the isothermal mixing baffles, as well as the vapor evolved from the phase separator upstream therefrom is commingled and directed to enter the helical channel coil that serves as the reactor external jacket, wherein it exchanges sensible thermal energy with the reactor contents, gaining temperature to approach that of the reactor contents as it travels further along the inside of the coil.
The present invention thus controls heat transfer regimes by assuring that distinct single phases will exist in the isothermal mixing baffles (boiling liquid for cooling mode; condensing vapor for heating mode) and helical channel coil (vapor increasing in temperature for cooling mode; liquid decreasing in temperature for the heating mode).
The isothermal mixing baffles, of which there are typically at least two, are vertically oriented, elongated, generally cylindrical devices with an inlet and an outlet. As with the jacket, the isothermal mixing baffles may be used for heating or cooling the contents of the reaction vessel. Where heating is desired, a hot liquid or gas can be introduced into the isothermal mixing baffles through the inlet. The resultant cooler liquid or condensed vapor or liquid can be removed via the outlet. Where cooling is desired, upstream of the isothermal mixing baffles inlet there is provided a phase separator to insure only a liquid stream enters the isothermal mixing baffles. The inlet to the isothermal mixing baffles is typically placed into the top of the reactor and a liquid of desired boiling point is allowed to enter the isothermal mixing baffles while the reactor is in use. Where cooling is desired, the liquid selected would have a boiling point at or below the desired reaction temperature. The heating and boiling of the liquid introduced into the isothermal mixing baffles provides for the removal of heat from the reactor contents. For additional temperature control, the vapor produced from the boiling of the isothermal mixing baffles contents may be taken from the top of the isothermal mixing baffles, coming led with gas emanating from the phase separator and passed through the channel coil surrounding the outside of the reaction vessel.
The isothermal mixing baffles are designed and arranged so that their combined cross-sectional area will be such that the velocity of the vapor evolved from the liquid phase boiling therein will be below a critical value, Uc, above which droplets or slugs of the liquid phase will be entrained in the evolved gas and expelled from the isothermal mixing baffles. To accomplish this requirement, the inlets and outlets of the isothermal mixing baffles will be piped in parallel.
Thus in one aspect the present invention is an insulated chemical reactor comprising; a reaction vessel having a wall with inner and outer surfaces, an evacuated insulation shell spaced apart from and surrounding the reaction vessel, at least one isothermal mixing baffle disposed within the reaction vessel, a phase separator in fluid communication with the baffle so that only one saturated or sub-cooled liquid phase of a heat transfer working fluid enters the isothermal mixing baffle, a temperature controlling helical channel coil fixed to the outer surface of the wall of the reaction vessel, the helical channel coil having at least two walls disposed normal to the outer surface of the wall of the vessel, thus defining an open helical channel coil fixed to the wall of the vessel, the helical channel coil having a winding pitch so that successive coils of the channel coil are spaced apart from each other, thus defining a closed path to receive a fluid to contact the wall of the reaction vessel, the wall of the reaction vessel being of a thickness less than that required for use under a given temperature and pressure regime, the channel coil serving to add structural strength to the wall of the reaction vessel, so that the reaction vessel with the channel coil fixed thereto can be operated under the temperature and pressure regime; the helical channel coil fixed to the outer surface to enhance conductive heat transfer and transfer of convective energy flow inside the helical channel coil through the wall of the vessel; and means to combine vapor from the phase separator and vapor from the isothermal mixing baffle and introduce the vapor into the helical channel coil.
Thus in another aspect the present invention is an apparatus for isothermally cooling contents of a reaction vessel having a top and bottom, by allowing a saturated or subcooled liquid to boil inside an isothermal mixing baffle immersed in the reactor contents, to produce gas inside the isothermal mixing baffle, comprising; a vertically oriented, elongated generally cylindrical isothermal mixing baffle having a top and a bottom, the isothermal mixing baffle immersed in the contents in the reaction vessel, means for introducing the liquid into the top of the isothermal mixing baffle to a predetermined level, means for removing gas from the isothermal mixing baffle, and, means for controlling the level of liquid in the isothermal mixing baffle.
In yet another aspect the present invention is an apparatus for supplying saturated or superheated gas to a temperature controlling helical channel coil disposed helically around a reaction vessel, comprising; an isothermal mixing baffle, immersed in contents contained in the reactor, as mixing baffle containing a saturated or subcooled liquid, means for supplying vapor discharged from the isothermal mixing baffle to the helical channel coil, means for monitoring flow of the vapor into the helical channel coil, and, means for controlling flow of vapor into the helical channel coil.
In still another aspect the present invention is a method for controlling the temperature in a reaction vessel comprising the steps of; disposing a helical channel temperature control coil around an outside surface of the reaction vessel, introducing a heat transfer working fluid into a phase separator, withdrawing a liquid portion of the working fluid from the phase separator and introducing the liquid portion into an isothermal mixing baffle disposed in contents contained in the reaction vessel, withdrawing a vapor portion of the working fluid from the phase separator and mixing it with a vapor phase working fluid withdrawn from the isothermal mixing baffle to produce a mixed heat exchange fluid; and introducing the mixed heat exchange fluid into said helical channel coil.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1A is a flow diagram that depicts the flow scheme of the present invention in a cooling mode for the phase separator and the reaction vessel, which contains internal isothermal mixing baffles and an external helical channel coil.
FIG. 1B is a flow diagram that depicts the flow scheme of the present invention in a heating mode for the phase separator and the reaction vessel, which contains internal isothermal mixing baffles and an external helical channel coil.
FIG. 2A is a side view of a reaction vessel having a cylindrical cross-sectional shape with an external channel coil according to the present invention.
FIG. 2B is a side view of reaction vessel with an external channel coil according to an alternate embodiment of the present invention.
FIG. 3A is a cross-sectional view of the generally cylindrical reaction vessel of FIG. 2A with an external helical channel coil, and integral isothermal mixing baffle entering the reactor vessel from the top in accordance with the present invention.
FIG. 3B is a cross-sectional view of the reaction vessel of FIG. 2B with an external helical channel coil, and integral isothermal mixing baffle entering the reactor vessel from the top.
FIG. 4 is a cross-sectional view of a reaction vessel with an external channel coil, integral isothermal mixing baffle entering the reactor vessel from the top and evacuated jacket, in accordance with the present invention.
FIG. 5A is a partial cross-sectional view of an isothermal mixing baffle according to the present invention with circular cross-section the isothermal mixing baffle shown entering the reactor vessel from the top.
FIG. 5B is a partial cross-sectional view of an isothermal mixing baffle according to the present invention with circular cross-section, the isothermal mixing baffle shown entering the reactor vessel from the bottom.
FIG. 5C is an alternate embodiment of the device of FIG. 5A showing the use of an internal snubber made to be removable from outside the reactor vessel without disturbing the reactor vessel contents or evacuated shell.
FIG. 5D is an alternate embodiment of the device of FIG. 5B showing the use of an internal snubber made to be removable from outside the reactor vessel without distributing the reactor vessel contents or evacuated skill.
FIG. 5E is a horizontal cross-sectional view of an alternate embodiment of the cross-sectional shape of the device of FIG. 5A .
FIG. 5F is a horizontal cross-sectional view of an alternate embodiment of the cross-sectional shape of the device of FIG. 5B .
FIG. 6A is a cross-sectional view of the reaction vessel with external channel coil, evacuated jacket, and integral isothermal mixing baffle according to the present invention showing the integral isothermal mixing baffle entering the reactor vessel from the top.
FIG. 6B is a cross-sectional view of the reaction vessel with affixed channel coil, evacuated jacket, and integral isothermal mixing baffle according to the present invention, showing the integral isothermal mixing baffle entering the reactor vessel from the bottom.
FIG. 7A is a partial cross-sectional view of the reaction vessel with external channel coil, evacuated jacket, two isothermal mixing baffles, and a mixing apparatus, according to the present invention, with the integral isothermal mixing baffles entering the reactor vessel from the top.
FIG. 7B is a partial cross-sectional view of the reaction vessel with affixed channel coil, evacuated jacket, two isothermal mixing baffles, and a mixing apparatus, according to the present invention, with the integral isothermal mixing baffles entering the reactor vessel from the bottom.
FIG. 8A is a fragmentary cross-sectional view of one embodiment of the channel coil according to the present invention.
FIG. 8B is a fragmentary cross-sectional view of an alternate embodiment of a channel coil according to the present invention.
FIG. 8C shows a comparison of a conventional half-pipe jacket cross-section to that of the present invention.
FIG. 8D is a fragmentary cross-sectional view of another alternate embodiment of the channel coil wherein the full reaction vessel wall can be exposed to the fluid in the channel coil.
FIG. 9A is a partial cross-sectional view of an alternate embodiment of the isothermal mixing baffle of the present invention.
FIG. 9B is a partial cross-sectional view of another embodiment of the isothermal mixing baffle of the present invention.
FIG. 10 is a cross-sectional view of a preferred embodiment of the phase separator of the present invention for use in cooling or heating according to the present invention.
FIG. 11 is a partial cross-sectional view of an alternative embodiment of the phase separator of the present invention for use in cooling or heating according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the prior art, increasing reactor size (diameter and length) affects heat transfer to the reactor contents as the distance from the reactor external jacket to the centerline of the reactor increases (this is the radius). The present invention eliminates this problem as the insertion of isothermal mixing baffles in the reactor contents brings heat sinks (cooling) or sources (heating) to the contents as required to achieve temperature uniformity.
Since most reactors are basically cylindrical, there is a circular interface region between the highest level of the content and the empty (head) space above it. The ratio of this content/head space cross-sectional area to the volume of the content increases with increasing level of content.
With good mixing and temperature uniformity, the reactions in the content occur homogeneously in the bulk of the liquid content. Evolved gases, however, must pass through the circular content/head space interface. Therefore, as the reactor content level is increased the surface to volume ratio decreases and the potential for the flux of evolved gases increases. In this instance, foaming of contents can occur.
Foaming occurs because the evolved gas flux across the content/head space interface increases above a critical point. The gas flux in question is defined as velocity/cross-sectional area. Once foaming occurs, some of the contents are out of solution and remain un-reacted, thus affecting the uniformity and extent of the desired reactions.
Consider a simple experiment where a pint of beer is poured into a regular 1 pint glass with diameter D and height h where h/D≈4. Then pour an equivalent amount in a shallow pan with h/D≈1. The beer in the pint glass will require three to four times more “breathing” time than the beer in the shallow pan.
This problem is exacerbated by the use of an agitator (for mixing reactor content) which, consistent with the First law of Thermodynamics, delivers shaft energy to the content as kinetic energy and can locally exceed the latent heat of vaporization at the blade edges. This is known as cavitation amongst mariners.
The careful placement of the isothermal mixing baffles and the engineering of the geometry thereof can mitigate or eliminate the foaming problem.
The last performance characteristic of note is the requirement that the reactor content must be able to be placed under a vacuum for the purpose of crystallization, evaporation of solvent or vacuum distillation. In typical commercial-size reactors, typically 300 gallons and larger, the vessel wall must be thicker to withstand the external pressure due to vacuum on the inside, than otherwise required for internal pressure alone; external pressure is said to be the controlling wall thickness criteria. The present invention addresses this issue by configuring the jacket coil in such a unique way that allows for smaller wall thickness under internal content vacuum conditions, thus internal pressure becomes the controlling wall thickness criteria for the operating range of the reactor.
FIG. 1A is a flow diagram that depicts the flow scheme of the present invention in a cooling mode for the phase separator 50 and the reaction vessel 110 , which contains isothermal mixing baffles 400 and the helical channel coil 100 fixed to the outer surface of reaction vessel 110 . For the purposes of illustration only one baffle is shown. In a preferred embodiment the helical channel coil 100 may also extend to cover the upper head 112 and lower head 113 of reaction vessel 110 . Low “quality” (low vapor content) working fluid shown by arrow 10 enters the phase separator 50 and is split into a vapor phase shown by line 13 and a liquid phase shown by line 11 , the separation effected by gravitational means. The liquid phase 11 from the phase separator is piped to the isothermal mixing baffle(s) 400 , wherein it changes into a vapor shown by line 12 by boiling and absorbing thermal energy from the contents inside the reaction vessel 110 . The vapor 13 emanating from the phase separator 50 is commingled with the vapor 12 generated in the isothermal mixing baffles 400 in a mixing chamber 60 . The now combined vapor streams shown by line 14 are fed into the helical channel coil 100 , wherein the vapor absorbs sensible thermal energy from the content inside the reaction vessel 110 until it exits the channel coil via line 15 at a temperature very close to that of the average temperature of the reactor content.
FIG. 1B is a flow diagram that depicts the flow scheme of the present invention in a heating mode for the phase separator 50 and the reaction vessel 110 , which contains the isothermal mixing baffle(s) 400 and the helical channel coil 100 fixed to the outer surface of reaction vessel 110 . In a preferred embodiment the helical channel coil 100 may also extend to cover the upper head 112 and lower head 113 of reaction vessel 110 . High “quality” (mostly vapor content) working fluid shown in line 30 enters the phase separator 50 and is split into a vapor phase shown by line 13 and a liquid phase shown by line 11 , the separation effected by gravitational means. The vapor phase 13 from the phase separator 50 is piped to the isothermal mixing baffle(s) 400 , wherein it changes into a liquid by condensing and delivering thermal energy to the content inside the reaction vessel 110 . The liquid 11 emanating from the phase separator 50 is commingled with the condensate in line 32 generated in the isothermal mixing baffle(s) 400 in a separate mixing chamber 34 . The now combined liquid streams in line 36 are fed into the channel coil 100 , wherein the liquid delivers sensible thermal energy to the content inside the reaction vessel 110 until it exits the channel coil in line 15 at a temperature very close to that of the average temperature of the reactor content.
FIG. 2A is a cross-sectional view of a reaction vessel 110 with a channel coil 100 fixed to the outer surface in a helical wound arrangement. In a preferred embodiment, the reaction vessel 110 consists of a cylindrical section 120 and two “dished” heads, an upper head 112 and a lower head 113 . The inside wall of channel coil 100 is the outside surface of wall 120 of reaction vessel 110 and will be disposed along the axial length of the cylindrical section 120 of reaction vessel 110 . The channel coil 100 may also cover part of the upper head 112 and/or the lower head 113 . The channel coil 100 , before it is fixed to the reaction vessel 110 , has only three outer sides, 121 , 122 , and 123 . A fourth side of the channel coil 100 is formed by the outer surface of the wall of cylindrical section 120 of the reaction vessel 110 . A closed channel is only achieved when the channel coil 100 is fixed to the outer surface of reaction vessel 110 . The channel coil 100 surrounds the reaction vessel 110 in a helical configuration. The configuration allows for helical and corresponding downward or upward flow, with respect to the central vertical axis of the reaction vessel 110 . The channel coil 100 may be constructed from any suitable material, the most likely for industrial use being carbon steel, stainless steel, Inconel (trademark for an alloy of nickel and chromium available from the Huntington Alloy Products Division of International Nickel Co. Inc. of Huntington, W. Va.), and any number of Hastelloy alloys, including Hastelloy C-276 and Hastelloy B-2. Hastelloy is a trademark for nickel-based corrosion-resistant alloys obtained from Union Carbide Corp. of New York, N.Y. Hastelloy C-276 is a nickel-based alloy containing nickel, chromium, molybdenum, tungsten, iron, carbon and silicon. Hastelloy B-2 differs from Hastelloy C-276 in that it does not contain tungsten and the other components appear in different concentrations.
As shown in FIG. 2B , in an alternate embodiment, the cylindrical section 120 of reaction vessel 110 of FIGS. 1A and 1B can be fabricated as a conical reactor 114 having a tapered wall 125 and two “dished” heads, a larger upper head 115 and a smaller lower head 116 . This alternate embodiment allows for better mixing of the contents and is advantageous in applications where gaseous reaction by-products are generated in the reaction vessel content.
FIG. 3A is a cross-sectional view of the cylindrical reaction vessel 110 of with integral channel coil 100 and integral isothermal mixing baffle 400 (one only shown for simplicity). FIG. 3B is a cross-sectional view of a conical reactor 114 with integral channel coil 100 and integral isothermal mixing baffle 400 (one only shown for simplicity). FIG. 2A , FIG. 2B , FIG. 3A and FIG. 3B show two characteristics of channel coil 100 , which combine to add mechanical strength to reaction vessel 110 . The first is that the point of contact 130 , 131 is a right angle to the reaction vessel wall 120 , 125 respectively in the vertical section of the reaction vessel 110 or the tapered wall section of conical reactor 114 , as well in the upper heads 112 , 115 and lower heads 113 , 116 respectively. That is, walls 121 and 123 form a right angle with walls 120 and 125 . In the preferred embodiment shown in FIGS. 1A and 3A , walls 121 and 123 must form a right angle with the axis of the cylinder reaction vessel 110 having a vertical cylindrical section where the channel coil is fixed to the wall 120 . In the upper 112 and lower 113 head sections of the reaction vessel 110 , walls 121 and 123 are perpendicular to the line tangent to the convex (external) surface of the head, 112 or 113 , where the tangent point is at the bisector between 121 and 123 . The channel coil 100 surrounding wall 120 of vessel 110 and wall 125 of vessel 114 can be covered with insulation 700 .
The same effect is achieved for the reaction vessels of FIGS. 2B and 3B where the vertical section has a cone shaped wall 125 by fixing portions 121 and 123 perpendicular to wall 125 . The perpendicularity of portions 121 and 123 of channel coil 100 to wall 120 or wall 125 of the reaction vessel 110 or 114 is required in order to meet the criteria established by section UG-28 of the ASME Boiler And Pressure Vessel Code Section VIII Division 1 so that elements 121 , 122 and 123 can be considered as adding strength to the wall 120 under external pressure. The second characteristic adding strength to reaction vessel 110 concerns the pitch at which the helical channel coil 100 is affixed to the reaction vessel wall 120 . For the vertical portion (cylindrical or tapered wall) of the reaction vessel 110 or 114 , the pitch is the slope of the coil 100 , with respect to a horizontal radial plane which is perpendicular to the vertical axis of the reactor. A larger slope is considered a higher pitch. The channel coil 100 is affixed at a pitch less than or equal to a maximum pitch, which is that pitch beyond which the desired improvements in the reaction vessel wall 120 , 125 section modulus are no longer achieved, as dictated by the rules of pressure vessel design codes such as ASME Section VIII, Division 1, sections UG-27 and UG-28 thereof. Section UG-27 explains how to calculate “Thickness of Shells Under Internal Pressure”, and section UG-28 describes how to calculate “Thickness of Shells and Tubes Under External Pressure”. Exactly what this pitch is will depend on many factors. As to reaction vessel 110 or 114 these include the diameter of reaction vessel 110 , the average diameter of vessel 114 , the material of construction of the reaction vessel and the operating parameters for which the reactor is designed. As the pitch (or slope) of the coil increases, the distance between successive coils increases. The coil is made of elements 121 and 123 that are perpendicular to the vessel wall, 120 , 125 which allows for the vessel, under the rules of pressure vessel design codes such as ASME Section VIII, Division 1 to take credit for the reinforcement to reaction vessel wall 120 , 125 . As the distance between successive coils increases the degree of reinforcement decreases. At some point, the degree of reinforcement becomes too low and reaction vessel wall 120 , 125 becomes too weak for the desired function. The reinforcement required will depend upon the differential pressure between the inside and outside of reaction vessel wall 120 , 125 . This is a design parameter easily calculated by one skilled in the art. Thus, the maximum pitch of channel coil 100 will depend on the designed maximum operating pressure for reaction vessel 110 , 114 among other factors. For example for the head sections 112 , 113 of the reaction vessel 110 , the pitch is the distance of each helical 360° course of the coil 100 , with respect to the previous and/or subsequent helical 360° course. A greater separation is considered a higher pitch. The channel coil 100 is fixed at a pitch less than or equal to a maximum pitch, which is that pitch beyond which the desired improvements in the reaction vessel wall 120 section modulus are no longer achieved, as dictated by the rules of pressure vessel design codes such as ASME Section VIII, Division 1, sections UG-27 and UG-28 thereof. Section UG-27 explains how to calculate “Thickness of Shells Under Internal Pressure”, and section UG-28 describes how to calculate “Thickness of Shells and Tubes Under External Pressure”. Exactly what this pitch is will depend on many factors including the diameter of reaction vessel 110 , the material of construction of the reaction vessel 110 and the operating parameters for which the reactor is designed. As the pitch (separation) of the coil 100 fixed to the upper or lower heads 112 and 113 of reaction vessel 110 increases, the distance between successive coils increases.
The points of contact 130 and 131 between reactor vessel wall 120 and channel coil 100 of reaction vessel 110 and between reactor vessel wall 125 and channel coil 100 of reactor vessel 114 ( FIGS. 2A , 3 A and FIGS. 2B , 3 B respectively) is a right angle, and the pitch of the channel coil 100 is less than or equal to the maximum pitch. These two factors combine to increase the section modulus of the reaction vessel 110 . Under the rules of pressure vessel design codes such as ASME Section VIII, Division 1, section UG-28 thereof this resultant increase in the section modulus, due to the channel coil 100 , allows the reaction vessel wall 120 be thinner than that which would otherwise be required when the channel coil 100 is not fixed according to the present invention in order to achieve desire maximum allowable pressure for reaction vessel working conditions. Because the reaction vessel wall 120 may be thinner than that which would be required without channel coil 100 , improved heat transfer efficiency is achieved. A thinner reaction vessel wall increases the overall heat transfer coefficient across the reaction vessel wall because the thermal resistance resulting from the thermal conductivity of the reaction vessel wall is reduced. Under the rules of pressure vessel design codes such as ASME Section VIII, Division 1, the greatest advantage of the present invention is realized in larger diameter reaction vessels that operate at relatively low pressures, e.g., up to 10 bar and at full vacuum (FV). Under these conditions, the FV condition inside the reaction vessel dictates the use of thicker wall 120 , 125 than otherwise be required to withstand positive internal pressure only. By using the present invention, the thickness of wall 120 , 125 is controlled by positive internal pressure in the reaction vessel and will be thinner.
One additional advantage of the present invention is evident by examining FIG. 8C , which depicts a comparison of a conventional half-pipe jacket cross-section R to that of the present invention with proportional dimensions. The cross-sectional area of a jacket coil 100 in accordance with the present invention, compared to that of a conventional half-pipe jacket coil R of proportional dimensions, is 4/π or 27% greater. This allows for higher fluid flow for the same unit pressure drop, and thus greater heat transfer.
The channel coil 100 may be additionally insulated with insulation 700 attached directly to the three outer sides, 121 , 122 , and 123 , of the coil 100 as shown in FIG. 8C . Alternatively, insulation 700 may be wrapped around channel coil 100 and reaction vessel 110 or reaction vessel 114 as shown in FIG. 3A and FIG. 3B , before placement in an evacuation shell. FIG. 4 shows vessel 110 placed inside evacuation shell 300 . Insulation 700 may be any suitable material which does not out-gas when it is evacuated and/or heated. Reflective multi-layer insulation, made of alternating layers of fiberglass cloth, cured of any residues, which would otherwise out-gas when evacuated and/or heated, and aluminum foil are preferred. The alternate layer method of application may be varied, e.g. two layers of cloth and one layer of aluminum foil, etc. The “no out-gassing” requirement is essential for the evacuated multi-layer reflective insulation of the preferred embodiment to be successful.
An alternative insulation method for the reaction vessel entails the use of evacuated dry perlite powder in the annular space between the reaction vessel, which comprises the jacket coil 100 and vessel wall 120 , and the evacuated shell 300 , ( FIG. 4 ). In this alternative embodiment, the physical space between the jacket coil 100 and the evacuated shell 300 must be at least six (6) inches, but typically eight (8) to twelve (12) inches in order for evacuated dry perlite powder to serve as a suitable insulation medium.
FIG. 4 is a sectional view of reaction vessel 110 with the channel coil 100 fixed to the outer surface of reaction vessel 110 , integral isothermal mixing baffle 400 (one only shown for simplicity) and an evacuated shell 300 . The evacuated shell 300 completely encloses reaction vessel 110 and channel coil 100 , with the exception of related piping and utilities, which penetrate the evacuated shell 300 . The placement of the evacuated shell 300 around the apparatus as described above allows for additional insulation of reaction vessel 110 and channel coil 100 from the ambient air. Insulation from the ambient air results in decreased heat transfer through both the reaction vessel wall 120 and the channel coil walls 121 , 122 , and 123 , as some of the energy is parasitically lost outwardly to the environment through the insulation 700 . The utilization of evacuated shell 300 results in greater temperature control of the reaction vessel contents, making the insulation 700 more thermally efficient. The evacuated shell may be constructed from any suitable material, including carbon steel, stainless steel, Inconel, or Hastelloy C. Further, evacuated shell 300 can also include reflective material on the inner or outer surface thereof to reduce radiant heat transfer.
FIG. 5A is a partial cross-sectional view of an isothermal mixing baffle of uniform circular cross-section (a cylinder) in accordance with the present invention. In the exemplary embodiment, an isothermal mixing baffle 400 is used where there exists a need to cool the reaction vessel contents. However, such isothermal mixing baffles can also be used where heating of the contents of the reaction vessel, e.g. reaction vessel 110 of FIG. 4 is needed. The isothermal mixing baffle 400 is inserted into the reaction vessel contents through the top head 112 and evacuated shell 300 as shown in FIG. 6A . For cooling, a saturated or subcooled liquid is introduced into the isothermal mixing baffle 400 through an inlet pipe 410 . As previously discussed, the liquid is selected primarily because of its boiling point, providing, of course, other factors do not prevent its use, such as availability, cost, reactivity, toxicity, etc. A liquid having a boiling point lower than that of the reaction vessel contents will boil when heat is absorbed from the reaction vessel contents. Fluids which may be used for cooling or heating in the present invention include, but are not limited to nitrogen, brine, steam, chilled water, carbon dioxide, ammonia, CF 4 , ethane, ethylene and hot water. Other fluids may also be used depending on the particular needs of the reaction for which the reactor is designed.
The ideal temperature (or range of temperatures) of the reaction vessel contents can be determined from the chemistry of the reaction. This temperature, along with the physical characteristics of the isothermal mixing baffle (dimensions, material of construction, number of baffles, etc.) and relevant heat transfer equations, are combined to give rise to a required amount of heat transfer which must occur across the wall 448 ( FIGS. 5A , 5 B, 5 C, and 5 D) of the isothermal mixing baffle 400 in order to maintain the reactor contents at the desired temperature. From this required value of heat transfer, a fluid is selected such that the latent heat of vaporization plus any sensible heat transfer occurring from any rise in temperature of the fluid to its boiling point, will give the desired total heat transfer. It should be noted that a fluid with precisely the right characteristics does not have to exist for accurate control of the temperature. Controlling the flow rate of the fluid into the isothermal mixing baffle 400 or the liquid level thereof will allow for fine tuning the heat transfer and corresponding temperature of the reactor contents. Further, controlling the pressure of the liquid could help alter its boiling point and fine tune the cooling power and range of the liquid. The selected fluid need only fall within a range of necessary heat transfer requirements. Where heating is desired, as shown in FIG. 1B , a hot gas, such as gaseous ammonia, is introduced via line 13 into isothermal mixing baffle 400 , the condensed ammonia in line 32 is then combined with other condensed ammonia in line 11 emanating from the phase separator 50 and introduced via line 36 into the channel coil 100 . This condensate then heats the contents of reaction vessel 110 .
For instance, if a higher rate of cooling is desired, then fluid flow into the isothermal mixing baffle 400 can be increased. This will raise the level of boiling liquid 450 to a level shown as 451 in FIG. 5A in the isothermal mixing baffle 400 . This in turn will expose a greater surface area of boiling liquid 450 to wall 448 of isothermal mixing baffle 400 , thus allowing greater heat transfer from the reaction vessel contents through wall 448 of baffle 400 into boiling liquid 450 .
Alternatively, the isothermal mixing baffles 400 can be used in one of several different heating and cooling schemes. The isothermal mixing baffles 400 may be used to gain only sensible heat, in which case they will serve as sensible energy mixing baffles. The isothermal mixing baffles 400 can also be utilized with a liquid having a boiling point higher than the desired temperature of the reactor contents. Cooling or warming liquid could be passed through the isothermal (or sensible energy) mixing baffles. Additionally, a gas may be passed through the isothermal (or sensible energy) mixing baffles 400 . Any fluid that provides the necessary heat transfer properties can be used in the isothermal (or sensible energy) mixing baffles for effective temperature control of the reaction vessel contents. In these cases, the isothermal (or sensible energy) mixing baffles 400 act as simple heat exchangers.
Isothermal mixing baffles 400 can be inserted from the top of the reactor, as shown in FIG. 5A and FIG. 6A or from the bottom of the reactor, as shown in FIG. 5B and FIG. 6B . In the preferred embodiment, isothermal mixing baffles 400 have been inserted from the top of the reactor as a matter of convenience and tradition.
In cooling applications, the isothermal mixing baffles 400 are designed and arranged in so that their combined cross-sectional area will be such that the velocity of the vapor evolved from the liquid phase boiling therein will be below a critical value, Uc, above which droplets or slugs of the liquid phase will be entrained in the evolved gas and expelled from the isothermal mixing baffles. As shown in FIGS. 5A , 5 B, 5 C, and 5 D in order to accomplish this requirement, the saturated or sub-cooled inlets 410 and vapor outlets 430 of the isothermal mixing baffles 400 will be piped in parallel. Discrete cooling control can be accomplished by isolating individual isothermal mixing baffles from the plurality of isothermal mixing baffles piped in parallel.
FIG. 5A shows a sintered, porous metal phase separator or “snubber” 411 placed at the end of inlet pipe 410 . The snubber 411 curtails the flow of the liquid into or out of the isothermal mixing baffle, just as a kitchen faucet nozzle controls the water flow into a sink, thereby minimizing splashing. Snubber 411 also serves to disengage and allow the phases to separate inside the isothermal mixing baffle.
FIG. 5A and FIG. 5B also show a means for the gas formed from the boiling liquid inside the inside the isothermal mixing baffle 400 to escape. An annular space 420 surrounds the inlet pipe 410 . Annular space 420 comprises the same atmosphere as that above the liquid level in the isothermal mixing baffle 400 . As liquid flows into the isothermal mixing baffle 400 through inlet pipe 410 , resultant vapor or gas is pushed upward and out of the isothermal mixing baffle 400 through exit 430 . The exiting gas may then be utilized in various ways. If environmentally safe gas is used, it may be exhausted to the atmosphere by venting it, although this is likely not cost effective. The gas may be recovered by piping it to a condenser, or used at another site where the particular vapor or gas is needed. Finally, the exiting gas may be transported, through vacuum jacketed or otherwise insulated pipe, to the channel coil 100 for further cooling of the reactor contents, as dictated by the preferred embodiment of this invention and depicted in FIG. 1A .
FIG. 5A shows means for detecting the level of liquid in the isothermal mixing baffle 400 . A dual leg dip tube 440 is inserted into the isothermal mixing baffle 400 . The top opening 445 of the dip tube 440 is near the top of the isothermal mixing baffle 400 , and the bottom opening 447 of the dip tube 440 is near the bottom of the isothermal mixing baffle 400 . The level of liquid 450 in the isothermal mixing baffle 400 is maintained below the top opening 445 and above the bottom opening 447 of the dip tube. The pressure differential is detected as the pressure of the head of liquid in the dip tube. The pressure at the top opening 445 is the pressure of the gas above the liquid 450 . The pressure at the bottom opening 447 is the pressure of the gas above the liquid 450 plus the pressure caused by the weight of the liquid 450 which is above the bottom opening 447 . The pressure created by the weight of liquid 450 above the bottom opening 447 can be found by subtracting the value of the pressure at the top opening 445 from the value of the pressure at the bottom opening 447 . This pressure can be used (in conjunction with the density of the liquid) to calculate the height of liquid above the bottom opening 447 . FIG. 5B shows the mixing baffle 400 inserted through the bottom of the reactor vessel. In this instance the top opening is 446 and the bottom opening 449 of dip tube 440 .
FIGS. 5C and 5D are alternative embodiments of FIGS. 5A and 5B , respectively, wherein the internal sintered, porous metal phase separator or “snubber” 411 is made to be removable from outside the reactor vessel, without disturbing the reactor vessel contents or evacuated shell 300 .
FIGS. 5E and 5F are alternative embodiments 470 of the isothermal mixing baffles 400 which employ non-circular cross-sectional geometries, such as ellipsoids and airfoils 448 . These alternative embodiments may be prescribed to augment surface area and/or direct the flow of reactor contents to enhance mixing.
FIG. 6A shows the present invention including reaction vessel 110 , channel coil 100 , and one isothermal mixing baffle 400 inserted from the top of the reactor, which penetrates the upper head 112 and evacuated shell 300 . It would be apparent to one of ordinary skill in the art that multiple isothermal mixing baffles 400 could be used to increase the overall rate of heat transfer between the reactor contents and isothermal mixing baffle contents. An additional advantage to utilizing multiple isothermal mixing baffles 400 is seen where the reactor contents are agitated with a mixing blade apparatus.
FIG. 7A shows an embodiment where multiple isothermal mixing baffles 400 are used in conjunction with an agitator 460 . In such a case, the isothermal mixing baffles 400 must be arranged outside the radius of mixing blades 490 of agitator 460 . In such a configuration, the isothermal mixing baffles 400 also act as mixing baffles, thus our use of the term isothermal mixing baffles.
FIG. 6B shows an alternative embodiment of the present invention including reaction vessel 110 , channel coil 100 , and one isothermal mixing baffle 400 inserted from the bottom of the reactor, which penetrates the lower head 113 and evacuated shell 300 .
Where the reactor is agitated as shown in FIG. 7A and FIG. 7B , formation of frozen reactor contents on the outside surface of the isothermal mixing baffle 400 is prevented by placing the isothermal mixing baffle 400 in or near the streamlines corresponding to maximum free stream velocity. By placing the isothermal mixing baffle 400 in these high velocity streamlines, turbulent flow around the isothermal mixing baffle 400 is maximized. By maximizing turbulent flow immediately adjacent to the isothermal mixing baffle 400 , the thickness of the laminar thin film at the surface of the isothermal mixing baffle 400 is minimized. Minimizing the thickness of this film is important in preventing material from solidifying on the surface of the isothermal mixing baffle 400 . Formation of ice on the surface of the isothermal mixing baffles 400 is detrimental as the temperature of the ice will be at the freezing point of the reactor content fluids, not the much lower boiling liquid 450 inside the isothermal mixing baffles 400 .
The correlation between high turbulence and avoidance of ice (or solid) formation is due to the fact that heat transfer through a laminar layer is largely conduction controlled, but heat transfer through a turbulent fluid is largely convection controlled. Convective heat transfer takes place because a fluid is in motion and eddies within the fluid effectively carry heat throughout the fluid. This is very efficient heat transfer. Conductive heat transfer, however, is due to interaction (molecular) between the molecules comprising the medium through which the heat passes. This type of heat transfer is much less efficient than convective heat transfer. Where heat transfer is convection controlled, it occurs much more quickly than for the same fluid, not moving, where conduction is the only source of heat transfer. Moreover, when a fluid has turbulent flow characteristics, heat transfer is much quicker than where the same fluid is not moving (and other pertinent factors are the same). So where the laminar, non-moving, fluid film thickness is minimized, more heat is transferred through it in a given time period and the formation of ice is subsequently slowed or prevented. Where the laminar layer is thick, heat transfer is limited, and the layer freezes more quickly than where the layer is thinner. The above mentioned probe placement provides for an overall heat transfer coefficient that is largely convection-controlled, corresponding to fully developed turbulent flow. This maximizes overall heat transfer and prevents formation and build-up of frozen reactor contents on the probe surface. A further requirement to prevent the formation of ice on the external surface of the isothermal mixing baffles 400 is that the convective film heat transfer coefficient, on the outside of the isothermal mixing baffles 400 (in contact with the reactor contents), be greater than the convective film heat transfer coefficient on the inside of the isothermal mixing baffles 400 (in contact with the boiling liquid 450 ). This outcome can be achieved through a programmable control device available through Arencibia Associates Inc., Center Valley, Pa.
FIGS. 7A and 7B show alternative embodiments of the isothermal mixing baffles 400 , wherein the cross-sectional area of the isothermal mixing baffles is increased at axial locations where there will not be interference with reaction blades 490 of agitator 460 . This alternative embodiment results in increased heat transfer area.
FIGS. 8A and 8B show additional embodiments of the cross-sectional shape of channel coil 100 . The outside walls 121 , 123 of the channel coil 100 may be of nearly any shape. It is critical, however, that the portion of outside walls 121 , 123 adjacent wall 120 of vessel 110 shown as walls 701 , 702 ( FIG. 8A) and 703 , 704 ( FIG. 8B ) are both normal to the outside reaction vessel wall 120 . In this configuration, channel coil 100 supports and strengthens reaction vessel wall 120 , allowing use of a thinner wall and greater heat transfer.
FIG. 8D shows a particular embodiment wherein the cross-sectional area of channel coil 100 available for flow of heat transfer working fluid can be increased by joining adjacent coils with wall 124 , which may be flat, as shown, or nearly any shape. If flat, like wall 122 , wall 124 will also ad strength to the reaction vessel and further allow for the reduction of the thickness of the reaction vessel wall 120 , if external pressure is controlling. The channel defined by wall 124 and adjacent walls of the helical channel coil can be used to introduce additional fluid to contact wall 120 to thus further improve the heat transfer. The fluid in this channel can be different than the fluid in the helical channel coil.
FIGS. 9A and 9B are alternative embodiments of FIGS. 5A and 5B , respectively, wherein the wall 449 a comprises cylindrical sections of different diameters so that the smaller diameter accommodates the trajectory of agitator blades and the larger diameter allows for greater heat transfer area.
FIG. 10 is a cross-sectional view of a preferred embodiment of phase separator 50 having an internal vessel 57 and an evacuated shell 59 of the present invention for use in a cooling or heating mode application. The evacuated shell 59 completely encloses internal vessel 57 , with the exception of related piping and utilities, which penetrate the evacuated shell 59 . The placement of the evacuated shell 59 around the apparatus as described above allows for additional insulation of internal vessel from the ambient air. Insulation from the ambient air results in decreased heat transfer through the internal vessel 57 , as some of the energy is parasitically lost outwardly to the environment through the insulation 58 . The utilization of evacuated shell 59 results in greater temperature control of the reaction vessel contents, making the insulation 58 more thermally efficient. The evacuated shell 59 may be constructed from any suitable material, including carbon steel, stainless steel, Inconel, or Hastelloy C. Further, evacuated shell 59 can also include reflective material on the inner or outer surface thereof to reduce radiant heat transfer.
Working heat transfer fluid which may be sub-cooled, saturated or contain both phases enters the phase separator at the inlet nozzle 10 and is ducted vertically through an internal coaxial pipe 51 to a porous membrane diffuser 52 through which it enters the internal phase separator vessel 57 .
In order for the liquid and vapor phases of the working heat transfer fluid to separate by gravity, the cross-sectional area of the internal vessel 57 of phase separator 50 will be such that the velocity of the vapor separated from the liquid phase entrained therein will be below a critical value, Uc, above which droplets or slugs of the liquid phase will be entrained in the evolved gas and expelled from the phase separator.
The liquid phase of the working heat transfer fluid enters the annulus between the external coaxial pipe 55 and the internal coaxial pipe 51 through apertures 56 on the external coaxial pipe 55 located at the lower end of the internal vessel 57 . The liquid phase of the working heat transfer fluid then exits the phase separator at the outlet liquid nozzle 11 . The vapor phase of the working heat transfer fluid then exits the phase separator at the outlet vapor nozzle 13 .
FIG. 11 is a cross-sectional view of alternate embodiment of the phase separator of the present invention for use in a cooling or heating mode application. In this alternative embodiment the working heat transfer fluid inlet nozzle is located on top along with the outlet vapor nozzle 13 . The outlet liquid nozzle 11 is located in the bottom.
Upper sensing line 53 in FIG. 10 and FIG. 11 and lower sensing line 54 in FIG. 10 and FIG. 11 detect liquid inventory of working heat transfer fluid in the phase separator 50 , by the same mechanism described for determining liquid level in the isothermal mixing baffles 400 , in connection with FIG. 5A . Upper sensing line 53 in FIG. 10 and FIG. 11 is analogous to 445 in FIG. 5A . Lower sensing line 54 in FIG. 10 and FIG. 11 is analogous to 447 in FIG. 5A .
Although the present invention has been described with reference to exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed to include other variants and embodiments of the invention, which may be made by those of ordinary skill in the art without departing from the true spirit and scope of the present invention.
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A reaction vessel which includes internally placed temperature controlling mixing baffles in which liquid is boiled, resulting in an isothermal heat sink. The energy of vaporization is supplied by the reaction vessel contents. The vapor produced by the boiling is directed to channel coils which surround the outside of the reaction vessel wall. The channel coils contact the outside wall of the reaction vessel perpendicularly, and provide mechanical support for the reaction vessel. The mechanical support from the channel coils allows for a decrease in the thickness of the reaction vessel wall and corresponding increased heat transfer efficiency between the channel coil contents and the reaction vessel contents. The entire above described apparatus is enclosed within an evacuated shell to provide additional insulation. The apparatus includes a gravitationally powered device that ensures that saturated or sub-cooled liquid enters the isothermal mixing baffles, thus guaranteeing that isothermal phase change will occur therein.
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FIELD OF THE INVENTION
[0001] The present invention relates to artificial intelligent and information technology, particularly, relates to an intelligent ontological agent model as the basic framework and development environment for e-commerce applications.
BACKGROUND OF THE INVENTION
[0002] In information technology, especially intelligence and computer science field, intelligent agent is considered to a device which can recognize the environment by its sensors, and respond to the environment with its executive device. For example, referring to human body, eyes, ears and other sensory organs are the cognitive devices, while the executive devices are hands, legs, mouths and other parts of the body. When it comes to software, the cognitive and executive organs are encoded character streams.
[0003] The main purpose of artificial intelligence is to design intelligent agent programs, that is, to implement the mapping methods of cognition and action. This intelligent agent program has to operate on a certain computing device called framework. Said framework may be a common computer, or a special hardware tailored to perform certain tasks, or certain software between a computer and intelligent agent program for providing a certain degree of isolation, which enables programming in higher layers. In general, the structure enables the information as received by the sensors to transform as cognition, and provide feedback via execution program and hence produce a response.
[0004] Owing to the rapid development of e-Commerce and Internet technology in the recent years, many different e-Commerce applications and mobile computing systems have been operated in this cyberspace.
[0005] E-business is viewed as a big business opportunity as more and more people are focusing on the Internet. Numerous products are now available on the Internet, and product searching has become a burden for buyers. Meanwhile, sellers are difficult to locate target buyers and provide targeted promotion. It will be convenient to implement intelligent agent system, such that the agent system may actively search for online advertisements for buyers, go shopping online and even bargain for a better price, while the agent system simultaneously works for the seller to analyze different consumers' trends, and promote certain products to potential customers.
[0006] Therefore, in this ‘sea’ of information pool, the provision of an intelligent-based system (such as intelligent agents) seems to be a ‘New Hope’ in the future. However, contemporary agent-based developing environment such as IBM Aglet and ObjectSpace Voyager the provision of ‘real’ intelligent agent functionality is failed to support.
BRIEF SUMMARY OF THE INVENTION
[0007] We propose an innovative intelligent ontological agent-based development environment namely IATopia—“Intelligent Agent Utopia”. The aim of IATopia is to provide comprehensive AI and ontological agent-based APIs and applications for future e-commerce and ontological-based applications.
[0008] The framework composes of two main model. The first module is “Application-Ontology-Intelligent-Technology-Supporting Layer” (AOITS) and the second module is “Data-Neural Network-Application Layer” (DNA)
[0009] The first module is a full artificial intelligence and ontology agent based application interface which constructs various intelligent agent application; and
[0010] The second module is used for data storage, intelligent data analysis process, and providing analyzed results to said first module.
[0011] The said first module comprises:
[0012] Application layer, comprises various intelligent ontology agent based application programs, said application programs are integrated by intelligent agent components of the intelligent layer and the data of said second module.
[0013] Ontology layer, base on the brain knowledge of agent, provides necessary knowledge for agent to initiate its logical and knowledgeable thinking. This layer of brain knowledge is named IATology-20000.
[0014] Intelligent layer, provides artificial intelligence basic base on the sense field, logical illation field and analysis field, while utilizes agent components provided by technology layer.
[0015] Technology layer, provides necessary mobile agent object application program interface for intelligent agent components of intelligent layer, comprises providing IATo SDK software development tools of full multi-intelligent agent based development platform, and providing understandable marking language to increase the communication of intelligent agent and IATo ML development tools of data transferring; and
[0016] Supporting layer, provides all necessary systems for supporting said layer, comprises programming languages, communication protocols and standardized file exchange format that are adopted to facilitate the development of the IATopia framework.
[0017] The said second module comprises:
[0018] Data layer, for storing raw data from intelligent agent brain. It is also the source of knowledge.
[0019] Neural network layer, for manipulating the data stored in the data layer so that knowledge can be generated and the thinking process can be initiated as well as the agent can learn or correct itself according to its experiences; and
[0020] Application layer, with the fully support from the data layer and neural network layer, agent have enough knowledge and thinking capability to live and work autonomously.
[0021] The application programs in the said application layer comprise:
[0022] IATo eMiner, an intelligent ontological web-mining agent system for e-shopping.
[0023] IATo InfoSeeker, an intelligent ontological knowledge based information searching system.
[0024] IATo WeatherMAN, an intelligent ontological weather forecasting agent.
[0025] IATo WShopper, an integrated ontological intelligent fuzzy shopping agent for intelligent mobile shopping on the Internet.
[0026] IATo Stock Advisor, an intelligent ontological agent based stock prediction system.
[0027] IATo Surveillant, the automatic ontological agent based surveillance system.
[0028] The said intelligent agent comprises the following requirements: autonomous, mobile, reactive, proactive, adaptive, robust, communicative, learning, task-oriented, goal-driven.
[0029] The said IATo SDK development tools comprise all the mandatory components arranged on intelligent agent development platform. Said mandatory components comprise intelligent agent managing system, information transferring server and index arbitrator.
[0030] The basic function and run time properties of the said intelligent agent are defined by intelligent agent, lifecycle manager that provides all the control function, registration manager that records intelligent agent registration information in the intelligent agent development platform, and communication manager that controls the message transfer in intelligent agent platform.
[0031] The said application program interface comprises: the first region that provides the functions of creating, activating, invalidating, copying, distributing, releasing and exiting, the second region that provides the functions of writing logs and displaying the information of activation in the server, the third region that provides tree type intelligent agent list, and the forth region that provides information broadcasting type.
[0032] The present invention provides an intelligent agent system with real sense, analysis and logical illation capability. In addition, an intelligent agent utopia (IATo) based development platform is provided to be the basic frame and development platform of the future intelligent E-business.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 is the block diagram of the present invention.
[0034] FIG. 2 is the block diagram of the user interface, in accordance with the present invention.
[0035] FIG. 3 is the basic structure diagram of IATo SDK Intelligent Agent platform, in accordance with the present invention.
[0036] FIG. 4 is the schematic diagram of Intelligent Agent communication, in accordance with the present invention.
[0037] FIG. 5 is the schematic diagram of registration Intelligent Agent, in accordance with the present invention.
[0038] FIG. 6 is the schematic diagram of creation Intelligent Agent, in accordance with the present invention.
[0039] FIG. 7 is the schematic diagram of dispatch Intelligent Agent (sending end), in accordance with the present invention.
[0040] FIG. 8 is the schematic diagram of dispatch Intelligent Agent (receiving end), in accordance with the present invention.
[0041] FIG. 9 is the schematic diagram of the user interface, in accordance with the present invention.
[0042] FIG. 10 is the schematic diagram of creation Intelligent Agent dialog box, in accordance with the present invention.
[0043] FIG. 11 is the schematic diagram of dispatch Intelligent Agent dialog box, in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0044] The present invention disclosed a new intelligent ontology agent based development platform, called The Utopia of Intelligent Agent (IATopia) based development platform. The object is to develop a fully integrated intelligent ontology based multi-Intelligent Agent system, so as to be the basic frame and development platform of the future intelligent E-business.
[0045] The present invention may implement various Intelligent Agent based applications, comprising IATo TravelGuider and IATo Stock Advisor, etc.
[0046] In order to clarify the object, technical scheme and advantages of the present invention, various embodiments are described to provide detailed description of the present invention.
[0047] The framework of the present invention (functions and modules):
[0048] The present invention has fully integrated intelligent agent E-business application based intelligent ontology agent module. The system framework is shown in FIG. 1 , unlike the Intelligent Agent system and Application Programming Interfaces (APIs) in the prior art, such as, IBM Aglets, ObjectSpace Voyager and IATo products. The present invention focuses on multi-Intelligent Agent communication and automatic operation. The object is to provide full artificial intelligence and ontology agent based APIs, as well as future E-business application and ontology agent based application.
[0049] As shown in FIG. 1 , the framework of the present invention comprises two main modules: The first module is Application-Ontology-Intelligent-Technology-Supporting layer (AOITS) module, the second module is Data-Neural-Network-Application Layer (DNA) module. AOITS module comprises application layer, ontology layer, intelligent layer, technology layer and supporting layer. DNA module comprises data layer, neural network layer and application layer. Various layers of AOITS are described in detail as follows.
[0050] Application layer: On the top layer of the system, comprises different intelligent ontology agent based application programs. Said application programs (IATo) are integrated by the intelligent ontology agent components from intelligent layer and data knowledge fields from DNA module. Various exemplary application programs are realized in this layer, which comprises:
[0051] IATo eMiner, an intelligent ontological web-mining agent system for e-shopping, comprises 1) IATo Authenicator—an automatic authentication system based on human face recognition, and 2) IATo Shopper—a fuzzy agent based Internet shopping agent.
[0052] IATo InfoSeeker, an intelligent ontological knowledge based information searching system.
[0053] IATo WeatherMAN, an intelligent ontological weather forecasting agent, which is the extension of previous research on mult-station weather forecasting using fuzzy neural networks. Unlike traditional Web-mining agents, which focus on the automatic extraction and provision of the latest weather information. IATo WeatherMAN possesses neural network based weather forecasting capability (AI services provided by the ‘Conscious Layer’ of the IATopia module) to act as a ‘virtual’ weather reporter as well as an ‘intelligent’ weather forecaster for weather prediction.
[0054] IATo Shopper series, an integrated ontological intelligent fuzzy shopping agent with WAP technology for intelligent mobile shopping on the Internet.
[0055] IATo Stock Advisor, an intelligent ontological agent based stock prediction system using HRBFN (Hybrid Radial Basis Function Recurrent Network) for time series prediction.
[0056] IATo Surveillant, the automatic ontological agent based surveillance system.
[0057] Ontology Layer: based on the brain ontology knowledge of intelligent agent, provides necessary knowledge for intelligent agent to initiate its reasonable and knowledgeable thinking process. Said layer provides said ontology frame, that is the ontology centre, comprises the following 5 modules: Intelligent ontology based sensation centre (IAToSC), intelligent ontology based memory centre (IAToMC), intelligent ontology based knowledge centre (IAToKC), intelligent ontology based language centre (IAToLC), intelligent ontology based ethics centre (IAToEC).
[0058] Said five functional modules measure up the FIPA ontology service specification (XC00086D), an ontology agent (IATo Agent) will be designed and constructed with the following functions (namely, the “RATE” requirements):
[0059] Representation: to represent and discover public ontologies (especially ontologies in foreign platforms)
[0060] Administration: to maintain and administer the services and facilities provided by the iJAOS.
[0061] Translation: to communicate and translate concepts, meanings, and universals between different ontologies and/or different content languages.
[0062] Explanation: To respond to and explain all queries concerning relationships between different concepts and ontologies.
[0063] Intelligent layer: This layer provides the intelligent basis of the IATopia system, using the agent components provided by the ‘Technology layer’. The ‘Conscious Layer’ consists of the following three main intelligent functional areas:
[0064] Sensory area, for the recognition and interpretation of incoming stimulates, comprises: visual sensory agents using EGDLM (Elastic Graph Dynamic Link Model) for invariant visual object recognition, and, auditory sensory agents based on wavelet based feature extraction and interpretation technique.
[0065] Logic reasoning area, conscious and reasoning support, such as fuzzy and GA (genetic Algorithms) rule based systems.
[0066] Analytical area, comprises various AI tools for analytical calculation, such as recurrent neural network based analysis for real-time prediction and data mining.
[0067] The technology layer: This layer provides all the necessary mobile agent implementation APIs for the development of intelligent agent components in the ‘Conscious Layer’.
[0068] In the proposed latest version (v2.0) of the IATopia module, instead of IBM Aglets as the agent ‘backbone’, two innovative IATopia development tools have been developed, namely:
[0069] IATo SDK (IATopia Development Kit) and
[0070] IATo ML (IATopia Markup Language)
[0071] The main function of IATo SDK is to provide a comprehensive intelligent multi-agent based development platform with the provision for all the intelligent agent-based Java classes and library, comprises: agents' communications, negotiations, intelligent agent tools, etc. The main function of IATo ML is the provision of a comprehensive markup language to enhance the intelligent agent communication and data exchange.
[0072] In this layer, server-side computing using Java Servlet technology is also adopted due to the fact that for certain intelligent agent-based applications, such as the IATo Shopper Series, in which limited resources (in terms of memory and computational speed) are provided by the WAP devices (e.g. WAP phones), all the IATo agents interactions are invoked at the ‘backend’ WAP server using Java Servlet technology.
[0073] The supporting layer: This layer provides all the necessary system supports to the ‘Technology Layer’, comprises:
1. Programming language support based on Java, 2. Network protocols support such as HTTP, HTTPS, ATP, etc., and 3. Markup languages support such as HTML, XML, WML, etc.
[0077] Each layer of DNA module is described in detail as follows.
[0078] Data layer: This layer is for storing initial data from agent brain and for IATology-20000 to generate knowledge, at this point, the thinking process may be initiated, and agent may learn or correct itself according to its experiences. This layer also explains why agent may think as a human.
[0079] Application layer: With fully support from data layer and neural network layer, the agent has enough knowledge and thinking capabilities to live and work on its own.
[0080] Further description of intelligent agent technology (IAT) is provided as follows:
[0081] Presently, most of the E-business systems on the Internet employ client/server manner. The disadvantages are: 1) High communication burden; 2) reciprocity between enhanced and low level users. Certain objects are need to achieve said functions: Play the role of a human, to operate independently in the Internet, being autonomous, and to identify, process and solve problems on its own.
[0082] The definition of intelligent agent is: Intelligent agent (IA) is an example of intelligent in terms of device. IA may be a system, software program, program object or even a robot.
[0083] The intelligent agent in the present invention is with the following 10 basic requirements: 1) autonomous; 2) mobile; 3) reactive; 4) proactive; 5) adaptive; 6) robust; 7) communicative and cooperative; 8) learning; 9) task-oriented; 10) goal-driven. According to these basic requirements, the working theory of the IATopia agent in the present invention is described as follows:
[0084] IATopia Agent is a Java-based program. It is a sub-class of Thread class, so it can execute its life cycle asynchronously and concurrently inside the IATopia server. It implements the Serializable interface for packaging agent itself to migrate from host to host, and it also implements the Cloneable interface for copying itself to work concurrently with other instances of the agent. IATopia Server uses Java RMI as the transporting layer of IATopia Agents between IATopia hosts; agent will be serialized and sent to the target host by using RMI remote call.
[0085] IATo SDK framework in the implementation of IATopia:
[0086] IATo SDK is an intelligent agent development platform which implements FIPA Agent Management Specification utilizing Java 2 as the development language. The goal of IATo SDK is to provide an agent platform together with a set of API for simplify the development of agent system while ensuring the system is compliance to FIPA standard. The following table shows the basic building blocks of the platform.
[0000]
Application Agents or Non-agent based user
application layer
Agent Management
Directory Facilitators
Service
Agent Transport and communication System
Java 2 Standard Edition (JDK 1.4)
[0087] To achieve this goal, IATo SDK offers the following features:
1. A FIPA-compliant Agent Platform with Agent Management System, Directory Facilitators and Message Transporting System. All these components are automatically started with the agent platform. 2. A registration manager to act as a directory facilitator to act as yellow page for registering or searching an agent inside the platform. 3. Message transporting mechanism for agents to communicate with each other and dispatching agents. 4. A lifecycle manager as an agent management system to control the agent's lifecycle within an agent platform. 5. A graphical user interface for the users to manage, monitor and log an agent's activities ( FIG. 2 )
[0093] Basic component of IATo SDK: The IATo SDK agent platform is developed compliant with FIPA Agent Management Specification and includes all mandatory components that must be the in starting lineup with the agent platform, that are Agent Management System, Message Transport Service and Directory Facilitator. IATo SDK agent platform is developed by using pure Java 2 Standard Edition (JDK1.4). The mandatory components to startup IATo SDK agent platform are LifeCycleManager, RegistrationManager and CommunicationManager. FIG. 3 shows the basic architecture of the IATo SDK agent platform. IATo SDK provides the necessary mobile agent implementation APIs for the development of mobile intelligent agent systems. The basic functionalities and runtime properties of agents are defined by the Agent, LifeCycleManager RegistrationManager and CommunicationManager classes.
[0094] IIATo SDK provides necessary mobile intelligent agent object APIs for the development of mobile intelligent agent system. The basic function and run time property of intelligent agent are defined by Intelligent AgentPool, LifeCycleManager RegistrationManager and CommunicationManager.
[0095] Intelligent AgentPool: Basically, all agents must execute within a virtual place called AgentPool within the server. Thus, when an agent is created or dispatched, it must be put inside the AgentPool to start execution.
[0096] LifeCycleManager: LifeCyleManager act as the Agent Management System within the agent platform. It provides all functions of controls within the agent platform, comprises creating, suspending, resuming, dispatching and disposing agents.
[0097] Intelligent Agent: The Agent is the main character of the mobile agent concept. This is because it is a mobile software object that can transfer its softare code and status from one host to another in order to perform a specific task. This can convince the development of a Code on Demand system. The agent has its own mechanism to broadcast or send messages to another agent for communication. When agent wants to ask for a specific service from another agent, firstly it will ask the RegistrationManager for the related agent's information and then ask the AgentPoolManager to get the reference of the wanted agent for further communication using the message passing mechanism ( FIG. 4 ).
[0098] RegistrationManager: The RegistrationManager maintains a list of the registered agent's information including the agent's name, classes location and information about the service that the agent provides. It also protects the IATopia Server from anonymous attack. This is because an agent must be registered before it is allowed to execute inside the agent platform.
[0099] CommunicationManager: The message channel is maintained by the CommunicationManager. It controls the messages passing within the agent platform. It also provides a network communication channel for the agent to dispatch from local to remote sites.
[0100] Internal operation of IATo SDK (Data flow and input/output): By using these basic components, IATopia Server can provide a number of operations that helps mobile agent to perform their task.
[0101] Register Intelligent Agent: as shown in FIG. 5 , Agents must be registered before they can live in the IATopia Server. Therefore, users are required to input the agent's information (e.g. Agent's name, code base and task description) by using the graphic user interface provided by IATopia Server (IATopia Server GUI). After receiving agent's information from user input, IATopia Server GUI will generate a request to the RegistrationManager. RegistrationManager then initialize an object RegistrationInfo and then save in the RegistrationTable. Finally IATopia Server GUI will be updated to inform the user after the registration is successful.
[0102] Create Intelligent Agent: as shown in FIG. 6 , after registering an agent, user can create an agent by using the IATopia Server GUI, by choosing an appropriate agent's name in the list. The IATopia Server GUI will ask the RegistrationManager to get the basic code of the agent class file.
[0103] Then, IATopia Server GUI will send a request to the LifeCycleManager to create an agent. After the agent file is loaded into Java VM, the LifeCycleManger will send the agent's reference to the AgentPoolManager, the AgentPoolManger will add the agent reference to the ActiveAgentPool. Finally IATopia Server GUI will be updated to inform the user after the creation is successful.
[0104] Dispatch Intelligent Agent: as shown in FIGS. 7 and 8 , when the agent is created within the IATopia Server, user can use the IATopia Server GUI to select and dispatch agent. When the IATopia Server GUI receives the user's request, it will forward the request to the LifeCycleManager. LifeCycleManager will ask the RegistrationManager for the AgentCodeBase and then AgentPoolManager for the AgentReference.
[0105] And then send a dispatch request to the CommunicationManager to dispatch the agent object and class file if necessary. There is a server listener in to the remote machine. When the listener receives the dispatch request, it will forward the request to the LifeCycleManager. The LifeCycleManager will then check with the RegistrationManager that is that agent already registered in the remote server.
[0106] And then it will receive the agent object and then ask the AgentPoolManager to add the AgentReference into the ActiveAgentPool and update the IATopia Server GUI to notify the user that an agent has come to this server.
[0107] Programming IATo SDK: IATo SDK is developed with Java 1.4, since Java is an object oriented language. By using object oriented approach, program class or interface can be reused or further extend its function, so that the effect of outputting basic functionality may be saved. Java is a popular programming language; development of java program is cheaper and quicker then other programming languages. The portability of Java compiled code can easily be migrated to different kinds of system. Finally, the built-in network supporting programming mobile intelligent agent is another advantage.
[0108] User interface: As shown in FIG. 9 , there are 4 regions on the user interface. The upper part contains a set of button including Create, Activate, Deactivate, Clone, Dispatch, Dispose and Exit. These buttons provide a user-friendly interface for the user to control the lifecycle of an agent. The lower part of the interface is the system log that will show the activities that have been taken place inside the server.
[0109] The middle part of the interface is divided into two areas. The left area displays the lists of agents that are in different status tree style, while the right hand side displays in a message broad style.
[0110] A mobile agent must be registered before starting its activities. This feature is also a security protection of the mobile agent system because it can prevent anonymous agent entering the system to car out expected damaging action. The registration of agent must be done by user by clicking the Create button. Then a “Create Agent Dialog” will pop up to ask for required information about the mobile agent ( FIG. 10 ).
[0111] User must input a valid class name of the agent and the source path that is contains the class files inside the file system. Task description is an optional input, it is used to register the service in the RegistrationManager. Then the other agent can search for this agent by searching the registered service. After registering the agent with the task description and source path, user can activate the agent at any time to initiate its operation.
[0112] User can dispatch the mobile agent object to the other remote host at any time by clicking the Dispatch button. Then the “Dispatch Agent Dialog” will pop up to ask for information about where the mobile agent should be dispatched ( FIG. 11 ). Users are required to input the destination host name/IP and the port number that the remote server is listening to.
[0113] Intelligent Agent Class: The Agent is the main character of the mobile agent concept. This is because it is a mobile software object that can transfer its software code and status from one host to another in order to perform a specific task. This can ensure the development of a Code on Demand system. The agent has its own mechanism to send messages to another agent for communication.
[0114] The Agent class is the basic class that the programmer can extend to create their own customized mobile agent. The API provides all functionalities that the agent can control its own lifecycle including the method for dispatching, deactivating, and disposing itself.
[0115] The dispatch method makes the agent hang the execution, save its status into a file and then send the status to the remote host. And to resume the execution code with the most updated status in the remote host. The deactivate method make the agent stop the execution. The dispose method will stop the agent thread's execution and also clear the status in the memory.
[0116] The Agent class also has a set of methods to get the attributes or the current status of the agent object. The getAgentName method can get the name of the agent inside the platform. The getAgentID method can get the ID assigned is to the agent. The getStatus method can check the agent in active or inactive state.
[0117] Now let's see how do we program our agent with the Agent class. We should import the IATopiaserver,*, in order to include all of the libraries that supporting us to write our agent. Then we can define our own agent by extending the Agent class.
[0000]
import IATopiaserver.Agent;
public class HelloAgent extends Agent {
// implementation of the agent's method.
}
[0118] When an agent is created inside the agent platform, the platform must call the run method as default to start the execution of the agent thread. Therefore, we can write what is the default action that the agent must take by overriding the run method.
[0000]
public void run( ) {
// default action of the action when created.
}
[0119] The agent can dispatch itself to the remote host by simply using the host name/IP and the port number that the remote server is listening to public void dispatch(String host_name, int port_num);
[0120] When the agent arrived the remote server, the IATopia Server of the remote host will call the arrived method on default to resume the execution of the agent thread. Therefore, we should tell the agent what to do in the remote host by overriding the arrived method.
[0000]
public void arrived( ) {
// what action need to take when resuming the execution on the
remote host.
}
[0121] When one agent wants to talk to the other agent, it must get the reference of the other agent from the LifecyleManager by using getOtherAgent method with the agent's name.
[0122] public Agent getOtherAgent(String agent_name);
[0123] After getting the reference of the other agent, the agent can communication with each other. By using the sendMessge method, we can send an object which is in any object type ad containing any information to the other agent.
[0124] public void sendMessage(Object msg)
[0125] On the other hand, when the agent receive a message from the other agent. We can override the handMessage method to hand and give the appropriate response to the message.
[0000]
public void handleMessage(Object msg) {
// what action need to take for the incoming message.
}
[0126] Sometimes we may need to get the reference of the LifeCycleManager in order to do some action, for example, creating the other agent. We can use the getLifeCycleManager method to get the reference of the LifeCycleManager.
[0127] public LifeCycleManager getLifeCycleManager( )
[0128] LifeCycleManager
[0129] LifeCyleManager act as the Agent Management System within the agent platform. It provides all functionalities of controls within the agent platform that include creating, suspending, resuming, dispatching and disposing agents.
[0130] After getting the reference of the LifeCycleManager, we can do some operations to control the lifecycle of the other agent inside the agent platform.
[0131] We can create a new instance or reactivate the agent object which is already be registered in the agent platform by using the agent class name.
[0132] public Agent activateAgent(String agentname, String activate)
[0133] By using the deactivateAgent method, the agent will stop its activity immediately and change the status to inactive.
[0134] public void deactivateAgent(String agentName)
[0135] The disposeAgent method will stop the activities of the agent immediately and remove the object from memory.
[0136] public void disposeAgent(String agentName)
[0137] When we need to talk to the agent by the client program, we can use the getOtherAgent of the LifeCycleManager to get the agent reference. So that we can send message to the agent and then inform the agent that what it may need to do.
[0138] public Agent getOtherAgent(String name)
[0139] Sometimes we may need to broadcast some message to all of the agent inside the agent platform. Therefore, we can call the getAllAgent to get an enumeration of agent reference to send message to every agent.
[0140] public Enumeration getAllAgent( )
[0141] RuntimeAgent: Sometimes we can write an application that is not necessary to be initiated by using the IATopia Server interface. Therefore, we can use a static class method from the RuntimeAgent class to create a new instance of the agent object by using the server name, listening port number and then agent class name as the parameter.
[0142] public static Agent createAgent(String server, int port, String agentname)
[0143] Various embodiments are provided below:
[0144] (1) HelloWorldAgent. This example shows the simplest way to create an agent which only display the Hello World Message on a awt frame.
[0000]
import IATopiaserver.Agent;
import java.awt.*;
public class HelloWorldAgent extends Agent {
transient Frame my_dialog; // transient means that this class will
not be transfer during the disptach
public void run( ) {
message = “Hello World! I am ” + getAgentName( );
my_dialog = new MyDialog(this);
my_dialog.pack( );
my_dialog.resize(my_dialog.preferredSize( ));
my_dialog.show( );
}
}
class MyDialog extends Frame {
private HelloAgent agent = null;
private Label msg = null;
MyDialog(HelloAgent agent) {
this.agent = agent;
layoutComponents( );
}
private void layoutComponents( ) {
msg = new Label(agent.message);
Panel p = new Panel( );
add(p);
p.setLayout(new FlowLayout( ));
add(msg);
}
public boolean handleEvent(Event ev) {
if (ev.id == Event.WINDOW_DESTROY) {
hide( );
return true;
}
return super.handleEvent(ev);
}
}
[0145] (2) HelloWorldAgent2. This example is the same structure as HelloWorldAgent but the agent will show the Hello World Message on a awt frame when it arrived the remote host.
[0000]
public class HelloAgent2 extends Agent {
transient Frame my_dialog;
String message = null;
public void run( ) {
dispatch(“IATopia1”, 4444);
}
public void arrived( ) {
message = “Hello World! I am ” + getAgentName( );
my_dialog = new MyDialog(this);
my_dialog.pack( );
my_dialog.resize(my_dialog.preferredSize( ));
my_dialog.show( );
}
}
[0146] (3) In this example, an agent called TalkAgent will be created in 2 IATopia Server. The user need to click the connect button to make the connection between the two chatting agent in different host. Then the users can talk to each other by using the chatting interface. This examples shows that how can we create a new instance of the other agent (msgAgent) by using the getLifeCycleManager method. Also, this example also demonstrates how do the agent send and handle the message to do the communications.
[0000]
import IATopiaserver.Agent;
public class TalkAgent extends Agent {
transient Frame1 frame;
String message = null;
public void run( ) {
frame = new Frame1(this);
// codes to show the Frame1 interface
}
public void setDialog(Frame1 dlg) {
this.frame = dlg;
}
public void handleMessage(Object msg) {
if
(msg.toString( ).substring(0,msg.toString( ).indexOf(‘@’)).equals(“Connect”)) {
frame.appendText(“Connected from ” +
msg.toString( ).substring(msg.toString( ).indexOf(‘@’) + 1,
msg.toString( ).length( )));
}
else {
frame.appendText(msg.toString( ).substring(msg.toString( ).indexOf(‘@’)
+ 1, msg.toString( ).length( )));
}
}
}
public class Frame1 extends JFrame {
TalkAgent agent = null;
msgAgent msgagent = null;
String host = “”;
int port = 0;
String chat = “”;
//Construct the frame
void btn_Connect_actionPerformed(ActionEvent e) {
try {
InetAddress addr = InetAddress.getLocalHost( );
host = destHost.getText( );
port = Integer.parseInt(destPort.getText( ));
msgagent =
(msgAgent)agent.getLifeCycleManager( ).activateAgent(“msgAgent”,
“ACTIVATE”);
msgagent.setMsg(“Connect@” + addr.getHostName( ));
msgagent.getLifeCycleManager( ).dispatchAgent(msgagent, host, port);
}
catch (UnknownHostException ex) {
}
}
void jbtn_Send_actionPerformed(ActionEvent e) {
msgagent = (msgAgent)
agent.getLifeCycleManager( ).activateAgent(“msgAgent”,
“ACTIVATE”);
msgagent.setMsg(“msg@” + msg.getText( ));
msgagent.getLifeCycleManager( ).dispatchAgent(msgagent, host, port);
msg.setText(“”);
msg.updateUI( );
}
public void appendText(String_msg) {
chat += _msg + “♯n”;
text.setText(chat);
}
}
import IATopiaserver.Agent;
public class msgAgent extends Agent {
String msg = “”;
public void arrived( ) {
Agent agent = getOtherAgent(“TalkAgent”);
agent.sendMessage(msg);
}
public void run( ) {
}
public void setMsg(String _msg) {
msg = _msg;
}
}
[0147] While implementing the present invention, base on the development platform of intelligent agent, the present invention is not limited in various embodiments described above. The present invention may expand to other application programs, as long as employing the intelligent agent based development platform to implement various application programs.
|
The present invention relates to an intelligent agent technology (IAT) based development platform. Said platform provides intelligent agent based development platform. The development platform comprises: a first module provides full artificial intelligence and intelligent agent technology (IATology) based application interface for constructing various intelligent agent application; a second module for data storage and analyzing data intelligently as well as provided the analyzed results to said first module. The present invention provides an intelligent agent system with real sense analysis and logical illation capability. In addition, an intelligent ontological agent-based development environment (IATo) is provided to be the basic frame and development platform of the future intelligent E-business.
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BACKGROUND
The present invention relates to an atomizer nozzle for a sanitary water outlet, for the purpose of atomizing water which is subjected to pressure, which atomizer nozzle has a swirl chamber into which opens out at least one feed channel, which is oriented transversely to the longitudinal axis of the nozzle and runs tangentially into the swirl chamber, wherein at least one inlet channel is arranged upstream of each feed channel, as seen in the flow direction, and wherein the swirl chamber tapers, in the outflow direction, towards a nozzle channel, at the end region of which the water jet exits into the atmosphere.
The invention also concerns a sanitary outlet fitting having a water outlet which has at least one atomizer nozzle of the type mentioned in the introduction.
WO 2012/055051 A1 has already disclosed an apparatus which is intended for spraying a liquid subjected to pressure and can serve as a mouthpiece of a sanitary outlet fitting or as a shower head. The previously known apparatus has a central feed channel for the liquid, said channel running along the apparatus axis. A plurality of vortex chambers are provided at a distance around the apparatus axis and each have an inlet, for feeding the liquid into the respective vortex chamber, and an outlet nozzle, for the exit of a liquid jet from the vortex chamber. The vortex chambers are connected to the feed channel via inlet channels, which are arranged essentially transversely to the apparatus axis. Each of the outlet nozzles is arranged obliquely in relation to the longitudinal axis of the apparatus such that liquid jets exiting from the outlet nozzles come into contact with one another at a predetermined distance from the outlet nozzles. The previously known apparatus can advantageously be used wherever it is desired to have a good cleaning performance along with a low volume flow. The previously known apparatus, however, has a comparatively complex structure, which can make the apparatus difficult to produce. Furthermore, the pattern of the water jet exiting from the previously known apparatus is also worthy of improvement.
WO 2004/016358 A1 discloses an atomizer nozzle of the type mentioned in the introduction for a sanitary water outlet, for the purpose of atomizing water which is subjected to pressure. The atomizer nozzle has a circular swirl chamber into which opens out a feed channel, which is oriented transversely to the longitudinal axis of the nozzle and runs tangentially into the swirl chamber, wherein at least one inlet channel is arranged upstream of each feed channel, as seen in the flow direction, and wherein the swirl chamber tapers, in the outflow direction, towards a nozzle channel, at the end region of which the water jet exits into the atmosphere. The construction of this previously known atomizer nozzle, however, is likewise relatively complex, which can make the atomizer nozzle, for example, difficult to produce. Furthermore, the pattern of the exiting water jet is also worthy of improvement.
SUMMARY
It is therefore an object to create an atomizer nozzle of the type mentioned in the introduction which can be produced with low outlay and is distinguished by a homogeneous pattern of the exiting water jet. It is also an object to create a sanitary outlet fitting which has a water outlet and, in respect of its water outlet, can be produced with low outlay and is distinguished by a homogeneous pattern of the exiting water jet.
This object is achieved, in the case of the atomizer nozzle of the type mentioned in the introduction that includes one or more features of the invention.
The atomizer nozzle according to the invention is intended for a sanitary water outlet, in order to atomize water which is subjected to pressure, and thus to form a homogeneous water jet. The atomizer nozzle according to the invention has a swirl chamber into which opens out at least one feed channel, which is oriented transversely to the longitudinal axis of the nozzle and runs tangentially to the swirl chamber such that the water flowing in the swirl chamber is swirled around the longitudinal axis of the swirl chamber. The swirl chamber tapers in the outflow direction towards a nozzle channel, and therefore the water jet, which is made to rotate in the swirl chamber around the longitudinal axis of the swirl chamber, is brought together in increasingly smaller circular paths and is directed through the nozzle channel, until the water jet exits, at the end region of the nozzle channel, into the atmosphere, where a fluid lamella forms, said lamella bursting, along the free peripheral region of its circumference, into individual droplets which are fine enough as to form a homogeneous water jet formed from fine water droplets. In the case of the atomizer nozzle according to the invention, provision is made for the atomizer nozzle to have a basic structure, which has an insertion opening on the inflow side, for at least one groove, which is intended for forming an inlet channel, to be provided on the circumferential wall of the insertion opening, for it to be possible for a plug to be inserted into the insertion opening as far as an annular shoulder, which runs around the inner circumference and has at least one groove, which is provided in order to form a feed channel, and for the plug to form that wall of the inlet and feed channels which is directed towards the plug. The atomizer nozzle according to the invention thus has a basic structure which has an insertion opening on the inflow side. At least one groove, which is intended for forming an inlet channel, is provided on the circumferential wall of the insertion opening. The plug can be inserted as far as an annular shoulder, which runs around the inner circumference and is interrupted by at least one groove, which is provided in order to form a feed channel. Following insertion of the plug into the insertion opening on the inflow side of the basic nozzle structure, the outside of the plug butts against the grooves such that said plug forms that wall of the inlet and feed channels which is directed towards the plug. This configuration of the atomizer nozzle according to the invention significantly simplifies the production of said atomizer nozzle.
In order that the water stream which is made to rotate in the swirl chamber around the longitudinal axis of the swirl chamber can be guided together, in the direction towards the nozzle channel, in increasingly small circular paths, a preferred embodiment of the invention provides for the swirl chamber, in the direction towards the nozzle channel, to be in the form of a funnel. A particularly advantageous embodiment of the invention here provides for the swirl chamber to be in the form in particular of a funnel which is conical or in the form of a rotational hyperboloid.
A preferred embodiment of the invention provides for a central protrusion, which is oriented in the longitudinal direction of the nozzle, to project into the swirl chamber. By virtue of the protrusion, which projects into the swirl chamber, the water jet, which is made to rotate along the wall of the swirl chamber, cannot yield into the center of the swirl chamber.
In order that it is not possible in particular for the water streams flowing in from a plurality of feed channels to affect one another and form vortices in an uncontrolled manner, it is advantageous if the protrusion projects, beyond an imaginary plane through the mouth openings of the feed channels, in the direction of the nozzle channel.
It is particularly advantageous here if the protrusion is provided on that end side of the plug which is directed towards the swirl chamber.
In order to render the atomizer nozzle according to the invention easier still to produce and design, it is advantageous if the at least one inlet channel of each feed channel is oriented in the longitudinal direction of the nozzle.
In order for it to be possible for the water coming from the water-supply network to be routed straightforwardly to the at least one feed channel, which is oriented transversely to the longitudinal axis of the nozzle, it is advantageous if an inlet channel, which is oriented in the longitudinal direction of the nozzle, is arranged upstream of each feed channel, as seen in the flow direction.
The pattern of the water jet exiting from the atomizer nozzle according to the invention is improved yet further if the atomizer nozzle has a plurality of feed channels which are distributed preferably at uniform intervals in the circumferential direction.
A preferred embodiment of the invention provides for the atomizer nozzle to be configured in the form of a hollow-cone nozzle. The water flowing in from the supply network flows tangentially into the swirl chamber of the atomizer nozzle configured in the form of a hollow-cone nozzle, and this gives rise there to a fluid vortex. The water, which flows through the nozzle channel in circular paths, forms, at the outflow end region of the nozzle channel, a lamella, which bursts into individual droplets along its end edge.
In order for it to be possible for the water flowing out in the form of a hollow cone to have good shaping, it is expedient if the outflow end region of the nozzle channel has a cross-sectional widened portion which widens in the direction of the outflow end and is preferably of spherical configuration.
In the case of the outlet fitting of the type mentioned in the introduction, the solution according to the invention consists in that the water outlet thereof has at least one atomizer nozzle with one or more features of the invention.
Preferred exemplary embodiments of the invention here provide for the water outlet to be designed in the form of a shower head or in the form of a jet regulator.
A preferred embodiment of the invention provides for the jet-regulator-form water outlet to be installed in the sanitary outlet fitting on the outflow side.
In order for the water jet flowing out of the sanitary outlet fitting to be one which, despite the comparatively small volume flow, has a sufficiently wide jet cross section, it is advantageous if the water outlet has at least two atomizer nozzles, which are distributed over the cross section of the water outlet.
The production of the outlet fitting in the region of the water outlet thereof is significantly simplified if the water outlet has a housing or a basic structure, and if the housing or the basic structure has provided in it at least one insertion opening, into which the basic structure of an atomizer nozzle can be inserted preferably in a releasable manner.
In order for it to be possible for the particles of dirt possibly entrained in the water to be filtered out before such particles of dirt adversely affect the function of the atomizer nozzles provided in the water outlet, it is advantageous if an attachment screen or a filter screen is arranged in front of the jet regulator, and if the attachment screen or filter screen can be fastened, preferably in a releasable manner, on the inflow end side of the jet regulator.
In order that the water can flow out in a state in which it is well distributed over the entire conduit cross section, even in the case of comparatively small atomizer nozzles, it is advantageous if the water outlet bears at least three atomizer nozzles, and if the atomizer nozzles are arranged on a circular path, running preferably concentrically in relation to the longitudinal axis of the shower head, or in a linear arrangement. A linear arrangement of the atomizer nozzles is recommended, for example, if the atomizer nozzles should be arranged in a star-shaped manner in relation to one another, or if the atomizer nozzles, in particular in a rectangular water outlet, should be arranged in at least one linear arrangement in relation to one another.
The water exiting from the atomizer nozzles is, in the first instance, in the form of a hollow cone, which is formed by a wall of water which runs around in the form of a circle. In order also for the water to be provided in the interior of each hollow cone, and in order also to promote the formation of a homogeneous jet over the cross section of the jet, it is advantageous if the longitudinal axes of the atomizer nozzles are inclined in relation to one another such that liquid jets exiting from the nozzles come into contact with one another at a predetermined distance from the nozzles.
A preferred embodiment of the invention here provides for the longitudinal axes of the atomizer nozzles to be arranged at an angle of 1 degree to 10 degrees to the longitudinal axis of the water outlet and, in particular, to the longitudinal axis of the housing thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
Developments according to the invention can be gathered from the claims in conjunction with the drawing and the description of the Figures. The invention will be described in yet more detail below, with reference to the various exemplary embodiments, in the drawings, in which:
FIG. 1 shows an atomizer nozzle which is intended for a sanitary water outlet and is provided for forming or atomizing water which is subjected to pressure, wherein the atomizer nozzle is shown here in a plan view of its inflow side,
FIG. 2 shows a side view of the atomizer nozzle from FIG. 1 ,
FIG. 3 shows a plan view of the outflow side of the atomizer nozzle from FIGS. 1 and 2 ,
FIG. 4 shows a longitudinal section of a plug-form constituent part of the atomizer nozzle shown in FIGS. 1 to 3 ,
FIG. 5 shows a longitudinal section of the plug-form constituent part from FIG. 4 ,
FIG. 6 shows a perspective longitudinal section of a constituent part which belongs to the atomizer nozzle shown in FIGS. 1 to 3 and is provided in the form of a basic nozzle structure,
FIG. 7 shows a longitudinal section of the constituent part from FIG. 6 , which is provided in the form of the basic nozzle structure,
FIG. 8 shows the atomizer nozzle according to FIGS. 1 to 3 in a longitudinal section through its constituent parts formed from the plug and basic nozzle structure,
FIG. 9 shows a detail of the atomizer nozzle, as seen in longitudinal section, in the region of the plug inserted into the basic nozzle structure,
FIG. 10 shows a side view of the constituent part which belongs to the atomizer nozzle according to FIGS. 1 to 3 and is provided in the form of a basic nozzle structure,
FIG. 11 shows a plan view of the inflow side of the basic nozzle structure from FIG. 10 ,
FIG. 12 shows a plan view of the outflow side of the basic nozzle structure from FIGS. 10 and 11 ,
FIG. 13 shows a perspective longitudinal section of the basic nozzle structure from FIGS. 10 to 12 ,
FIG. 14 shows a detail of the basic nozzle structure, as shown in longitudinal section, in the region of a feed channel leading to a swirl chamber,
FIG. 15 shows a longitudinal section of the basic nozzle structure from FIGS. 10 to 14 ,
FIG. 16 shows a detail of the basic nozzle structure from FIG. 15 as seen in longitudinal section in the region of a hollow-cone nozzle on the outflow side,
FIG. 17 shows a side view of a water outlet which is intended for a sanitary outlet fitting and, in this case, is configured in the form of a jet regulator,
FIG. 18 shows a plan view of the inflow side of the jet regulator from FIG. 17 , wherein in this case it is possible to see a filter screen or attachment screen arranged in front of the jet regulator,
FIG. 19 shows a perspective plan view of the inflow side of the jet regulator from FIGS. 17 and 18 ,
FIG. 20 shows a plan view of the inflow side of the jet regulator from FIGS. 17 to 19 , the filter/attachment screen having been removed,
FIG. 21 shows a perspective plan view of the outflow side of the jet regulator from FIGS. 17 to 20 ,
FIG. 22 shows a plan view of the outflow side of the jet regulator from FIGS. 17 to 21 ,
FIG. 23 shows a longitudinal section of the jet regulator from FIGS. 17 to 22 ,
FIG. 24 shows an exploded perspective illustration of the constituent parts of the jet regulator from FIGS. 17 to 23 ,
FIG. 25 shows the constituent parts of the jet regulator from FIGS. 17 to 24 in an exploded perspective illustration which has been rotated in relation to FIG. 24 ,
FIG. 26 shows an outlet fitting which is configured in the form of a hand-held shower attachment and has a water outlet designed in the form of a shower head, wherein the hand-held shower attachment is illustrated here in a perspective plan view of the outflow side of the shower head,
FIG. 27 shows a plan view of the outflow side of the shower head of the hand-held shower attachment from FIG. 26 ,
FIG. 28 shows a side view of the shower head of the hand-held shower attachment shown in FIGS. 26 and 27 ,
FIG. 29 shows a plan view of the inflow side of the shower head from FIG. 28 ,
FIG. 30 shows a perspective plan view of the inflow side of the shower head from FIGS. 28 and 29 ,
FIG. 31 shows an exploded perspective illustration of the constituent parts of the shower head according to FIGS. 28 to 30 ,
FIG. 32 shows a plan view of the outflow side of the shower head according to FIGS. 28 to 31 , and
FIG. 33 shows a longitudinal section of the shower head from FIGS. 28 to 32 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 to 16 illustrate an atomizer nozzle 1 which is intended for a sanitary water outlet for atomizing water which is subjected to pressure. The atomizer nozzle 1 is intended to use a small volume flow to form a homogeneous water jet which nevertheless appears to be voluminous.
The atomizer nozzle 1 has a swirl chamber 2 which, on the inflow side, has a chamber portion 3 which is essentially cylindrical or disk-shaped over its clear cross section. Opening out in the swirl chamber 2 is at least one feed channel 4 , which is oriented transversely, and preferably at right angles, to the longitudinal axis of the nozzle and runs tangentially into the swirl chamber 2 .
As can be seen in the plan view in FIG. 11 , in which are illustrated the grooves 16 , each forming a feed channel, a plurality of feed channels 4 , which are spaced apart uniformly from one another in the circumferential direction, open out here in the swirl chamber 2 . The swirl chamber 2 tapers in the form of a funnel, in the outflow direction, towards a nozzle channel 5 , which nozzle channel 5 , at its outflow end region, has a cross-sectional widened portion 6 which widens in the direction of the outflow end and is preferably of spherical or rounded configuration here. The funnel-form portion 9 of the swirl chamber is configured, over its clear cross section, such that the swirl chamber, in the direction towards the nozzle channel 5 , is in the form of a funnel which is conical or in the form of a rotational hyperboloid.
So that the streams of water flowing out of the openings of the feed channels 4 cannot adversely affect one another, a central protrusion 8 , which is oriented in the longitudinal direction of the nozzle, projects into the swirl chamber 2 . As can be seen in FIG. 8 , this protrusion 8 projects, beyond an imaginary plane through the mouth openings of the feed channels 4 , in the direction of the nozzle channel 5 .
The atomizer nozzle 1 illustrated here has a basic structure 10 , which has an insertion opening 11 on the inflow side. At least one groove 12 , which is intended for forming an inlet channel, is provided on the circumferential wall of the insertion opening 11 . In each case one inlet channel 13 , which is oriented in the longitudinal direction of the nozzle, is arranged upstream of each feed channel 4 , as seen in the flow direction. A plug 14 can be inserted into the insertion opening 11 as far as an annular shoulder 15 , which runs around the circumference. The annular shoulder 15 is interrupted by at least one groove 16 , which is provided in order to form a feed channel 4 . While the outer circumference of the plug 14 closes the at least one groove 12 in respect of an inlet channel 13 , the end side of the plug 14 closes the at least one groove 16 in respect of a feed channel 4 . The protrusion 8 is provided on that end side of the plug 14 which is directed towards the swirl chamber 2 . The atomizer nozzle 1 has a plurality of feed channels and, in this case, three feed channels 4 , which are distributed at uniform intervals in the circumferential direction.
FIGS. 17 to 25 illustrate a jet regulator 17 which is intended as a water outlet of a sanitary outlet fitting (not shown specifically here) and has a plurality of the atomizer nozzles 1 shown in FIGS. 1 to 16 . The jet regulator 17 , which is shown in FIGS. 17 to 25 , has at least two, and preferably three, atomizer nozzles 1 , which are distributed over the cross section of the jet regulator 17 , which serves as a water outlet. The jet regulator 17 has a housing 18 , in which is provided at least one insertion opening 7 , into which the basic structure 10 of an atomizer nozzle 1 can be inserted preferably in a releasable manner. It can be seen in FIGS. 17 and 23 to 25 that an attachment screen or filter screen 19 is arranged in front of the jet regulator 17 . This attachment screen or filter screen 19 here can be fastened, preferably in a releasable manner, on the inflow end side of the jet regulator. It can be seen in FIG. 23 that the longitudinal axes of the atomizer nozzles 1 provided in the jet regulator 17 are inclined in relation to one another such that liquid jets exiting from the nozzles come into contact with one another at a predetermined distance from the nozzles. The atomizer nozzles 1 here define a longitudinal nozzle axis which runs at an angle of 1 degree to 10 degrees to the longitudinal axis of the jet regular 17 and, in particular, to the longitudinal axis of the housing thereof.
A water jet which is formed from fine water droplets, is generated from a small volume flow, is distinguished by a homogeneous jet pattern and gives the impression of a voluminous water jet exits from the jet regulator 17 illustrated here.
FIGS. 26 and 27 illustrate a sanitary outlet fitting which is designed in the form of a hand-held shower attachment 20 and of which the water outlet is configured in the form of a shower head 21 . The shower head 21 , which is illustrated in more detail in FIGS. 28 to 32 , has at least two atomizer nozzles 1 , which are distributed over the cross section of the shower head 21 . The shower head 21 has a housing or basic structure 22 , in which is provided at least one insertion opening 23 , into which the basic structure 10 of an atomizer nozzle 1 can be inserted preferably in a releasable manner. The shower head 21 has provided in it more than three, and here in particular six, atomizer nozzles 1 , which are arranged on a circular path running concentrically in relation to the longitudinal axis of the shower head. It is also the case that the longitudinal axes of the atomizer nozzles 1 provided in the shower head 21 are inclined in relation to one another such that liquid jets exiting from the nozzles come into contact with one another at a predetermined distance from the nozzles. The longitudinal axes of the atomizer nozzles 1 here define a longitudinal nozzle axis which runs at an angle of 1 degree to 10 degrees to the longitudinal axis of the water outlet, which is designed in the form of a shower head 21 , and, in particular, to the longitudinal axis of the basic structure 22 thereof.
The water exits from the hollow-cone nozzles 6 of the atomizer nozzles 1 in a spray cone of 15 degrees to 40 degrees in each case. This results in the formation of a fluid lamella, which bursts into individual droplets along its free outline or its end edge. These fluid droplets of the water flowing out of the atomizer nozzles 1 combine to form an overall jet which is homogeneous over the entire cross section of the jet and, despite its comparatively small volume flow, gives the appearance of a voluminous water jet with a customary level of cleaning force.
It is clear from the exemplary embodiments according to FIGS. 17 to 33 that the atomizer nozzle 1 shown in FIGS. 1 to 16 allows modular configuration of the water outlet intended for a sanitary outlet fitting. It is indeed the case that the water passing through the atomizer nozzle 1 exits there in the form of a hollow cone, but the inclined arrangement of a plurality of atomizer nozzles results in the formation of a homogeneous water jet which is formed from fine water droplets over the entire cross section of the jet. It can be seen from FIGS. 2, 6, 7 and 8 that the peripheral region on the inflow side of the basic nozzle structure has a basic-nozzle-structure portion 24 which widens counter to the inflow direction and can form a solid sealing lip once the basic nozzle structure has been inserted into the housing 18 or the basic structure 22 of a water outlet. This sealing lip formed by the portion 24 has a dual sealing function and retaining function, as a result of which the basic nozzle structure 10 is retained, for all practical purposes in the manner of a barb, in the housing 18 or in the basic structure 22 of the water outlet. It is also possible, however, for the basic nozzle structure 10 to be snap-fitted, welded, or fixed releasably or non-releasably in some other way, in the insertion openings 7 , 23 provided in the basic structure 22 or in the housing 18 of the water outlet. It has been found that the nozzle channel 5 should have, at its opening which opens out into the atmosphere, a break-away edge 25 , angled at less than/equal to 90 degrees, in order to achieve the best possible atomizing operation in the atomizer nozzle 1 . It can be seen in the detail view in FIG. 9 that the plug 14 has provided on it at least one preferably encircling sealing and/or retaining claw 26 , which retains said plug 14 in the insertion opening 11 of the basic nozzle structure 10 . It is clear in FIGS. 7 and 8 that the portion 27 of the nozzle channel 5 , said portion being designed preferably with a constant cross section, is of comparatively long configuration and has a length of at least ⅓ of the length of the basic nozzle structure, preferably a length of ⅓ to ½ of the basic nozzle structure 10 . The length of the spray cone formed by the atomizer nozzle 1 can be defined, and the outflowing water jet can be concentrated even more, over the length of the nozzle channel 5 and the portion 27 thereof which is configured with a constant cross section. The individual constituent parts of the atomizer nozzle 1 can be produced in a cost-effective and reliable manner. Although the feed and inlet channels 4 , 13 have a comparatively small cross section, these components of the atomizer nozzle 1 can be produced with low outlay and a sufficient level of precision. The atomizer nozzle 1 illustrated here makes it possible to produce a water outlet which facilitates minimal water consumption and nevertheless, even at low pressures of for example 2 to 3 bar, provides for good and full-surface-area wetting by means of the exiting water jet.
LIST OF DESIGNATIONS
1 Atomizer nozzle
2 Swirl chamber
3 (Cylindrical or disk-shaped) chamber portion
4 Feed channel
5 Nozzle channel
6 Hollow-cone nozzle
7 Insertion opening
8 Protrusion
9 (Funnel-shaped) chamber portion
10 Basic nozzle structure
11 Insertion opening
12 Groove
13 Inlet channel
14 Plug
15 Annular shoulder
16 Groove
17 Jet regulator
18 Housing
19 Attachment screen or filter screen
20 Hand-held shower attachment
21 Shower head
22 Basic structure
23 Insertion opening
24 Portion
25 Nozzle break-away edge
26 Retaining claw
27 Portion
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An atomizer nozzle ( 1 ) for a sanitary water outlet, which atomizer nozzle ( 1 ) is intended for atomizing water under pressure. The characterizing feature of the atomizer nozzle ( 1 ) according to the invention is that the atomizer nozzle ( 1 ) has a swirl chamber ( 2 ), in which at least one feed channel ( 4 ) that is oriented transversely in relation to the longitudinal axis of the nozzle and runs approximately tangentially into the swirl chamber ( 2 ) opens out, wherein the swirl chamber ( 2 ) tapers in the outflow direction, in the direction of a nozzle channel ( 5 ). The atomizer nozzle ( 1 ) can be used to produce a water jet of a homogeneous jet pattern that gives the impression of a voluminous water jet in spite of having a low volumetric flow.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to single acting, variable displacement fluid pressure vane pumps, such as fuel and hydraulic control pumps for aircraft use.
Over the years, the standard of the commercial aviation gas turbine industry for main engine fuel pumps has been a single element, pressure-loaded, involute gear stage charged with a centrifugal boost stage. Such gear pumps are simple and extremely durable, although heavy and inefficient. However, such gear pumps are fixed displacement pumps which deliver uniform amounts of fluid, such as fuel, under all operating conditions. Certain operating conditions require different volumes of liquid, and it is desirable and/or necessary to vary the liquid supply, by means such as bypass systems which can cause overheating of the fuel or hydraulic fluid and which require heat transfer cooling components that add to the cost and the weight of the system.
2. State of the Art
Vane pumps and systems have been developed in order to overcome some of the deficiencies of gear pumps, and reference is made to the following U.S. patents for their disclosures of several such pumps and systems: U.S. Pat. Nos. 4,247,263; 4,354,809; 4,529,361 and 4,711,619.
Vane pumps comprise a rotor element machined with axial slots supporting radially-movable vane elements, mounted within a cam member having fluid inlet and outlet ports in the faces of the cam member through which the fluid is fed radially to the inlet areas or buckets of the rotor surface for compression and discharge from the outlet areas or buckets of the rotor surface and axially in both directions as pressurized fluid.
Vane pumps that are required to operate at high speeds and pressures preferably employ hydrostatically (pressure) balanced vanes for maintaining vane contact with the interior cam surface in seal arcs and for minimizing frictional wear. Such pumps may also include radially-rounded vane tips to reduce vane-to-cam surface stresses. Examples of vane pumps having pressure-balanced vanes which are also adapted to provide undervane pumping, may be found in U.S. Pat. Nos. 3,711,227 and 4,354,809. The latter patent discloses a vane pump incorporating undervane pumping wherein the vanes are hydraulically balanced in not only the inlet and discharge areas but also in the seal arcs whereby the resultant pressure forces on a vane cannot displace it from engagement with the interior cam surface in seal arc areas.
Variable displacement vane pumps are known which contain a swing cam element which is adjustable or pivotable, relative to the rotor element, in order to change the relative volumes of the inlet and outlet or discharge buckets and thereby vary the displacement capacity of the pump.
Among the disadvantages of known vane pumps are their lack of durability, susceptibility to wear, complexity of rotor and cam structures, necessity for end sealing plates to seal the ends of the rotor for the purpose of containing the pressurized fluid, and other essential elements which can provide vane pumps with variable metering properties not possessed by gear pumps but which detract from their durability or life span relative to the comparative durability and life spans of gear pumps. In conventional vane pumps the rotor is splined upon and driven by a central drive shaft having small diameter journal ends which are not strong enough to withstand the opposed inlet and outlet hydraulic pressure forces generated during normal operation. This problem is overcome by forming such pumps as double-acting pumps having opposed inlet arcs and opposed outlet or discharge arcs which balance the forces exerted upon the journal ends, as disclosed by the prior art such as U.S. Pat. Nos. 4,354,809 and 4,529,361, for example.
The present invention is directed to improving the durability and reducing the susceptibility to wear with respect to the vane tips and the cam surface upon which they ride. In double acting vane pumps the liquid, such as fuel, is admitted to the cam chamber axially, from both directions, in the low pressure inlet arc areas, and is pumped or discharged axially, in both directions in the high pressure discharge arc areas. This has been found to result in overheating of the tips of the vanes, at their centerpoints, causing uneven wear of the vane tips and scoring of the cam surface.
SUMMARY OF THE INVENTION
The present invention relates to novel single acting, variable displacement vane pumps, and components thereof, which have the durability, ruggedness and simplicity of conventional gear pumps, and the versatility and variable metering properties of vane pumps, while incorporating novel features and properties not heretofore possessed by prior known pumps of either type.
The novel vane pumps of the present invention avoid the vane tip overheating and wear problems of prior known vane pumps by providing the surface of each vane tip, and/or the cam surface, with a central fluid-permeable recess or groove, which functions as a pressure relief or sump at the symmetrical center of the pump to avoid or relieve flow stagnation. Such flow stagnation, due to the even introduction and the even discharge of the liquid fuel in opposed axial directions has been found to result in an isolation or stagnation of a portion of the liquid and a loss of cooling of the vane tips, at the midpoint of their contact surfaces with the cam surface at the inside diameter of the cam, resulting in thermal expansion or bowing of the vane tips and scoring of cam surface in such areas.
Applicants have discovered that fluid flow stagnation, and the consequences thereof are avoided by providing the aforementioned vane tip recesses and/or cam surface groove to prevent the fluid from being isolated in the areas of the centerpoints of the vane tip surfaces and/or at the central circumference of the inner cam surface, where it will stagnate and increase in temperature and be unable to perform an intended function of cooling the vane tips and the cam surface. The vane tip recesses and/or cam surface groove of the present invention enable the liquid, such as fuel, to circulate beyond the midpoint of the vanes by flowing through the vane tip recesses into an adjacent bucket area in the same arc and/or circumferentially over the inner cam surface during axial introduction of the fuel and also during axial discharge of the fuel, whereby fresh fluid, having cooling properties, is introduced and displaces prior fluid during each cycle of operation of the pump. Moreover, the vane tip recesses and/or cam surface groove separate the vane tips and cam surface from each other at the centerpoint to avoid any friction or wear in this area.
The novel pumps of the present invention comprise a durable, substantially uniform diameter rotor member which is machined from barstock, similar in manner and appearance to the main pumping gear of a gear pump. The rotor has large diameter journal ends at each side of a central vane section which comprises a plurality of radially-extending teeth, adjacent pairs of said teeth being formed as wall extensions of a plurality of axially-elongated radial vane slots having central deeper well areas, slidably-engaging a mating vane element. The rotor slots are such that the vanes may be significantly greater in thickness than is permitted in pumps constructed in accordance with the prior art. Axial grooves or depressions may be included in the surface of the rotor between the vane slots. These depressions provide increased volume, to reduce sudden pressure build-up which can occur when the enclosed volume between the vanes is reduced as it is during the pumping process. This can create an effect similar to "water hammer" in a residential plumbing system. An adjustable, narrow cam member having a continuous circular inner cam surface eccentrically surrounds and encloses the central vane section, and the cam surface is engaged by the outer surfaces of the vane elements during operation of the pump. The cam housing is provided with means for adjusting the operating "displacement" of the pump. Pressure forces within the cam are directed axially in both directions, through the porting structures or fluid outlets of the pump, so that the cam loads are centrally (i.e., symmetrically) located relative to a pivot, thereby reducing the force needed to actuate the cam and reducing the stresses on the pivot. The journal ends of the rotor member are rotatably supported within opposed durable bearings, such as manifold bearings which may be made for example from barstock material, and which have manifold faces which contact and seal opposite faces of the cam member and overlap the outer ends of the elongated radial vane slots. Each manifold bearing has interior inlet and discharge passages communicating with the cam--contacting manifold faces. The latter comprise an inlet arc segment opening to the inlet passages of the bearing, and a smaller discharge arc segment opening to the discharge passages of the bearing, separated from each other by opposed small sealing arc segments. Rotation of the journals of the vaned rotor member within the manifold bearings and of the central vane section within the cam member causes fluid such as liquid fuel to be admitted axially from both directions through the inlet arc segments of the bearings into the cam chamber and into expanding inlet bucket chambers between the vanes, and also through the inlet manifold passages and the vane slot extensions to under-vane chambers. Continued rotation of the rotor member through a sealing arc segment into a discharge arc segment changes the pressure acting upon the leading face of each vane from inlet pressure to increasing discharge pressure as the volume of each bucket chamber is gradually compressed at the discharge side or arc of the eccentric cam chamber. The pressurized fuel escapes axially, in both directions, into the discharge ports of each manifold bearing, through the discharge passages, and is channelled to its desired destination.
The pressures acting upon the vanes are balanced so that the vanes are lightly loaded or "floated" throughout the operation of the present pumps. This reduces wear on the vanes, permits the use of thicker, more durable vanes and, most importantly, provides elasto-hydrodynamic lubrication of the interface of the vane tips and the continuous cam surface. Such balancing is made possible by venting the undervane slot areas to an intermediate fluid pressure in the seal arc segments of the manifold bearings whereby, as each vane is rotated from the low pressure inlet segment to the high pressure discharge segment, and vice versa, the pressure in the undervane slot areas is automatically regulated to an intermediate pressure at the seal arc segments, whereby the undervane and overvane pressures are balanced which prevents the vane elements from being either urged against the cam surface with excessive force or from losing contact with the cam surface. The intermediated pressure at the seal arc segments is derived from the servo piston pressure which is used to move the cam.
The regulation of the undervane pressure permits the use of thicker, more durable vanes by eliminating the unbalanced pressures which are found in the prior art. Within the inlet arcs of the present pumps the undervane areas are subjected to inlet pressure as are the overvane areas. Within the outlet arcs of the pump, the undervane areas are subjected to outlet pressure as are the overvane areas. Within the seal arcs of the pump, the undervane areas are subjected to a pressure that is midway between inlet and discharge pressure, to compensate for the overvane areas which are also subjected half to inlet and half to discharge. More importantly, the regulation of the undervane pressure and "floating" of the vanes causes the centrally-recessed tips of the present vanes to float over the optionally-grooved cam surface which is lubricated by the fluid being pumped, whereby metal-to-metal contact and wear are eliminated at the center of the pump. This overcomes the need for hard, brittle, wear-resistant, heavy metals, such as tungsten carbide, for the vanes and/or for the cam surface and permits the use of softer, more ductile, lightweight metals, particularly if the outer vane tips are radiused or rounded and a wear resistant coating, such as of titanium nitride, is applied to the outer rounded vane tip surfaces and to the cam surface.
The novel vane pumps of the present invention preferably also provide substantial undervane pumping of the fluid from the undervane slot areas axially in both directions by piston action as the vanes are depressed into the slots at the discharge side of the cam chamber. Such undervane pumping can contribute up to 40% or more of the total fluid displacement.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-sectional view of a fuel pump assembly according to one embodiment of the present invention, illustrating fluid flow paths therethrough;
FIG. 2 is a schematic diagram of the fuel pumping system through the assembly of FIG. 1, including an adjustment system for the cam member to vary the fuel displacement volume;
FIG. 3 is a schematic cross-sectional view of the single acting vane stage of FIG. 1 taken along the line 3--3 thereof;
FIG. 4 is a simplified schematic depiction of the supply or discharge of fluid to or from the undervane slot areas in the areas of the inlet and discharge arcs respectfully, and of the porting of the undervane slot areas to an intermediate, balancing pressure in the areas of the seal arcs of the cam chamber, and
FIG. 5 is a perspective view of a novel cam member having a central continuous recess or groove cut into the inner diameter surface of the cam chamber.
DETAILED DESCRIPTION
Referring to FIG. 1, the fuel pump assembly 10 thereof comprises a variable displacement single acting vane pump 11 having a rugged barstock rotor member 12 having a plurality of vane elements 13 radially-supported within axially-elongated, concave vane slots 32 disposed around the central area of the rotor member 12. The outer tip 13b of each vane element 13 is provided with a central surface recess 13c, and the tips 13b preferably are rounded to reduce their areas of contact with the interior continuous surface 14a (FIG. 3) of an adjustable cam member 14, and a pair of manifold bearing blocks or members 15 and 16 rotatably support the large diameter journal ends 12a and 12b of the rotor member 12 and provide axial sealing of the pressurized cam chamber. In this regard, the blocks 15 and 16 serve the function of the "side" or "end" plates of a conventional vane pump.
The cam chamber of the vane pump 11 is fed axially, in both directions, with fluid from a centrifugal boost stage 17 comprising an axial inducer and radial impeller 18 and associated collector and diffuser means 26 mounted within a housing section 19 connected to a housing section 20 mountable on a main engine gearbox.
Power is extracted in conventional manner from an engine through a main drive shaft 21 which includes an oil-lubricated main drive spline 22, a fuel-lubricated internal drive spline 23, a shear section 60 and a main shaft seal 61. A second shaft 24 drives the boost stage 17 from a common spline with the main shaft 21.
The pump is mounted to the main engine gearbox, and ports are provided to passages through the housing section 19 for an outlet 25 from the boost stage 17 through diffuser means 26 to an external heat exchanger and filter (FIG. 2) and back into inlet passage 36 (FIG. 2) to the inlet arc section 27 of the manifold bearings 15 and 16 for axial introduction of the fuel, under inlet pressure, past the hemispherical bevels or undercut slots 28 on the opposed faces of the cam member 14 in the area of the inlet arc of the cam chamber and into the expanding fuel inlet buckets 29 formed between adjacent vane elements 13 within the inlet arc section of the cam member 14, as shown in FIG. 3.
Rotation of the rotor 12 and vanes 13 within the cam member 14 causes the inlet buckets 29 to move into a 36° seal arc area where they become isolated from the 180° inlet arc sections 27 of the manifold bearings 15 and 16 and begin to become compressed due to the non-concentric axial position of the rotor member 12 within the cam chamber, as shown in FIG. 3. Within the seal arc zones, which are transition zones between the lower-pressurized inlet pressure zone and the 180° increased discharge pressure zone, each vane experiences a different overvane pressure on each side of it, which normally can cause intermediate overvane forces. However, as illustrated by FIG. 4, the present pumps provide special pressure relief passages 30 to a source of fluid at intermediate pressure in the seal arc areas whereby fuel is supplied at intermediate pressure through axial passages 30 in the manifold bearings 15 and 16 (FIG. 1) to the extremities 31 of the vane slots 32, beyond the vane elements 13, to produce an intermediate fluid pressure in the undervane slot areas 33 which balances the overvane fluid pressures and reduces the stresses or forces exerted by the vane tip surfaces against the continuous cam surface 14a in the area of the sealing arc zones. As can be seen from FIGS. 3 and 4, the undervane areas 33 are biased directly to inlet pressure, through slot extensions 31 and bearing ports and passages when the vane is in the inlet arc, and to discharge pressure when the vane is rotated to the discharge arc zone. In this manner, the vane loading in the inlet, seal, and discharge arc zones is held to very tolerable levels since the vane loads are achieved primarily through a combination of balanced pressure forces an low dynamic forces.
FIG. 2 is a simplified depiction of a cam member mechanism adjustable between minimum and maximum displacement flow positions. The cam 14 pivots on a pin 34 supported within housing section 20 at the top of the pump structure member. The pump is at maximum displacement when the cam 14 is positioned so that the vane buckets experience maximum contraction in the discharge arc zone. Likewise, minimum flow occurs when the cam 14 and the rotor 12 are almost concentric. Mechanical stops 35 are designed into a piston adjustment system 35' to limit cam displacement, generally, for the purpose of assuring that the cam will not contact the rotor surface (exceeds max displacement). These stops include shims for final production calibration. The piston adjustment system 35' is supplied with fluid at a predetermined pressure selected to be "intermediate" or "half-way" between the inlet and discharge pressures of the pump. This arrangement permits the use of a common source of fluid pressure (not shown) for both the adjustment system 35' and the axial relief pressure passages 30 and associated sealing arc ports, passages 30 being shown in FIG. 4 and described elsewhere herein.
As illustrated by FIGS. 1 and 2, the fuel exits the booster stage 17 of the pump through an external flanged outlet 25 and a collector/diffuser means 26 from the axial inducer/impeller 18 at the front of the boost stage 17. The axial inducer imparts sufficient pressure rise to the fluid to eliminate poor quality effects associated with line losses or fuel boiling and assures that the main impeller, downstream from the inducer, will be handling non-vaporous liquid. Angled slots in the impeller hub allow some of the flow to move from the front to the back side of the impeller. Hence fuel passes radially outward through the vaned passages on both sides of the impeller, subsequently to be collected and diffused. As shown in FIG. 2, the fuel exits the booster stage 17 through outlet 25 to pass through the external engine heat exchanger and filter, subsequently, to return, via an inlet passage 36 in housing section 20, to the main vane stage. Fuel enters around the main vane stage cam 14 in the inlet arc zone 27 and is admitted, axially, to the expanding inlet vane buckets 29 through an undercut slot 28 on each cam face from face recesses in each of the bearings 15 and 16 and on both sides of the cam 14. Each vane bucket 29 then carries the fuel circumferentially into the discharge arc where contracting discharge buckets 29a squeeze the fuel axially outward into discharge ports 55 cut into the faces of the bearings 15 and 16 in the discharge arc zone, subsequently to be discharged to the engine through cored passages 38 and 39 in the housing sections 19 and 20. FIG. 1 provides a depiction of the flow path through the system.
As illustrated by FIGS. 1 and 4, the fuel inlets to the cam chamber open through passages 47 in the low pressure 180° inlet arc segment between the ends of the vanes 13 member and the adjacent faces of the bearings 15 and 16. The fuel is drawn axially from both directions into the vane slot extremities 31 and the expanding vane buckets 29 and into the undervane areas 33 for compression and discharge as the rotation of the rotor member 12 around the eccentric cam surface 14a produces contracted vane buckets 29a and depresses the contoured undersurfaces 13a of the vanes 13 into the undervane areas 33 in the high pressure discharge arc segment of the bearings 15. This pumps the liquid through 180° discharge ports 55 in the outlet arc segment of the bearings 15 and 16 and through discharge passages 37 to the engine or other destination.
In operation, the fuel is introduced to the expanding inlet bucket areas 29 and undervane areas 33 axially from both directions towards the center of the vanes 13 in the 180° inlet arc, and is discharged axially in both directions in the discharge arc, the liquid present at the center of the vanes 13 and undervane areas 33 in the contracted vane bucket areas being furthest from the discharge ports 55 in the opposed bearings 15 and 16. In conventional vane pumps this has resulted in a reduced circulation of the liquid at the centerline of the rotor and cam chamber, producing stagnant residual or uncirculated fluid which becomes overheated due to its continued residence within the pump and contact with the vanes 13 which are in continuous frictional engagement with the cam surface. While continuously-replenished fluid serves as a coolant for the vanes and vane slots, uncirculated stagnant fluid can become overheated and the center of the vane tips can expand or swell or bulge to cause scoring of the contacting cam surface and eventually pump failure.
These problems are overcome or avoided by the discovery that the failure of the fluid to continuously circulate through the central bucket and undervane areas of the conventional vane pumps can be corrected by providing the tips 13b of the vanes 13 with a central recess 13c, shown in FIGS. 1 and 4, and/or by providing the cam surface 14a with a central continuous transverse recess or groove 14b, shown in FIG. 5. The central recesses 13c enable the fluid to circulate between bucket areas, from one bucket area through a vane recess 13c into the next bucket area in the inlet and seal arcs of the pump and also in the discharge and seal arcs of the pump, thereby avoiding stagnant fluid at the center of the bucket areas or developing an air pressure or a vacuum barrier blocking the flow of fluid thereto or therefrom. The vane recesses 13c vent the central bucket areas to improve fluid circulation and avoid fluid stagnation.
The central groove 14b in the cam surface may be used instead of or in addition to the vane tip recesses 13c, and functions in the same manner to allow fluid to fill the bucket areas and undervane areas and flow into the vane groove 14b in the inlet and seal arcs of the pump, and to allow the fluid to be pumped from the bucket areas and undervane areas and the groove 14b in the discharge and seal arcs of the pump, thereby also providing cooling flow over the vane tips as the fluid leaks through the groove 14b. Additionally the cam groove 14b, being continuous equalizes the vane stage internal pressure and helps to suppress bubble formation during low inlet pressure operation of the vane stage.
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A variable displacement vane pump having a vaned rotor adjustably contained within a cam member for rotation between fuel inlet and fuel discharge arcs. Adjacent vanes form enclosed fuel bucket areas which are expanded and axially-supplied with fuel in the fuel inlet arc and are contracted and axially-discharge the fuel in the fuel discharge arc. Fuel circulation is improved by providing a central recess at each vane tip and/or a central groove in the cam surface to prevent trapping, stagnation and overheating of fuel at the centerpoints of the bucket areas, which overheating can result in expansion of the vane tips, scoring of the cam surface and pump failure.
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TECHNICAL FIELD
[0001] This invention relates to a hair removal apparatus.
BACKGROUND
[0002] From DE 36 10 736 A1 there is known a hair removal apparatus, in this case an electrically driven shaving apparatus, on which an actuator head, in this case a short-hair cutter, is movably fastened to the housing. The short-hair cutter includes two shaving foils that extend essentially parallel to the axis of rotation of the actuator head and under each of which respectively one oscillating under cutter with individual sheet-metal disks is slidingly arranged. On this electric shaving apparatus, the short-hair cutter forms the only actuator system.
[0003] From DE 198 59 017 C1 there is known in addition a hair removal apparatus which is constructed as a hair clipper and on which the actuator head includes two different actuator systems. In this arrangement two cutting blades are assigned to a single clipper comb and can be coupled, respectively according to the pivot position of the actuator head relative to the housing, to a drive element of the drive mechanism. In this way the clipper comb, which has two rows of cutting teeth, can be brought by means of a pivot movement into an optimum cutting position relative to a skin surface.
[0004] The construction of two cutting blades on one clipper comb also enables in advantageous manner a different construction of the teeth on the clipper comb and the teeth on the two cutting blades, for example in that the width of one row of cutting teeth is constructed substantially smaller than the width of the other row of cutting teeth. As a result it is possible, for example, to cut long hair with the one row of cutting teeth and short hair with the other row of cutting teeth. To make this possible, the actuator head must be pivoted about a pivot axis that in this case lies outside the clipper comb. According to FIGS. 6 and 7 of DE 198 59 017 C1, the cutting teeth row 41 thus comes to rest on the housing 1 and is inactive in this position while the cutting teeth row 40 according to FIG. 7 now projects freely outward and can make contact with the skin. According to FIG. 6, the cutting teeth row 41 had adopted its active position, meaning its shaving position, and the cutting edge 40 its rest position before the actuator head was pivoted.
[0005] With this hair clipper, the apparatus must also be turned in the hand when switching from the one clipper comb to the other clipper comb because the direction of the cutting plane is also shifted from one side of the housing to the other. Consequently, the electric switching device is moved from the outside, where it was easy to actuate with the thumb, to the inside of the hand where it is therefore no longer easy to reach. Because the pivot axis lies outside the clipper comb, the comb is rotatable only to a limited degree in the housing.
SUMMARY
[0006] In one aspect, a hair removal apparatus features actuator systems that can be brought into their active operating position through adjustment of the actuator head with easy handling of the apparatus. Because the actuator head forms a rotary body that is freely rotatable about an axis of rotation in the housing of the hair removal apparatus, the entire circumference of the actuator head can be used for providing actuator systems, each of which reaches the required hair treatment plane respectively once during one rotation of the actuator head through 360°. At the same time the apparatus can be held in the same position without any change of position by the hands.
[0007] Through the circumferential construction of the individual actuator systems on the actuator head, the actuator head in one embodiment takes on a roller or drum-shaped form, whereby the axis of rotation of the actuator head also extends in the longitudinal direction of the individual actuator systems. If two actuator systems are provided on the actuator head, said systems are advantageously arranged in diametrically opposite positions and the actuator head takes on the form of a right parallelepiped whose circumferential end faces are slightly curved outwards in order to produce better contact with a user's skin.
[0008] Actuator heads may include, for example, a short-hair cutter in the form of one or two foils and a cutter engaging the foil(s) from underneath, a center cutter, a long-hair cutter or a plucking device for plucking hairs, which are provided circumferentially on the actuator head and driven by at least one or more drive mechanisms. In addition the actuator head can be equipped with a parking position, i.e., when said head is turned into this plane, all other actuator systems are deactivated and enclosed by the housing to the extent that it is hardly possible for these systems to be damaged, for example during a cleaning operation or accidental bumping of the apparatus.
[0009] Hence the actuator systems are not accessible in the rest position. Such a concept enables, for example, a shaving head to be equipped with various shaving systems. Examples of possible variations in the construction of an actuator head include a short-hair cutting system with an opposite, extendible long-hair cutting system and a parking position that is provided between the two shaving systems on the actuator head. In this arrangement the short-hair cutting system rests protected in the housing while the long-hair cuffing system projects radially outwards and can make contact with a user's skin in order to cut off the hairs as close as possible to the skin.
[0010] Also conceivable however would be a hair removal apparatus with two opposing short-hair cutting systems equipped with different foils such that the one short-hair cutting system could be used for pre-cutting and the other short-hair cutting system for finish-cutting. As another variant it would also be conceivable to make added provision for a long-hair cutting system that is radially extendible from the circumferential side of the actuator head for cutting contours or for forming designer stubble. Instead of constructing different cutting systems on the actuator head it is also possible in addition for an epilator to be integrated in the head.
[0011] In some implementations, the plane of rotation of the actuator head extends in the longitudinal direction of the treatment planes of the individual actuator systems, thus resulting in particular ease of handling of the hair removal apparatus. Like a rotating drum, the actuator head can be turned about its axis of rotation until the corresponding actuator system, for example a short-hair cutter, points radially outwards away from the hair removal apparatus, i.e., its treatment plane extends perpendicular or at an angle to the longitudinal axis of the housing, and therefore can be easily moved against the hair surface to be treated without the housing getting in the way.
[0012] In some cases, the actuator head has both its ends rotatably mounted on the housing, and a stable mounting of the actuator head on the housing results; in this case, however, the actuator head is accessible only circumferentially from the outside and not from its two ends. With this embodiment, the axis of rotation is supported on the housing at both ends.
[0013] In other cases, the actuator head has only its one and narrower end rotatably mounted on the housing, thus enabling better accessibility also from the one side of the actuator head. The overhung mounting of the actuator head simplifies the mounting and enables a simpler housing design to be obtained. However, with the overhung mounting arrangement it is necessary to construct the mounting stable enough for the bending forces acting on the actuator head when placed against a user's hair surface to be absorbed by the mounting without damage. Another advantage is that, because of the freely accessible side of the one actuator surface, the freely accessible side can better reach into individual surface depressions or into other intractable corners of the skin such as certain areas behind the ear or the region underneath the nose.
[0014] With the overhung mounting of the actuator head, a bearing journal projects from the end for close-fitting engagement with a bore constructed on the housing where the journal is fixedly located. In this arrangement the journal and the bore combine to form a closely toleranced slide fit in which the actuator head can be turned free of play. It is possible to select, for example, snap rings or other clip fasteners as fixing elements for fixing the actuator head via the journal in the housing.
[0015] In some embodiments, the actuator head is turned by hand about its axis of rotation in order to move a desired hair treatment system into the active position of the actuator head. In some cases, provision is made between the actuator head and the housing for detent means which indicate to a user when the desired actuator system has adopted its correct position relative to the housing and a shaving or plucking operation can be started. Thereafter the actuator head can be moved into its rest position, which can also be done automatically by the apparatus itself after the apparatus is switched off. At the same time the actuator head is locked against rotation in order to prevent the actuator head from being turned accidentally during a hair treatment operation.
[0016] As another alternative for adjusting the actuator head it is possible to use for the actuator head an electrically driven adjusting unit which with each actuation of the switch for the adjusting unit turns the actuator head until the switch is switched off again. It is also conceivable for the electric adjusting unit to turn, with each actuation of the switch, the actuator head until the next actuator system is moved into its operating position. In this arrangement it is an advantage for the electric adjusting device to include an electrically driven motor which is arranged in addition to the cutting system and turns, via a transmission device, the actuator head into the desired active position.
[0017] In some implementations, the transmission device includes a gearwheel arrangement between the drive motor and the actuator head, whereby the bearing journal can then be constructed simultaneously as a gearwheel which is coupled via a gearwheel connected to the drive shaft of the drive motor. However, it is also conceivable to provide a toothed belt that connects the drive shaft of the electric motor to the bearing journal. Also possible are transmission belts or other transmission units for transmitting the torques. It is also conceivable for the drive motor to be coupled directly to the journal of the actuator head in order to dispense entirely with the transmission device.
[0018] In some implementations, rotation of the actuator head by the additional electric drive mechanism is variable such that the optimum accessibility of the actuator face to the corresponding skin region can be set for each individual user. For this purpose an electric switch is switched on and off in order to attain in small steps the optimum actuator position for the corresponding skin surface.
[0019] In certain embodiments, the actuator head is turned back, by means of the electric adjusting device for the actuator head, into its correct position if during the hair treatment operation it leaves its optimum position due to overloading.
[0020] In some embodiments, the actuator system includes a short-hair cutter and a long-hair cutter. Preferably, the short-hair cutter and the long-hair cutter are arranged in diametrically opposite positions on the circumference of the actuator head. In this embodiment there remains sufficient space in the actuator head for accommodating the drive mechanisms of the two cutting systems.
[0021] In some implementations, there results between the two systems on the circumferential surface of the actuator head a free space that can serve as a rest for the hair treatment apparatus and thus protects the cutting systems from external impacts or influences. Of course, other combinations of actuator systems on the actuator head are possible such as any combinations of long-hair cutter, medium-hair cutter, short-hair cutter, beard trimmer, epilators, etc. In addition it is possible to construct on the actuator head another guard surface that assumes the rest position of the hair treatment apparatus and protects the cutting systems from external influences when the hair treatment apparatus is not in use. The rest position can also be an advantage in particular when the hair treatment apparatus is inserted in a cleaning center for cleaning the actuator head; by providing one or more slits in the guard surface they could then be used as inlets and outlets for the cleaning fluid.
[0022] It is also possible for a hair removal apparatus to have an actuator head on which an epilator in addition to a long-hair cutter and short-hair cutter is provided on the actuator head.
[0023] In some cases, a drive mechanism for the actuator head is provided. The drive mechanism can include a linear motor that is accommodated in the interior of the actuator head. Compared to conventional rotary electric motors, linear motors have the advantage of dispensing with transmission devices and of being able to transmit the oscillating movement directly onto the actuator system. Such linear motors can be well integrated in the actuator head because they can be built to particularly small dimensions.
[0024] In certain implementations, a water-tight linear motor is disclosed which is particularly easy to manufacture and mounted on both side walls of the actuator head in oscillatory manner. Preferably on a hair cutting system, the linear motor sets the system in oscillation such that the under cutter moves relative to the outer cutter or the blade block moves relative to the shaving foil in order thus to be able to cut off hairs that penetrate between the cutting edges. It will be understood, of course, that the drive mechanism could also be used on epilators.
[0025] Two embodiments of the present invention are illustrated in the accompanying drawings and will be described in more detail in the following.
DESCRIPTION OF DRAWINGS
[0026] FIG. 1 is a schematic representation of a hair removal apparatus, preferably a shaving apparatus on a reduced scale, on which the actuator head is movably mounted with both its end faces in the housing, the view looking into the interior of the housing;
[0027] FIG. 2 is a partial plan view of the front side of the hair removal apparatus of FIG. 1 ;
[0028] FIG. 3 is a perspective front view of a second embodiment of a hair removal apparatus, here preferably a shaving apparatus, showing the apparatus on an enlarged scale and, unlike in FIGS. 1 and 2 , the actuator head movably mounted on the housing with only one end;
[0029] FIG. 4 is a view of the hair removal apparatus of FIG. 3 , showing the housing partially cut-away and components of the actuator head drive mechanism in a schematic representation;
[0030] FIG. 5 is a perspective partial view of part of the housing and the entire actuator head of FIGS. 3 and 4 , with the actuator head having been turned about its axis of rotation such that a second cutting system, namely a long-hair cutter, has been moved into the active position in lieu of the cutting system occupying the active position in FIGS. 3 and 4 ;
[0031] FIG. 6 is a perspective view, in the direction X of FIG. 5 , of the upper part of the hair treatment apparatus in the region of the actuator head, the side view in the direction X being of that side of the actuator head that is not movably mounted on the housing;
[0032] FIG. 7 is a plan view on a reduced scale from obliquely above the actuator head as seen looking from the mounting end of FIG. 5 , with the actuator head having been turned into its cleaning position where it can be held under a water faucet (schematically shown above) for cleaning purposes;
[0033] FIG. 8 is a perspective view of the actuator head itself, according to FIGS. 3 to 7 , but in the demounted state and on an enlarged scale; and
[0034] FIG. 9 is a schematic sectional representation of a linear motor that can be integrated, for example, in the interior of the actuator head shown in FIGS. 3 to 8 .
DETAILED DESCRIPTION
[0035] The hair treatment apparatus 1 schematically presented as a shaving apparatus in FIGS. 1 and 2 includes a housing 2 having on its upper side 3 a respective bearing arm 4 , 5 extending upwardly on the edges of the housing 2 , thus forming between said arms a receptacle 6 that serves to accommodate an actuator head 7 , in this case a shaving head. The actuator head 7 is rotatably mounted via bearing journals 73 , 74 on the bearing arms 4 , 5 . The center line of the bearing journals 73 , 74 forms the shared bearing axis 8 , which is the axis of rotation of the actuator head 7 . The bearing axis 8 extends perpendicular to the longitudinal dimension of the housing 2 , i.e., horizontally according to FIGS. 1 and 2 . The actuator head 7 is freely rotatable, meaning rotatable through 360°, in the housing 2 .
[0036] Arranged circumferentially on the actuator head 7 are two actuator systems 9 , 10 , whereof, for example, the first actuator system 9 can be a long-hair cutter and the second actuator system 10 a short-hair cutter. In FIGS. 1 and 2 the first actuator system 9 , namely the long-hair cutter, is in its active plane 22 . In this case the long-hair cutter occupies a position in which it can be optimally moved against a user's skin surface. Long hairs can be particularly well cut in this position.
[0037] In FIG. 1 the housing 2 is shown partially cut-away to expose the interior of the housing. Evident in schematic form in the housing 2 is a first drive motor 11 that drives, via a drive shaft 12 , a gearwheel 75 that is rotationally connected, via a toothed belt 46 , to a rotary gearwheel 76 in the right-hand bearing arm 5 , which gearwheel drives a shaving system constructed in the shaving head 7 in order to drive both the long-hair cutter 9 and the short-hair cutter 10 . The bearing axis of the output-side gearwheel 76 extends concentrically within the bearing journal 74 , which is constructed as a hollow shaft. The drive motor 11 can be switched on and off via an On/Off switch ( FIG. 2 ).
[0038] In FIG. 1 the housing 2 accommodates above the drive motor 11 another drive motor 14 that drives, via its drive shaft 15 , a drive pinion 77 that for its part drives, via a toothed belt 16 , a gearwheel 78 arranged centrically to the bearing axis 8 and rotatably mounted in the left-hand bearing arm 4 , said gearwheel 78 being non-rotatably connected, via the bearing journal 73 , to the actuator head 7 and rotating said actuator head into the corresponding active plane 22 in accordance with the desired cutting position. Provided on the outside of the housing 2 is a switching device 17 ( FIG. 2 ) whose actuating button 18 can be moved either into the short-hair cutting position 19 or into the long-hair cutting position 20 . The off position 21 can be used, for example, to turn the actuator head 7 about its axis of rotation 8 until both cutting systems 9 , 10 are turned into a protected position in the receptacle 6 and instead a rest region on the actuator head 7 arrives in the active plane 22 , said rest region serving to intercept external mechanical influences acting on the actuator head in order thus to protect the cutting systems 9 , 10 from damage.
[0039] Because the shaving head 7 of FIGS. 1 and 2 has both its ends rotatably mounted on the bearing arms 4 , 5 via its axis of rotation 8 , it can also transfer the transverse forces, which act on the shaving head 7 during a shaving operation, evenly to the housing 2 . Integrated as actuator systems in the actuator head 7 there can also be an epilating arrangement for plucking the hairs as well as a long-hair cutting arrangement or a short-hair cutting arrangement, all of which are driven by one and the same drive motor 11 .
[0040] According to FIGS. 3 to 7 , the actuator head 7 shown here as a shaving head has only one of its ends mounted on a left-hand bearing arm 4 and is likewise freely rotatable, meaning rotatable through an angle of 360°. By virtue of the overhung mounting of the actuator head 7 of FIGS. 3 to 7 , said head can be used in particular on hard-to-reach areas of skin in that the region of the actuator system 10 in the vicinity of the free end of the actuator head 7 is guided into the skin depressions.
[0041] To avoid repetitions, like reference numerals are selected as a rule in FIGS. 3 to 8 for correspondingly like elements of FIGS. 1 and 2 .
[0042] In FIGS. 3 to 8 the actuator head 7 includes a shaving head, which could be replaced however by an epilator head with an integrated shaving part.
[0043] In FIG. 3 the shaving head 7 has adopted the position which corresponds to the active plane 22 of the short-hair cutter 10 and of an integrated center cutter 23 . The short-hair cutter 10 includes two outwardly curved shaving foils 24 , 25 which extend in longitudinal direction parallel to the axis of rotation 8 , underneath each of which an associated under cutter is reciprocated in oscillating fashion. The same applies analogously also for the center cutter 23 . The active position of the short-hair cutter 10 and the center cutter 23 is selected such that when the active plane 22 touches a user's skin surface, the housing 2 stands off obliquely or perpendicularly outwards from the skin surface and therefore is no hindrance during the shaving operation.
[0044] The shaving head 7 can be moved about its axis of rotation or bearing axis 8 either by hand or electrically, as becomes apparent from FIG. 4 . If the shaving head 7 is turned about its axis of rotation 8 by hand, then it is advantageous for detent means provided between the shaving head 7 and the bearing arm 4 to lock the shaving head 7 in place as soon as the short-hair cutter 10 or the long-hair cutter 26 ( FIG. 5 ) has reached the active plane 22 . The detent means can be, for example, a spring-loaded ball that lockingly engages into a depression provided on the end face 27 . Hence two depressions would be needed on the shaving head 7 for two actuator systems.
[0045] According to FIG. 8 the shaving head 7 is rotatably mounted, via a centrally projecting bearing journal 28 on the left-hand end face 27 , in a mating bore formed in the bearing arm 4 , whereby the actuator head 7 , in this case a shaving head, can be turned according to FIG. 6 in both directions of rotation 29 , 30 . Constructed circumferentially on the bearing journal 28 is a groove 31 that serves to fixedly locate the journal in its mating bore on the bearing arm 4 . For this purpose it is possible preferably for a spring-loaded lock ring to be fastened in an annular groove in the mating bore so that when the bearing journal is inserted into the mating bore, said lock ring engages in the groove 31 , thereby supporting the shaving head 7 such that it is fixedly located on the bearing arm 4 but is free to rotate about the axis of rotation 8 .
[0046] As the shaving apparatus 1 of FIG. 4 shows, the interior of the housing 2 accommodates an electrically driven drive motor 14 that is connected via electric leads to the switch for turning the actuator head 7 into the active position of the short-hair or long-hair cutting system 19 , 20 and is adapted to be coupled via further electric connections to a storage battery 32 provided in the housing 2 . The storage battery 32 is electrically controlled by a printed circuit board 33 .
[0047] According to FIG. 4 the drive motor 14 is rotationally connected via a transmission device 34 to the bearing journal 28 of the actuator head 7 . In this arrangement the transmission device 34 includes several meshing gearwheels 35 , whereby the output-side wheel 36 serves as a belt drive and thus drives a belt 70 . The belt 70 is connected to a gearwheel 37 formed on the bearing journal 28 . At this point it should be noted that the teeth formed on the belt 37 on the inside and the teeth formed on the circumference of the wheel 36 are not shown in the drawing for the sake of simplicity. However, in FIG. 4 the gearwheel formed on the bearing journal 28 is shown in the drawing whereas in FIG. 8 it is shown for the sake of simplicity simply as a groove but of course it also has teeth the same as in FIG. 4 .
[0048] In FIG. 4 there is also fastened to a mounting plate 39 in the bearing arm 4 an electrically driven position detector 38 that registers with windows 40 provided in the end face 78 and evenly distributed over the circumference in order to stop the electrically driven drive motor 14 via electric leads when the desired actuator system 9 , 10 is in the correct actuator or active plane 22 .
[0049] In FIG. 7 the actuator head 7 is shown turned to the point where a cleaning opening 41 is accessible from above so that water (represented by a droplet 42 ) can be filled into the actuator head 7 . A water faucet 43 symbolizes the source of cleaning fluid.
[0050] Illustrated in FIG. 9 is finally another electric drive mechanism 79 that includes a linear drive motor 44 . This linear drive motor 44 is also suitable, for example, for installing in the actuator head 7 of the shaving apparatus of FIGS. 3 to 8 , whereby the shaded rectangles to the right and left of the linear drive motor 44 of FIG. 9 represent parts of the two side walls 47 , 48 of the actuator head 7 that carry the linear drive motor 44 , hereinafter referred to only as linear motor.
[0051] According to FIG. 9 the linear motor 44 is comprised essentially of a stator frame 49 , which is constructed in the shape of a box and closed to be watertight, with external spring elements 50 , 51 similar to leaf springs being fastened to both sides of the frame to serve as oscillating bridges. The spring elements 50 , 51 have their other ends securely connected to the side walls 47 , 48 of the actuator head 7 . In this way the stator frame 49 can oscillate to and fro in the horizontal direction according to the arrows 52 , 53 . The external spring elements 50 , 51 can be manufactured preferably from metal and can simultaneously provide the power supply for the linear motor 44 . Fastened to the bottom of the stator frame 49 is a stator 55 with magnets 56 mounted on the upper side.
[0052] Extending upwards on the side walls of the stator 55 are respectively one oscillating spring 57 , 58 , said springs being connected with each other via a coil core 59 . Extending downwards from the coil core 59 are two adjacent cylindrical core sections 60 , 61 , which are encompassed by respectively one annular coil 62 , 63 . The free ends of the core sections 60 , 61 end a short distance from the magnets 56 on the stator 55 , thus defining a predetermined gap S. The core sections 60 , 61 are arranged such that each is arranged between a north pole and a south pole of the magnet 56 . The north pole is indicated with N and the south pole with S in FIG. 9 .
[0053] On the one hand the leaf springs 57 , 58 of FIG. 9 establish the predetermined gap S and on the other hand they form the oscillating springs that are necessary for the resonance operating mode. However, the leaf springs 57 , 58 could also be separate elements, such as for example compression springs, which can be inserted between the stator 55 and the core sections 60 , 61 .
[0054] The mode of operation of the shaving apparatus 1 of FIGS. 1 and 2 is as follows:
[0055] First a user must decide whether he wants to use the short-hair cutting system 10 or the long-hair cutting system 9 . If he wants to use the short-hair cutting system 10 , then he sets the actuating button 18 to the position “Kurz” (short) 19 . The drive motor 14 now switches on and rotates the drive belt 16 and hence the actuator head, in this case opposite to the direction of rotation, about the axis of rotation 8 until the short-hair cutting system 10 has reached the active plane 22 . To reach this position the drive motor 14 could be a stepper motor that is turned by an electronic control device.
[0056] It is also conceivable, however, for a sensor device to be provided between the bearing arm 4 and the actuator head 7 , such as becomes apparent from FIG. 4 . On a standard shaving head 7 it is possible as a rule to select among only three positions, namely the fine shave position, the long shave position and the rest position, hence three markings corresponding to these positions can be provided on the actuator head 7 such that the sensor detects and selects them according to the desired actuator system and stops upon reaching the optimum shaving position. The active plane 22 is the plane which with regard to the housing 2 represents the optimum shaving plane of the actuator head 7 relative to the housing 2 . In this position a user's hand also adopts an optimum position relative to the housing 2 and a user's skin surface. The switch 13 can now be switched on and the short-hair cutting system 10 will be driven.
[0057] If, after the short-hair shave, a user would now like to cut for example his sideburns, then he must first push the actuating button 18 into the long-hair cutting position 20 . For this purpose the switch 18 is moved into the “Lang” (long) position 20 . The drive motor 14 now turns, via the transmission device 16 , the actuator head 7 until the long-hair cutter 9 has reached the active plane 22 . The sideburns can now be cut by moving the switch 13 into the On-position. The drive motor 11 now turns, via the transmission device 15 , 77 , 16 , 78 , 73 , the shaving system provided in the actuator head 7 . This applies similarly for switching on the short-hair cutting system, as was previously mentioned.
[0058] If the user now wants to put down the shaving apparatus 1 , the actuating button 18 is switched to the Off-position 21 and the drive motor 14 turns, via the transmission device 16 , the actuator head 7 about the longitudinal axis 8 until both shaving systems 9 , 10 are concealed in the receptacle 6 and therefore cannot be damaged. This is possible, when both shaving systems lie close together in order to be protected in the receptacle 6 .
[0059] The mode of operation of the shaving apparatus of FIGS. 3 to 9 is as follows:
[0060] Here too the user first decides which cutting system 19 , 20 he wants to use. If the short-hair cutting system 10 (System 1 ) is to be used first, then there is no need to actuate the short-hair cutter button 19 because the shaving apparatus 1 of FIGS. 3 and 4 has already adopted this position, i.e., the two short-hair cutters 10 , which extend side by side and parallel with each other, and the center cutter 23 arranged in between are already in the active plane 22 . The apparatus can now be switched on via the On/Off switch 13 , and the electronic controller on the printed circuit board 33 controls via power connections, not shown in the drawing, the linear motor 44 provided in the actuator head 7 . Through the magnetic excitation of the coil core 59 and the core sections 60 , 61 integrally formed therewith, by the coil 62 , 63 , there develops on the core sections 60 , 61 an alternating magnetic field that causes said sections to oscillate relative to the stator 55 .
[0061] As the arrows 52 and 53 in FIG. 9 show, the core sections 60 , 61 oscillate in opposite direction of the stator 55 , whereby the stator frame 49 is set in oscillation by the acceleration forces, said motion being promoted by the spring elements 50 , 51 . The oscillating motion of the stator frame 49 is transmitted via the spring 64 onto the moving part 65 (blade block), which thus produces the shaving motion relative to the stationary part (shaving foil). A user can now slide the short-hair cutter 10 across the skin surface and cut off very fine hairs in the process.
[0062] The drive of the linear motor 44 operates in oscillating fashion at very high short-stroke frequencies, with the entire linear motor 44 being embedded completely watertight in the stator frame 49 . The actual oscillating shaving parts are arranged outside the stator frame 49 and as such can easily be cleaned with water without water being able to penetrate into the internal space 67 of the linear motor 44 . It will be understood, of course, that it is possible, instead of coupling the shaving parts 65 , 66 to the stator frame 49 , to couple different types of drive elements directly and without sealing to various locations. Such drive elements can be, for example, long-hair cutters, short-hair cutters, center cutters and other actuator systems that can be driven via oscillating movements.
[0063] If the user now wants to cut sideburns or head hair profiles, then according to FIG. 5 he must move the long-hair cutting system 26 into the active plane 22 . This is done by actuating the actuating button 20 for the long-hair cutting system (System 2 ). Using electric control means, the drive motor 14 is now set in rotation and for its part turns, via gearwheels 35 , 36 , 37 and the toothed belt 70 , the actuator head 7 about its axis of rotation 8 until the long-hair cutter 26 has reached the active plane 22 ( FIG. 5 ). In this position, a position detector 38 sends an electric signal to the electronic components on the printed circuit board 33 so that the drive motor 14 switches off. To determine the correct position of the actuator head 7 , windows 40 are evenly distributed over the circumference on the side wall 47 through which the position detector 38 detects the desired position of the actuator head 7 and then switches off the electric motor 14 . The switch 13 can now be switched on again and the long-hair cutting system 26 is driven and profiles can be cut.
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A hair removal apparatus with a housing and an actuator head movable in the housing. The actuator head accommodates an actuator system that removes the hairs and is adapted to be driven by an electric drive mechanism arranged in the hair removal apparatus. The actuator system is movable into at least one active position for hair treatment. According to the invention, the actuator head is freely rotatable in the housing about an axis of rotation for adjustment of an active position. Using a single hair removal apparatus it is thus possible to employ various hair treatment systems such as long-hair cutter, short-hair cutter, or epilator, requiring only the actuator head to be turned about its bearing axis until the cutting unit provided for the respective hair treatment operation is turned into the actuator plane. Since several hair treatment operations can be performed with just one apparatus, manufacturing costs can be reduced.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to Ser. No. 08/377,732, filed Jan. 25, 1995, now abandoned and Ser. No. 08/489,729 filed Jun. 13, 1995.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a hand-held optical reader comprising a reader module and a terminal module in particular for reading an indicia such as a bar code symbol.
2. Description of the Related Art
Various readers and optical scanning systems have been developed for reading printed indicia such as bar code symbols appearing on a label or the surface of an article and providing information concerning the article such as the price or nature of the article. The bar code symbol itself is a coded pattern of indicia comprised of, for example, a series of bars of various widths spaced apart from one another to form spaces of various widths, the bars and spaces having different light reflecting characteristics. The readers electro-optically transform the graphic indicia into electrical signals which are decoded into alpha-numeric characters that are intended to be descriptive of the article or a characteristic thereof. Such characters typically are represented in digital form, and utilized as an input to a data processing system for applications in point of sale processing, inventory control and the like.
Known scanning systems comprise a light source for generating a light beam incident on a bar code symbol and a light receiver for receiving the reflected light and decoding the information contained in the bar code symbol accordingly. The readers may comprise a flying spot scanning system wherein the light beam is scanned rapidly across a bar code symbol to be read or a fixed field of view reading system wherein the bar code symbol to be read is illuminated as a whole and a CCD (Charge Coupled Device) array is provided for detecting the light reflected from the bar code symbol. The reader may be either a hand-held device or a surface-mounted fixed terminal.
The information decoded by the reader is down-loaded to a processor which stores and/or processes the information as appropriate. For example where the reader is used at a point of sale price information relating to the product is retrieved. Information relating to the product may also be forwarded to a database for assessing buying patterns and/or demand for the product as well as other applications that will be evident to the skilled man. Similarly in inventorying applications, the data relating to the product must be processed appropriately. Generally at present the reader communicates with the processor via either a cable link or a wireless link.
It is desirable, however, in some cases for the user to be able to access and/or process information from the reader directly. At the same time it is desirable to provide a lightweight, easily held reader without the encumbrance of appropriate intermediate processing circuitry. The user may also wish to have the capability to modify the parameters of operation of the reader via an intermediate processor. For example the user may wish to reconfigure the bar code reader dependent on the bar code symbol standard appearing on products to be read, or change the reading mode from field of view reading mode to flying spot scanning mode.
In addition conventional optical readers require the user to maintain the grip on a handle of the reader or on a portion of the reader throughout the time that the reader is being used which can lead to discomfort to the user in the long term.
Commonly assigned herewith is a European Patent Application having Publication No. 0653722 which relates to an electro-optical system for reading indicia such as bar code symbols including a pivotal scanning head moveable between first and second reading positions and first and second trigger switches to actuate the scanning head dependent on whether it is in its first or second position.
U.S. Pat. No. 5,349,497 relates to a terminal and reader arrangement including a detachable handle which is moveable between various positions.
SUMMARY OF THE INVENTION
Objects of the Invention
It is an object of the present invention to provide an arrangement comprising an improvement over the prior art.
It is a further object to provide a reader allowing the user to access information read by the reader.
It is yet a further object of the invention to provide a reader allowing the user to alter parameters of operation of the reader.
It is a still further object of the invention to provide a reader which can be comfortably used by the user for long periods of time.
It is a further object to provide a reader of improved ergonomic design.
It is a further object to provide a reader having various different gripping modes.
Features of the Present Invention
According to the present invention there is provided an optical reader, comprising:
a reader module including an optical source for generating a reading beam;
an actuator provided on the reader module for actuating the reader module;
a terminal module releasably connectable to the reader module for communicating with the reader module, said terminal module receiving a portion of the reader module.
A detector for detecting the generating beam may be provided in the reader module or in the terminal module.
The reader may further comprise a keypad for user input to the reader. The keypad may be provided on the terminal module or on the reader module.
The reader may further comprise a visual display provided on the terminal module or on the reader module.
The reader may comprise a further main module carrying a keypad, the main module being connectable with the terminal module.
The terminal module may include a recess portion into which a corresponding portion of the reader module is inserted or the terminal module may include a central portion which overlies a corresponding face portion of the reader module and skirt portions overlying portions of adjoining faces of the reader module.
The reader module may be configured to be gripped as a whole in the palm of the hand of a user, rendering the module more comfortable to use over long periods of time.
The reader module may comprise a head portion and a handle portion and the terminal module may be connectable to the base end of the handle portion or to the portion of the handle which, in use, faces the user or to the head portion. In each case, the terminal module is connected so as to be simply and comfortably accessed by the user.
According to the invention there is further provided a field of view optical reader, comprising:
a reader module including an optical source for generating a reading beam;
an actuator provided on the reader module for actuating the reader module;
a terminal module releasably connectable to the reader module for communicating with the reader module, said terminal module receiving a portion of the reader module.
According to the present invention there is yet further provided a flying spot optical scanner, comprising:
a scanner module including an optical source for generating a scanning beam;
an actuator provided on the scanner module for actuating the scanner module;
a terminal module releasably connectable to the scanner module for communicating with the scanner module, said terminal module receiving a portion of the scanner module.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing objects and advantages of the present invention may be more readily understood by one skilled in the art with reference being had to the following detailed description of several preferred embodiments thereof, taken in conjunction with the accompanying drawings wherein like elements are designated by identical reference numerals throughout several views, and in which:
FIG. 1a is a perspective view of a first embodiment of an optical reader according to the present invention;
FIG. 1b is a perspective view of a detail of the reader of FIG. 1a;
FIG. 2 is a perspective view of a second embodiment of the invention;
FIG. 3 is a perspective view of a third embodiment of the invention;
FIG. 4 is a perspective view of a fourth embodiment of the invention;
FIG. 5 is a perspective view of a fifth embodiment of the invention;
FIG. 6 is a perspective view of a glove mounted reader according to the invention;
FIG. 7 is a perspective view of an alternative embodiment of the reader of FIG. 6;
FIG. 8 is a perspective view of a conventional bar code reader according to the prior art;
FIG. 9a is a top plan view of an alternative embodiment of the invention;
FIG. 9b is a side elevational view of the embodiment of FIG. 9a;
FIG. 9c is a bottom plan view of the embodiment of FIG. 9a;
FIG. 9d is a front elevational view of the embodiment of FIG. 9a;
FIG. 9e is a sectional view taken along line A--A of FIG. 9c;
FIG. 10a is a side elevational view of the embodiment of FIGS. 9a to 9e in a different gripping mode arrangement;
FIG. 10b is a bottom plan view of the arrangement shown in FIG. 10a; and
FIG. 10c is a front elevational view of the arrangement shown in FIG. 10a.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 8 illustrates a typical bar code reader according to the prior art. The reader comprises a hand-held laser scanner, generally indicated at 700, having a main body 535 including a graspable hand portion 536 which carries a trigger 539. Within the body 535 is a laser module 515 (not shown in detail). Light from the laser module 515 is arranged to shine onto an oscillating mirror provided in the body 535. The resultant reflected beam passes through a lens, and out of the housing via a window 538. The mirror is arranged to oscillate in such a way that the beam traces out a scan line 513 across a bar code 600 to be read. In the example shown in FIG. 8, the bar code 600 is a linear bar code, but it will of course be appreciated that the scanner could instead be arranged to read two-dimensional bar codes: in such a case the mirror would be controlled to produce a raster scan rather than a single line scan. Rather than using an oscillating mirror, the laser module itself could be oscillated to form the scan line 513.
Light reflected back from the bar code 600 passes through the window 538 and is collected by a collecting mirror, from where it is reflected back to a photodetector. The optical signal is then converted into an electrical signal, and the features of the bar code symbol 600 determined.
Considering now the embodiment according to this invention shown in FIG. 1a, there is shown a hand-held optical reader including a reader module 1 and a terminal module 2. The reader module includes a reading window 3, a reading beam source 4 and a detector 5 (all shown generally internal to the reader module). The reader is actuated by a trigger 6 causing the source 4 to generate a beam 7 which is transmitted through the window 3, impinges on a bar code symbol 8 and is reflected back through window 3 and detected by detector 5. The scanner may include a preliminary processing means which controls operation of the beam source 4 and detector 5 on actuation of the trigger 6 and preprocesses information from the detector 5. The preprocessing unit is shown generally as 9 within the module housing. The processor is connected to an interface shown generally as 10 for down-loading information to an external processor and/or receiving information from such an external processor.
In prior art arrangements the interface 10 has comprised either a connector to a physical cable to an external processor or a wireless communication link using infrared, radio frequency or other means of wireless communication. Such an arrangement is inconvenient or inappropriate, however, where the user wishes to access information received from the reader or modify operation of the reader. Accordingly, in the present invention, a terminal module 2 is provided. The interface 10 of module 1 comprises a pin-type or other suitable type connector provided on an outer surface of the module 1. A pin-type interface is shown in FIG. 1b. A corresponding connector is provided on the terminal module 2 such that when the reader module 1 and terminal module 2 are connected an interface is formed allowing the communication of information between the modules.
It is desirable for the reader module to be as lightweight and simple as possible and hence the shape of the terminal module 2 is configured appropriately to interconnect on, around or with the module 1 such that the shape of the module 1 is affected as little as possible. In fact other than the pins at the interface 10, the shape of the reader module 1 may be configured solely with the comfort and convenience of the user in mind. The primary purpose of the apparatus as a reader is thus not affected, and when the terminal is not attached optimum use of the reader module itself can be achieved.
In the embodiment shown the terminal module 2 includes a recess 11 into which the lower portion of the reader module 1 is inserted. The interface pins on the terminal module 2 are provided at an appropriate location in the recess 11 for connection with the interface 10 of the reader module 1. As will be seen, by virtue of the positioning of the terminal at the base of the arrangement the terminal may be easily operated by the user while still holding the reader module 1 in an operation position. Suitable gripping means can be provided on the terminal module 2 for holding the reader module in place, for example a resilient rubber sleeve or suitable detent means. It will be seen that, once again, the shape of the reader module 1 itself is affected as little as possible.
The terminal module 2 includes a keypad 12 allowing the user to enter information into the reader module 1 to alter its mode of operation. The keypad may also be used to retrieve or access information processed by the reader module 1. A display is preferably provided on the terminal module 2 to assist the user in selecting various options, reviewing information and so forth. The display can be, for example, an LCD display provided on the terminal module either above or below the keypad 12. The display is not shown in FIG. 1a. Alternatively the display could be provided on the reader module 1, for example on the rear face facing the user, allowing the user to view the display with minimum difficulty.
An interface designated generally as 13 is provided on the terminal module 2 allowing communication of the terminal module 2 with a host processor either by a physical or cable link or by wireless communication in a similar manner to interface 10 discussed above. It will be appreciated that the terminal module 2 will include suitable processing means for processing information to and from the reader module 1.
Referring now to FIG. 2 a reader module 1 is inserted into a recess 11 of a terminal module 2 as discussed in FIG. 1a. Like reference numerals designate like parts. In the embodiment shown in FIG. 2, however, the distribution of various elements has been altered. In particular the keypad 12 is found on the handle portion of the reader module itself, on the rear face to allow improved access by the user. In addition a display 14 is provided on an upper surface of the terminal module 2. Communication between the various parts is carried by the interface between the modules. By using the surface of the reader module 1 in this manner a more compact terminal module can be arrived at rendering the combined system as a whole yet more compact and attractive to the user.
The reader module 1 shown in FIG. 3 is of a different configuration to that shown in FIGS. 1a and 2. In particular the reader module 1 does not include a handle portion but is designed such that the module 1 as a whole is gripped in the palm of the hand of the user. A trigger 6 is provided for actuation by the user's thumb. A more compact and ergonomically desirable reader is thus provided. The terminal module 2 is then shaped as a "shield" fitting over an upper portion of the reader module 1 and connecting with a suitably positioned interface 10 of the module 1 (not shown) in the manner discussed above. Once again, therefore, the shape of the reader module 1 itself is substantially unaffected allowing its design to be arrived at solely on the basis of comfort and convenience for the user in its principal operation as an optical reader. In addition, because of the corresponding shape of the terminal module 2, which is designed to overlie the upper rear portion of the module 1 with skirt portions of the terminal module 2 wrapping around side portions of the module 1, the ergonomic features of the system as a whole are retained. In particular the terminal module 2 includes on its upper face a keyboard 12 and a display 14 which are easily accessed by the user with the other hand not gripping the system as a whole.
In FIG. 4 yet a further alternative is shown. In this case the terminal module 2 is mounted on an upper portion of the reader module 1. The terminal module may, for example, overlie the upper portion of the reader module 1 and partially encapsulate the reader module 1, such that once again the shape of the reader module 1 need not be designed with interfacing needs in mind. It can be seen that user access to the keyboard 12 and display screen 14 are optimized for comfort and convenience by locating those elements on the upper face of the terminal module 2. In one embodiment the light beam generating source and window are provided in the reader module 1 and a further window 15 and detector 16 are provided in the terminal module, thus reducing the amount of circuitry and components required in the reader module.
The further alternative embodiment shown in FIG. 5 includes a reader module 1 inserted in the manner discussed above into terminal module 2 which includes an intermediate processor means. The terminal module 2 further includes a display screen 14 allowing the user to view information retrieved from the reader module 1. The reader module 1 and terminal module 2 are further insertable into a main module 20 via an interface component in the terminal module and corresponding connector in the main module 20 which interacts in much the same manner as the interface between modules 1 and 2. The main module 20 includes a keypad 12 allowing the user to input or retrieve information as appropriate. The main module 20 further includes an interface 21 for connection with a host terminal via a physical wired link or wireless communication. Alternatively the module 20 can comprise an integral part of a host processor.
It will be appreciated that features of the embodiments discussed above can be interchanged as appropriate to obtain variations and modifications not explicitly described herein.
In another aspect the invention relates to an optical reader which is worn on the hand of a user, thus allowing the user great mobility and removing the need for the user to grip the bar code reader at all times. In particular, as shown in FIGS. 6 and 7, the reader can be provided in a glove 30 to be worn by the user. The glove 30 includes a keypad 31 and a display 32 allowing the user to input and retrieve information from the reader. The glove further includes a flexible battery element 33 mounted around the wrist portion and a flexible film circuit computer 34 also mounted around the wrist portion. Of course those components may be provided elsewhere in the glove. Wiring between the various components can pass within the fabric of the glove itself.
The glove further includes a reader actuator 35 provided on the forefinger of the glove allowing a simple actuation by the user with the user's thumb. In a first arrangement, the scanner and receiver can be provided in an appropriate portion of the glove, for example at the knuckle portions or in the finger end portions allowing the user to simply direct his hand, or point his finger towards a symbol to be read. The reader is then actuated by operating the thumb actuator 35. Information from the reader can be down-loaded to a host processor using any suitable interface, intermediate processing and reviewing of the information being carried out using the keypad 31 and display 32.
In an alternative embodiment the glove corresponds to the terminal module described in relation to the preceding figures and a suitable interface is provided on the glove for connection with a corresponding interface on a separate reader module. In that case the keypad 31 and the display 32 can be easily and efficiently manipulated by one hand of the user while the reader module is held in the other, glove-bearing hand. The design is thus yet further ergonomically improved while minimal alterations or compromises of the shape of the reader module are required.
In a further alternative embodiment shown in FIG. 7 in which like reference numerals designate like parts the keypad 31 and the display 32 are provided on the palm of the glove rather than the back of the glove as shown in FIG. 6.
It will be appreciated that the readers discussed above can be either field of view or flying spot readers and can be configured to optically read any appropriate indicia including bar code symbols.
According to a further aspect of the invention a two-piece optical reader comprises, as shown in FIGS. 9a to 9e a reader portion 50 and a palm grip portion 51. The reader portion 50 includes a "fish eye", scan head 52 which is rotatable from the position shown in FIG. 9a pointing substantially leftwards as viewed on the page to the complementary position pointing substantially rightwards as viewed on the page. The reader portion 50 further includes a display screen such as an LCD screen 53 for displaying options and/or information as discussed above. The display screen 53 can be a touch-sensitive screen for the input of information and instructions or a separate keypad (not shown) may be provided. The reader as a whole is designed to be held in the palm of the user's hand, as discussed in more detail below, the display screen 53 is located on an upper face of the reader portion 50 so that the user can view the screen instantly when holding the reader in the user's palm, and the scanning head 52 is provided at the forward end so as to point outwards and away from the user when the reader is held in the user's palm.
When viewed from above the upper face of the reader portion 50 is of substantially oval profile so as to fit comfortably in the user's palm. The front end portion, in the vicinity of the scan head 52 is reduced to a circle segment shape giving the reader portion 50 profile as a whole an egg shape.
Referring now to FIG. 9b the spherical nature of the fish eye scanner head can be clearly seen. The front end face from which the scanner head 52 projects and the upper face, when viewed from the side are substantially square and the reader portion 50 as a whole is substantially L-shaped with the longer limb running parallel to the upper face and having a stepped profile towards the rear end of the upper face. The palm grip portion 51 is attached to the reader portion 50, fitting against the base of the reader portion 50 so as to complement the L-shaped profile. The palm grip portion 51 is slightly bulbous so as to fit yet more comfortably in the user's palm.
As can best be seen in FIG. 9c the underside of the reader includes various operating/actuating elements provided both on the palm grip portion 51 and on the reader portion 50. In particular a pair of triggers 54a, 54bare provided at the frontward portion of the palm grip portion 51. Accordingly the reader can be used in either hand of the user simply by ensuring that the scanning head 52 is pointed in an appropriate direction, in which case the appropriate trigger, either 54a or 54b can be used. The palm grip portion further includes optional features such as cursor buttons 55a, 55b (also positioned by the side of the palm grip portion for use in either hand by the user) for controlling parameters of the display, for example, and a mouse key 56 provided between the trigger and cursor buttons. The palm grip portion 51 further includes a strap slot 57 into which a strap can be inserted for wrapping around a user's wrist for added security. The palm grip portion further includes textured grip portions 58 for improving the user's hold. The palm grip portion may be formed partially of, or include a cover of moulded rubber or other material suitable for comfortable and long-term gripping by the user.
Provided on the lower face of the reader portion is a stabilizing rib and power contacts 60 allowing connection with a external power source or a recharger for an internal power source. There is further provided an interface means such as an infrared transfer 61 for communication with an external terminal.
In addition a speaker hole can be provided allowing the user to issue vocal commands. The speaker hole may be, for example, provided on the upper face of the reader portion 62. Status indicators such as LED's can be provided to indicate the operational status of the reader, battery status and so forth at 63 on the upper face. Additional front face buttons can also be provided on the upper face or elsewhere for allowing control of various options, for example transfer of the reader from left handed to right handed configuration. Front face buttons may be provided, for example, below the display screen on the upper face and may be provided symmetrically for left handed or right handed use. The front face buttons are not shown in the drawings.
FIG. 9d shows a view of the reader from the front in which the scanner head lens 64 can be viewed.
FIG. 9e is a cross-sectional view taken along line A-A of FIG. 9c, along the central longitudinal axis of the reader. As can be seen a latch mechanism 65 is shown for releasably attaching the palm grip portion 51 to the reader portion 50. The latch mechanism may be any suitable known type of latch mechanism, for example a resilient detent type mechanism.
FIGS. 10a to 10c show the reader of FIGS. 9a to 9e in an alternative gripping mode or configuration. The palm grip portion 51 has been removed by a suitable operation of the latch mechanism 65 and replaced by a handle portion 70. The handle portion 70 latches onto the reader portion 50 by means of a latching engagement identical to the palm grip portion latching mechanism 65 discussed above so that the gripping portions are immediately interchangeable.
The reader portion 50 is identical to that discussed in relation to FIGS. 9a to 9e and includes all of the same features. The handle portion projects downwardly at an obtuse angle to the reader portion 50 such that it may be comfortably gripped with the user's hand wrapped around it so as to facilitate aiming of the reader. The handle portion includes a trigger 71 suitably positioned for actuation by the user's fore-finger or other fingers.
Accordingly a single reader portion can be adapted for whatever mode of use is desired by the user--either palm-held use or handle-held use simply by attachment of the appropriate gripping portion. Such an arrangement is of particular benefit when the reader is intended for use in various different applications. For example when the reader is to be used in relation to easily accessible bar code symbols on items, the handle portion 70 can be attached and the user can simply point the reader in the gun-type gripping mode at the bar code symbols to be read. On the other hand, in some circumstances the bar code symbols will be positioned so as to be not easily accessible, such as when an inventorying operation is taking place in a warehouse. In that case the palm-held gripping mode can be adopted allowing the user more flexibility. Of course further types of gripping portion may be attached to the reader portion, dependent on the desired application.
Because of the configuration of the reader portion 50 further accessories may be mounted as appropriate. For example a light pen may be releasably attachable to the reader portion. The light pen may either lie alongside the display on the flat upper face of the reader portion or may be of curved profile and shaped to be mounted along a curved side of the reader portion.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can readily adapt to various applications without omitting features that, of the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of the invention and, therefore, such adaptions should and are intended to be compounded within the meaning and range of equivalents of the following claims.
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An electro-optical system for reading bar code symbols includes a reader module and a terminal module releasably interconnected to each other. The reader module includes a manually actuatable actuator to initiate the reading. Reading is initiated either when the modules are disconnected, or when the modules are interconnected, by manually actuating the actuator in both cases. A keyboard may be provided on either module to facilitate data entry.
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TECHNICAL FIELD
This disclosure relates to orthopedic implants. In particular, the disclosure relates to systems and methods of measuring wear of artificial knee joint replacements in vivo.
BACKGROUND
Total joint arthroplasty is an operation involving the replacement of a damaged joint with an artificial joint in order to restore motion to the joint and function to the muscles and ligaments and other soft tissue structures that operate and control the joint.
The operation is typically performed on individuals with a painful, disabling arthritic joint that is no longer responsive to conservative treatment regimens. This operation typically entails implantation of two or more artificial joint members into respective natural joint members to replace deteriorated natural articulating surfaces with artificial equivalents.
Artificial joint assemblies have been devised for a variety of joints including hips, knees, ankles, shoulders, elbows, fingers, toes and wrists. While artificial joint components are designed to provide stable and permanent attachment to the natural adjacent body tissue(s), at attachment interfaces, over time, the artificial joint can relocate, loosen and/or wear, which can lead to a loss of function, bone deterioration and tissue debris generation. An increase in wear to the articulating surfaces of the artificial joint typically results in reduced function of the artificial joint and, in addition, produces joint debris, which are expelled from the joint area to the surrounding tissues and may cause adverse reactions in these tissues. As wear of a joint progresses and larger amount of particles are expelled to the surrounding tissues, further bone absorption and loosening of the joint implant may occur. Such loosening of a prosthetic joint implant and damage to surrounding tissues is often left undetected in a patient even if regularly checked by a physician.
Most modern methods currently employed for determining the extent of wear of an artificial joint rely on X-ray imaging, computer tomography, isotope bone scans, magnetic resonance and the like to image the implanted joint. Known methods are known to have insufficient accuracy or are technically difficult to perform and/or interpret, even by highly skilled professionals. Most modern joint replacement assemblies incorporate metal backed plastic components, metallic components, or ceramic components within metallic shells and the available imaging methods cannot produce sufficient resolution in order to determine artificial joint loosening and/or articulating surface wear.
As a result of inefficient detection methods, oftentimes the only indication of early joint loosening is the pain and discomfort suffered by the patient. Bone absorption may progress to a stage necessitating replacement surgery using larger implants, and/or bone grafts to accommodate for the lost bone tissue. The prognosis for success and service life of the implant after such a corrective operation is less predictable and depends, among other factors, on the extent of bone absorption suffered. If performed relatively early on, such corrective surgery has an increased chance of success. Therefore, a method capable of detecting the extent and depth of wear of the articulating surfaces of an artificial joint, or a method that is capable of detecting minute displacement of artificial joint components, is important both to the patient and the treating physician. Also, a more exact understanding of the condition of the components of numerous joints through their lives can facilitate faster improvements to joint design for better performance and longer life. Typical life of an artificial joint now is 15 to 20 years. With such high precision in vivo measurements, joint like may be able to be increased to 25 years and more in a matter of years of developments rather than over decades.
It will be appreciated that this background description has been created to aid the reader, and is not to be taken as an indication that any of the indicated problems were themselves appreciated in the art. While the described principles can, in some respects and embodiments, alleviate the problems inherent in other systems, it will be appreciated that the scope of the protected innovation is defined by the attached claims, and not by the ability of any disclosed feature to solve any specific problem noted herein.
SUMMARY
In one aspect, the present disclosure describes a method of determining wear of an artificial knee assembly, the method including acquiring a first set of computed tomography data about the artificial knee assembly in vivo. A first volumetric artificial knee assembly file is generated based on the first set of computer tomography data. A first point cloud data set is generated based on the first volumetric artificial knee assembly file. A first dimensional analysis of the artificial knee assembly is performed using the first point cloud data set. A second volumetric artificial knee assembly file is generated based on a second set of acquired computed tomography data about the artificial knee assembly before implantation or acquiring the second volumetric artificial knee assembly file from a model. A second point cloud data set is generated based on the second volumetric artificial knee assembly file. A second dimensional analysis is performed using the second point cloud data set. The first dimensional analysis is compared to the second dimensional analysis. A determination is made if the first dimensional analysis is different from the second dimensional analysis an amount that exceeds a selected tolerance of the artificial knee assembly.
In another aspect, a system is disclosed for determining wear of an artificial knee assembly, including a CT x-ray machine configured to scan an artificial knee assembly in vivo and a computer system in communication with the CT x-ray machine. The computer system is configured to acquire a first set of computed tomography data about the artificial knee assembly in vivo, generate a first volumetric artificial knee assembly file based on the first set of computer tomography data, generate a first point cloud data set based on the first volumetric artificial knee assembly file and perform a first dimensional analysis of the artificial knee assembly using the first point cloud data set. The computer system is further configured to at least one of generate a second volumetric artificial knee assembly file based on a second set of acquired computed tomography data about the artificial knee assembly before implantation or acquire the second volumetric artificial knee assembly file from a model, generate a second point cloud data set based on the second volumetric artificial knee assembly file, perform a second dimensional analysis using the second point cloud data set, compare the first dimensional analysis to the second dimensional analysis, and determine if the first dimensional analysis is different from the second dimensional analysis an amount that exceeds a selected tolerance of the artificial knee assembly.
Further and alternative aspects and features of the disclosed principles will be appreciated from the following detailed description and the accompanying drawings. As will be appreciated, the principles related to determining wear of artificial joints as disclosed herein are capable of being carried out in other and different embodiments, and capable of being modified in various respects. Accordingly, it is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and do not restrict the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an expanded view of an embodiment of an artificial joint assembly.
FIG. 2 is a front view of the artificial joint assembly of FIG. 1 in vivo.
FIG. 3 is a front view of the artificial joint assembly in a holding fixture.
FIG. 4 is an embodiment of a system of measuring the initial, pre-implanted dimensions of an artificial knee joint assembly.
FIG. 5 is an embodiment of a system of measuring the dimensions of an artificial knee joint assembly in vivo.
FIG. 6 is a flowchart illustrating an embodiment of a method of determining wear of an artificial knee assembly.
DETAILED DESCRIPTION
FIG. 1 shows an exploded view of a conventional artificial knee joint assembly 24 including a femoral component 30 , a tibial tray 32 , and a spacer or insert plate 34 positioned between the femoral component 30 and the tibial tray 32 . The femoral component 30 is a rounded, cup-shaped component that may be made of metallic or ceramic materials. The insert plate 34 includes an upper slide surface 36 , which is shaped and sized to movably receive the femoral component 30 . The slide surface 36 permits articulation of the femoral component 30 on the insert plate 34 while supporting the motion of the femoral component by discouraging misalignment or displacement of the components. For clarity, a patellar component is not shown in this disclosure.
The insert plate 34 may be made of any suitable bearing material such as polyethylene. An upper surface or tray part 38 of the tibial tray 32 receives the insert plate 34 . The tibial tray 32 also includes an anchor part 40 extending from the tray part and may be made of metallic or ceramic materials.
FIG. 2 shows the artificial knee joint assembly 24 in vivo, with the soft tissue omitted for clarity, and with the femoral component 30 fixed onto a distal portion of a femur 42 . The tibial tray 32 is fixed onto a proximal portion of a tibia 44 via the anchor part 40 . The insert plate 34 is positioned onto the upper surface 38 of the tibial tray 32 to movably receive the femoral component 30 thereon. It will be understood that all configurations and variations of an artificial knee joint assembly 24 are contemplated by the present disclosure.
In a conventional artificial knee joint 24 , an insert plate 34 of the tibial component 32 is typically formed from ultra-high molecular weight polyethylene (UHMWPE). The insert plate wears, albeit slightly, since it slides in contact with the femoral component 30 that is made of a metal or ceramics. It has been known that the insert plate 34 becomes thinner through use over a period of time after being implanted in a human body. Therefore, it is a common practice to design the insert plate 34 with a predetermined thickness (normally from about 2 to 5 mm) and taking the wear loss into account. Since the slide surface 36 of the insert plate 34 is normally a concave surface that is recessed from the uppermost extent of the insert plate, the overall thickness of the insert plate must be made larger than the above-mentioned predetermined thickness to ensure sufficient thickness of the sliding surface.
The wear of the insert plate 34 can cause various problems for the user and can eventually lead to deterioration of the performance of the joint. At some point, it may become necessary to replace at least the insert plate 34 . The point at which some or all components of the artificial joint assembly 24 should be replaced is before a critical, predetermined wear threshold is exceeded. Timing of replacement may take into account several factors, including but not limited to medical indications, manufacturers recommendations regarding specified wear amounts, and patient symptoms. For purposes of the present disclosure, the point at which one or more component of the artificial joint assembly 24 should be replaced, typically the insert plate 34 may be referred to as a selected tolerance.
FIG. 4 illustrates an embodiment of a system 10 for measuring the initial dimensions of an artificial knee joint assembly, i.e., for measuring the assembled artificial joint assembly before implantation into a patient. The system 10 may include an artificial joint assembly holding apparatus 12 , a computed tomography (CT) x-ray machine 14 , and a computer 16 .
In general, CT x-ray machine 14 may be configured to obtain data from imaging artificial knee joint assembly 24 disposed on the joint holding apparatus 12 , while computer 16 may be configured to analyze the data acquired from scanning the artificial knee joint assembly 24 . The computer 16 also may be used to store the analysis for comparison with a CT x-ray scan and analysis of the same artificial knee joint assembly 24 after implantation ( FIG. 5 ), i.e., in vivo.
Joint holding apparatus 12 may be any type of elements, machines or a system of elements or machines suitable for holding the artificial knee joint assembly 24 for scanning by the CT x-ray machine 14 . Alternatively, the joint holding apparatus 12 is also configured to apply a selected load on the joint assembly 24 while it is being scanned. In alternate embodiments, the load may be zero or a selected, predetermined load, for example, body weight of the patient.
Referring to FIGS. 3 and 4 , joint holding apparatus 12 includes a femoral component fixture 50 and a tibial tray fixture 52 that comprise a joint assembly-holding fixture 51 . The femoral component fixture 50 has a shape and size to receive and attach to the femoral component 30 . The tibial tray fixture 52 has a shape and size to receive and attach to the tibial tray 32 .
When the joint holding apparatus 12 is being employed to hold the artificial knee joint assembly 24 , the insert plate 34 is disposed between the femoral component 30 and the tibial tray 32 such that the artificial knee joint assembly 24 is assembled into an anatomically correct and operable state. The femoral component fixture 50 and tibial tray fixture 52 are both mountable to the joint holding apparatus 12 by any suitable structure and method, including the use of fasteners, such as bolts.
The joint holding apparatus 12 includes a base 22 to which the tibial tray fixture 52 is attachable and an optional load measuring system 20 upon which the base 22 is mounted. The joint holding apparatus 12 includes a load-applying system 18 to which the femoral component fixture 50 is attachable. The joint holding apparatus 12 can include an Instron® type system or a similar variable load application system. The joint holding apparatus 12 may be rotatable to provide the CT x-ray system 14 with a plurality of positions for scanning necessary for computed tomography methodology. Alternatively, some of the components of the CT x-ray system 14 can be rotated and the joint holding apparatus 12 can be held stationary.
The joint holding apparatus 12 is operably associated with a CT x-ray system 14 . The joint holding apparatus 12 is configured to hold the joint assembly 24 so as to be scanned by the CT x-ray system 14 . The CT x-ray system 14 can include any suitable x-ray scanner that is capable of scanning the joint assembly 24 when held by the holding apparatus 12 and obtaining sufficient quality and amounts of data to accurately image and measure the joint assembly.
CT x-ray machine 14 may by any type of machine suitable for performing high-resolution, three-dimensional imaging of artificial knee assembly 24 . As illustrated in FIG. 4 , CT x-ray machine 14 includes a radiation emitter 26 and a radiation detector 28 . In one embodiment, radiation emitter 26 and radiation detector 28 may be fixed relative to artificial knee assembly 24 . In another embodiment, radiation emitter 26 and radiation detector 28 may be configured to rotate, for example, about 360 degrees around artificial knee assembly 24 (i.e., around a vertical, horizontal or selected axis passing through artificial knee assembly 24 ). Radiation emitter 26 may include any suitable type of x-ray tube, such as for example, a 100-500 kV, high-power or micro-focus x-ray tube. Moreover, radiation emitter 26 may include a plurality of radiation tubes, or sources. Radiation detector 28 may be a digital detector configured to detect radiation emitted from radiation emitter 26 , as affected by the geometry of artificial knee assembly 24 . For example, radiation detector 28 may include a 1-10 megapixel digital radiation detecting mechanism. In one embodiment, radiation detector 28 may include an array, or plurality, of digital detectors configured to cooperate with corresponding radiation emitters 26 . CT x-ray machine 14 may include a built-in processor 16 configured to control the operation of radiation emitter 26 and/or radiation detector 28 . CT x-ray machine may also include built-in processing for data storage, component feature extraction, volume reconstruction, rendering/visualization, dimensional analysis, and/or performing comparisons. In one embodiment, CT x-ray machine 14 may further include a built-in display monitor for displaying three-dimensional representations of components. In another embodiment, the artificial joint assembly 24 is positioned closer to the radiation emitter 26 than the radiation detector 28 to create a magnification effect based on the ratio of the distance of the artificial knee assembly divided by the distance of the artificial knee assembly to the radiation detector.
The computer 16 may be integral with the CT x-ray system 14 or separate and in communication with the CT x-ray system. Computer 16 may include a single microprocessor or multiple microprocessors that include control mechanisms to operate CT x-ray machine 14 . Numerous commercially available microprocessors may perform the functions of computer 16 . It should be appreciated that computer 16 could readily embody a general machine microprocessor capable of controlling numerous machine functions. Computer 16 may include or be associated with a memory for storing data such as for example, an operating condition, a design limit, and a performance characteristic or specification of CT x-ray machine 14 , and/or model artificial knee assemblies and actual artificial knee assemblies 24 . Various other known circuits may be associated with computer 16 , including power supply circuitry, signal-conditioning circuitry, solenoid driver circuitry, communication circuitry, and other appropriate circuitry. Moreover, because computer 16 may communicate with other components via either wired or wireless transmission, computer 16 may be disposed in a location remote from CT x-ray machine 14 , if desired. Alternatively, as discussed above, computer 16 may be integral with CT x-ray machine 14 . Accordingly, computer 16 may be configured to receive signals from CT x-ray machine 14 including CT data about the geometry of the artificial knee assembly 24 . Computer 16 may be configured to store, analyze and compare the CT data and send reports, images, alerts, and other information based on the raw or analyzed CT data.
Referring to FIG. 5 , CT x-ray machine 14 may perform the same operations as in the configuration shown in FIG. 4 , but of an in vivo artificial knee assembly 24 . Specifically, the system 10 includes a CT x-ray machine 14 with an x-ray emitter 26 and an x-ray detector 28 arranged as in the device shown in FIG. 4 . Also, a computer 16 is provided in communication with the CT x-ray machine 14 for receiving the data from the CT x-ray machine, performing storage and computational operations and generating outputs from scanning the artificial knee assembly 24 in vivo. It will be understood that the same operations are performed on the artificial knee assembly 24 that were undertaken during the initial or first imaging and analysis process. The CT x-ray machine 14 includes a base 20 that also may include a load cell. In one embodiment of the disclosure, the load on the artificial knee assembly 24 in vivo is made to be the same as during the initial imaging and analysis process. Loading the artificial knee assembly 24 the same in both processes, i) initially and, ii) in vivo, may ensure consistency of results and a reliable comparison. Tests may be performed with the artificial knee assembly 24 pre-implantation and in vivo with zero load or with a selected load applied to the assembly, such as equal to body weight of the patient or a selected suitable load.
In operation, CT x-ray machine 14 may acquire computed tomography data about the geometry of a particular artificial knee assembly 24 before implantation (step 100 ) by performing a scan of the artificial knee assembly. Alternatively, a reference data set may be acquired from a computer file or digitized 3D image in a suitable format of a model and/or reference artificial knee assembly, which will form the basis for comparison between the reference artificial knee assembly and the particular artificial knee assembly in vivo. For example, the model may be supplied by the manufacturer and may represent an ideal, unworn artificial knee assembly 24 .
To acquire data of an artificial knee assembly 24 , base 20 may intermittently rotate artificial knee assembly by 360 degrees, in half-degree increments, for example, about an axis. CT x-ray machine 14 may use radiation emitter 26 and radiation detector 28 to generate a cross-sectional artificial knee assembly image corresponding to each of the half-degree increments. Accordingly, CT x-ray machine 14 may generate 720 projection images, or “slices,” of artificial knee assembly 24 , each image being a two-dimensional representation of the features of artificial knee assembly 24 across a particular, rotationally-oriented plane (step 102 ). The number of images acquired in order to obtain a sufficiently detailed data set may be specified based upon the resolution of the detector.
The projection images are processed by standard CT software (step 104 ) associated with either CT x-ray machine 14 or computer 16 to generate a volumetric artificial knee assembly data file representing the physical characteristics of artificial knee assembly 24 (step 106 ). Specifically, CT x-ray machine 14 may communicate the acquired CT data to computer 16 , to be assembled into a three-dimensional, volumetric artificial knee assembly data file. Alternatively, the volumetric artificial knee assembly data file may be generated by a processor built-in to CT x-ray machine 14 . From the volumetric artificial knee assembly file cross sections of the artificial knee assembly may be obtained in a conversion process from the volumetric artificial knee assembly file (step 108 ).
A process to extract the surface of the scanned components is conducted (step 110 ). The surface extraction process may include beam hardening correction and/or localized corrected edge detection, both of which are known correction processes.
Either CT x-ray machine 14 or computer 16 may then generate point cloud data from the volumetric artificial knee assembly data file (step 112 ). Specifically, the volumetric artificial knee assembly file may be converted into point cloud data by various statistical and geometrical methods, with each data point in the cloud representing an approximate location of a point on one of the metal or ceramic surfaces of the artificial knee assembly 24 . A point cloud is a set of data points in a coordinate system. In a three-dimensional coordinate system, these points are usually defined by X, Y, and Z coordinates, and often are intended to represent the external surface of an object. The CT x-ray machine 14 measures a large number of points on an object's surface, and often output a point cloud as a data file. The point cloud represents the set of points that the device has measured. The generation of the point cloud data may be performed by commercially available software, for example Siemens Imageware™, Innometric Polyworks™, 3D Systems Geomagic™, GOM Inspect, Hexagon PC-DMIS Reshaper, or Volume Graphic Studio™. The point cloud data may be exported to a STL file, which is a file format native to a brand of stereolithography CAD software, or a similar mesh handling.
For example, each of the femoral component 30 and the tibial component 32 may be represented by approximately at least 100,000 data points defining a geometry of each component and a space therebetween that is occupied by the insert plate 34 , thereby defining the critical geometry of the insert plate. Even in the event that a selected type of CT x-ray machine 14 only obtains each data point to 6 or 7 um, the analysis of thousands of neighboring data points may be used to improve the imaging resolution to the micron level. For example, statistical averages and probabilities may be used to optimize an approximated location for a data point. Accordingly, the geometry of each of the femoral component 30 and the tibial component 32 , and even the insert plate 34 of the artificial knee assembly 24 , may be determined to a resolution as low as 3-5 um.
If the point cloud data is noisy, the noise may be removed according to any well-known process such as the use of a best fit process, wherein the data is compared to known geometric configurations, such as planes, spheres, cones, cylinders, and so on. Alternatively, or in addition, the data may be filtered with a robust filter (step 114 ) based on, for example, spline filtering.
There are two options for analyzing the wear or change of dimensions of a subject in vivo artificial knee assembly. The subject in vivo artificial knee assembly 24 may be compared to a reference standard artificial knee assembly (step 116 ) or alternatively, the subject in vivo artificial knee assembly may be compared to the same artificial knee assembly scanned before implantation (step 118 ). The subject in vivo artificial knee assembly 24 may be scanned, analyzed and compared to a reference or the pre-implanted assembly at selected time intervals so as to monitor the wear of components of the assembly over time.
The subject in vivo artificial knee assembly 24 is subjected to location and alignment procedures to perform a 3D comparison with the reference or the pre-implanted assembly (step 120 ). Differences between the reference or the pre-implanted assembly to the subject in vivo artificial knee assembly are quantified (step 122 ). The quantified differences are used to determine if the subject in vivo artificial knee assembly 24 exceeds a selected wear tolerance. If it is found that the wear tolerance has been exceeded, a decision can be made to replace the worn component.
The above-described steps of: generating the volumetric artificial knee assembly file, generating the point cloud data, and performing dimensional analysis may be performed within CT x-ray machine 14 or by computer 16 . Alternatively, each step may be performed on a separate computer 16 , separate processor, and/or a separate software package, in a so-called “parallel processing” or “pipe-lining” process. Because the processing steps may be divided across distinct computers, processors, and/or software suites, the processing of data in these steps may be expedited to a pace that may make possible the real time imaging of artificial knee assembly 24 . Full processing from imaging to 3D construction results can be accomplished in 10 minutes or less. Geometric dimensional analysis can then be performed after this under 10 minute data acquisition step.
INDUSTRIAL APPLICABILITY
The present disclosure is applicable to monitoring wear in an artificial joint, such as an artificial knee assembly in vivo. The subject in vivo knee assembly can be scanned and the assembly analyzed to acquire a point cloud data set that is comparable to a reference artificial knee assembly or the actual implanted knee assembly scanned before implantation. Wear of the knee assembly can be monitored over time and determined to a highly accurate degree.
It will be appreciated that the foregoing description provides examples of the disclosed system and method. However, it is contemplated that other implementations of the disclosure may differ in detail from the foregoing examples. All references to the disclosure or examples thereof are intended to reference the particular example being discussed at that point and are not intended to imply any limitation as to the scope of the disclosure more generally. All language of distinction and disparagement with respect to certain features is intended to indicate a lack of preference for those features, but not to exclude such from the scope of the disclosure entirely unless otherwise indicated.
Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context.
Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.
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A method of determining wear of an artificial knee assembly (AKA) includes acquiring a first set of computed tomography (CT) data about the AKA in vivo. A first volumetric file is generated based on the first set of CT data. A first point cloud data set is generated based on the first volumetric AKA file. A first dimensional analysis of the AKA is performed using the first point cloud data set. A second volumetric file is generated based on a second set of acquired CT data before implantation or from a model. A second point cloud data set is generated based on the second volumetric AKA file. A second dimensional analysis is performed using the second point cloud data set. The first dimensional analysis is compared to the second dimensional analysis and a determination is made if they are different from each other.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of copending U.S. application Ser. No. 06/770,423 filed on Aug. 29, 1985, hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to ground proximity warning systems of the type that monitor various flight parameters and generate a warning upon the occurrence of a hazardous flight condition, as well as to wind shear warning systems that detect the presence of a wind shear condition and generate a warning when a hazardous wind shear condition is detected. More particularly, the present invention relates to a warning system particularly usable during an approach to a landing phase of flight. The system determines the flight path angle of the aircraft during an approach and generates a warning in the event that the flight path angle (negative) is excessive for the altitude at which the aircraft is flying. The warning criteria are modified by a glideslope deviation signal from an ILS receiver and by a wind shear signal from a wind shear detector so that a less steep angle is required for a warning to be generated if the aircraft is below the glideslope or if wind shears are present. In addition, the glideslope warning criteria are altered during the presence of a wind shear so that a smaller deviation below the glideslope is required to generate a warning.
2. Description of the Prior Art
Various prior art warning systems are known. For example, U.S. Pat. Nos. 3,946,358; 3,947,808; 3,947,809; 4,060,793 and 4,215,334 disclose warning systems that generate warnings during an approach phase of flight when the descent rate of the aircraft is excessive for the altitude at which the aircraft is flying. U.S. Pat. No. 3,925,751 disclose systems that monitor the deviation of the aircraft below the glideslope beam and generate a warning if the glideslope deviation is excessive. U.S. Pat. Nos. 4,725,811 and 4,891,642 disclose wind shear warning systems that detect the occurrence of a wind shear condition and generate a warning upon the occurrence of a decreasing performance wind shear that exceeds a predetermined level. All of the above patents are incorporated herein by reference.
While these warning systems provide a warning upon the occurrence of an excessive deviation from normal operational conditions of the parameter they are monitoring, it is possible that a combination of conditions that are not individually sufficient to generate a warning in the prior art systems could be potentially hazardous. For example, a low intensity wind shear of a magnitude that would not be dangerous per se and hence would not normally cause a warning to be generated, could be hazardous if combined with other potentially hazardous conditions. For example, a low intensity wind shear could prove hazardous when combined with an excessively steep descent angle or with a below the glideslope condition, or with a combination thereof.
It has also been found that while systems that warn of an excessive descent rate during an approach to a landing are effective, the vertical speed varies during an approach along a 3° glideslope for different approach speeds and wind conditions. By measuring actual flight path angle, many of these variations may be reduced, particularly at altitudes below 300 feet above the ground.
SUMMARY
Accordingly, it is an object of the present invention to provide an enhanced warning system that overcomes many of the disadvantages of the prior art warning systems.
It is another object of the present invention to provide warnings of hazardous conditions that may not be detected by prior art warning systems.
It is another object of the present invention to provide a flight path angle based warning system.
It is yet another object of the present invention to provide a below glideslope warning system that is biased as a function of low intensity wind shears.
It is yet another object of the present invention to provide a flight path angle based warning system that is biased as a function of low intensity wind shears.
It is yet another object of the present invention to provide a flight path angle based warning system that is biased as a function of below glideslope deviation.
Thus, in accordance with a preferred embodiment of the invention, a flight path angle based warning system is provided, particularly at altitudes below 300 feet. The flight path angle based system determines the flight path angle, for example, from ground speed or true airspeed and barometric or inertial vertical speed. The flight path angle thus selected is compared with the altitude at which the aircraft is flying, and if the flight path angle is excessively steep for the altitude at which the aircraft is flying, a warning is generated. The flight path angle can be biased by either a below glideslope signal or a wind shear signal to provide earlier warnings in the presence of a below glideslope condition or a low intensity wind shear condition or both. The system also utilizes a below glideslope alert that is biased as a function of wind shear to provide earlier below glideslope warnings in the event of low level decreasing performance wind shears.
BRIEF DESCRIPTION OF THE DRAWING
These and other objects and advantages of the present invention will become readily apparent upon consideration of the following detailed description and attached drawing, wherein:
FIG. 1 is a block diagram illustrating the flight path angle based warning system according to the invention;
FIG. 2 illustrates the flight path angle based warning envelope of the system of FIG. 1 biased as a function of glideslope deviation and wind shear;
FIG. 3 is a graph showing the glideslope alert warning system of FIG. 1 biased as a function of wind shear; and
FIG. 4 illustrates a descent rate based warning envelope utilized by the system at higher altitudes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, with particular attention to FIG. 1, there is shown an improved warning system generally designated by the reference numeral 10. The system 10 receives signals from various instruments and discretes, such as an airport selector 12, a barometric or inertial vertical speed source 14, such as a barometric rate circuit or an inertial guidance system, a ground speed signal source 16, such as a Doppler radar based ground speed sensor or a true airspeed signal source 18, a glideslope receiver 20, a radio altimeter 22 and a wind shear detector 24 which may be a wind shear detector of the type disclosed in U.S. Pat. Nos. 4,725,811 and 4,891,642, incorporated herein by reference. The signals discussed above may be obtained from individual instruments as illustrated in FIG. 1 or from a data bus, particularly in newer aircraft. The airport selector 12 contains data peculiar to particular airports such as glideslope beam angles that are different than the standard 3° glideslope angle, and applies a bias signal to the summing junction 36 to compensate for such variations, for example, to avoid nuisance warnings.
The system according to the invention generates two alerts defined by a pair of envelope defining circuits 26 and 28, with the envelope 26 defining a flight path angle based warning system and the envelope 28 defining a glideslope deviation warning system. The warning envelope 26 is biased both as a function of glideslope deviation and wind shear, and the glideslope deviation envelope 28 is biased as a function of wind shear.
The system according to the invention utilizes a divider 30 that receives the vertical speed signal from the source 14 and divides it by either the ground speed signal from the source 16 or by the true airspeed signal from the true airspeed signal source 18. Preferably, the ground speed signal source 16 is utilized, but the true airspeed signal may be used if a ground speed signal is unavailable. A switch 32 is used to select either the ground speed or the true airspeed, and may be operated either automatically or manually. The output of the divider 30 is a signal representative of the flight path angle in radians, and is applied to a scaling amplifier 34 which converts the flight path angle to degrees. The flight path angle is then applied to the envelope circuit 26 via a pair of summing junctions 36 and 38.
The envelope circuit 26 receives the signal from the summing junction 38 and generates a warning signal if the flight path angle is negative at a steeper slope than is safe for the altitude at which the aircraft is flying, as determined by the altitude signal received from the radio altimeter 22. Specifically, with the basic alert envelope, a warning is given for combinations of altitude and flight path angle that are to the right of a line 50. The warning signal from the envelope generator 26 is applied to a delay circuit 52 and thence to a voice generating and priority circuit 54 which generates an appropriate one of several audible warnings and applies it to an annunciator 56 such as a speaker, headphones or cockpit communications system.
A glideslope deviation signal from the glideslope receiver 20 is also applied to the summing junction 38 via a function generator 58, a multiplier 42, a track and hold circuit 44, a summing junction 46 and a limiter 48. The aforesaid components serve to bias the flight path angle envelope 26 to make it more sensitive when the aircraft is below the glideslope and less sensitive when it is above the glideslope. A signal from the radio altimeter 20 is applied to the multiplier 22 via a function generator 40. The signal from the function generator 40 serves to reduce the glideslope deviation bias of the flight path angle signal for altitudes below 100 feet. Above 100 feet of radio altitude the envelope is biased by 1.5° when the aircraft is 2 dots above the glideslope beam and -0.7° when the aircraft is 2 dots below the glideslope beam, as is illustrated by the function generator 58. The effects of the bias are illustrated in FIG. 2, where the lines 60 and 62 show the warning boundaries when the envelope has been biased for deviations of 1 and 2 dots, respectively, above the glideslope beam. Lines 64 and 66 illustrate the warning envelope when the envelope has been biased for 1 and 2 dots below the glideslope beam, respectively. Below 100 feet of radio altitude, the bias is gradually reduced to zero as the signal from the function generator 40 applied to the multiplier 42 is gradually reduced to zero at zero feet of altitude. Since some glideslope beams are not usable below 100 feet, the track and hold circuit 44 is provided to track the glideslope deviation signal as long as the aircraft is above 100 feet of radio altitude. Below 100 feet, the average deviation that was previously measured at altitudes between 130 feet and 100 feet is determined and held by the track and hold circuit 44.
In addition to biasing the warning envelope 26 as a function of glideslope deviation, the envelope 26 is also biased as a function of wind shear. This is accomplished by applying a wind shear signal from the wind shear detector 24 to the summing junction 38 via a function generator 67, the summing junction 46 and the limiter 48. The function generator 67 applies a biasing signal to the summing junction 46 in the presence of decreasing performance shears in excess of 1 knot per second. In the illustrated embodiment, a -1° bias is generated for decreasing performance shears of 1.5 knots per second and greater. Thus, the warning envelope is biased a maximum of 1° negative as is illustrated by the line 68 (FIG. 2) for decreasing performance shears of 1.5 knots per second and greater, however, other values of bias could be used and the bias could be made a function of altitude with greater biases being utilized at higher altitudes.
The system according to the invention also employs a glideslope deviation warning that is defined by the glideslope warning envelope circuit 28 that receives a glideslope deviation signal from the glideslope deviation receiver 20 via a summing junction 70. The glideslope warning generator 28 also receives a signal from the radio altimeter 22 and generates a below glideslope alert if the below glideslope deviation is excessive for the altitude at which the aircraft is flying. Specifically, the alert is generated if the envelope above and to the right of a line 72 is penetrated. When such penetration occurs, the alert signal is applied to a delay circuit 74 and then to the voice generator 54 and annunciator 56 to generate the appropriate warning.
It has been found that low intensity wind shears having intensities of less than -1 knot per second that are insufficient to cause a normal wind shear warning in a wind shear detection system, can still pose a problem when the aircraft is below the glideslope. Consequently, the wind shear signal from the wind shear detector 24 is applied to the summing junction 70 via the function generator 67 and a function generator 76 in order to bias the warning envelope defined by the line 72 for negative wind shears. Specifically, the envelope is biased by 0.5 dots for each degree of negative bias received from the function generator 66 and limited to a maximum bias of 0.5 dots. The maximum bias of the envelope defined by the line 72 is illustrated by a line 78 (FIG. 3). Thus, an earlier below glideslope alert is provided upon the occurrence of a decreasing performance wind shear.
When a warning or advisory is given, it is desirable to provide the pilot with information defining the specific type of hazardous flight condition encountered. Thus, the voice generator 54 is programmed with different messages and the appropriate message is selected depending on the type of hazardous condition encountered. Thus, in addition to receiving the flight path angle based warning from the delay 52 and the below glideslope advisory from the delay 74, a low intensity shear discrete is also applied to the voice generator 54. The low intensity shear discrete is provided by a window comparator 80 that responds to both increasing and decreasing performance wind shear signals received from the wind shear detector 24 and provides an output to the voice generator 54 whenever the wind shear signal from the wind shear detector 24 exceeds ±1 knot per second. The low intensity shear discrete from the window comparator 80 is used in conjunction with the signals from the delay circuits 52 and 74 to select the specific warning to be given. For example, if a flight path angle based warning is received from the delay generator 52 in the absence of a low intensity shear discrete from the window comparator 80, a message such as "SINK RATE" may be generated. If low intensity wind shear were also present, the message could be changed to read "CAUTION SHEAR, SINK RATE". Similarly, if a below glideslope alert were received from the delay circuit 74 in the absence of a wind shear discrete, the message could be "GLIDESLOPE, GLIDESLOPE". In the presence of the low intensity shear discrete, the message could be changed to "CAUTION SHEAR, GLIDESLOPE". Thus, the specifics of the situation encountered can be communicated to the pilot using the messages described or similar messages.
As previously stated, the flight path angle based envelope 26 is particularly effective for altitudes below 300 feet above the ground. For higher altitudes, the envelope may be extended by extending the line 50 to higher altitudes or, alternatively, the warning may be switched to a barometric descent rate warning based envelope, such as the envelope shown in FIG. 4 above a predetermined altitude, such as, for example, 300 feet. The warning envelope illustrated in FIG. 4 is one of the envelopes utilized by the system disclosed in U.S. Pat. No. 4,215,334. The envelope illustrated in FIG. 4 compares the barometric descent rate (or an inertially derived descent rate) with the altitude above ground, and generates a warning if the descent rate is excessive for the altitude at which the aircraft is flying. If the descent rate is only moderately excessive, the warning "SINK RATE" will be given while the warning "PULL UP" will be given for greater descent rates. The switching can be accomplished by conventional switching devices that monitor radio altitude and switch between the flight path angle based envelope 26 (FIG. 1) and the barometric descent rate based envelope of FIG. 4 at the predetermined altitude above ground. Alternatively, in some systems, it may be desirable to utilize the envelopes of FIG. 1 and FIG. 4 concurrently.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. Thus, it is to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described above.
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A ground proximity warning system for aircraft having flight path angle based warning criteria generates a warning in the event of an excessively steep flight path angle during an approach to a landing. The warning criteria are altered to provide an earlier warning upon the occurrence of a low intensity wind shear or a below glideslope condition. A below glideslope warning system that is biased as a function of decreasing performance shear is also provided. A descent rate based warning system usable above a predetermined altitude may also be provided to supplement the flight path angle warning system.
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TECHNICAL FIELD
[0001] The invention relates to a dashboard for motor vehicles.
BACKGROUND OF THE INVENTION
[0002] In the manufacture of dashboards of this kind, points of view of both design and function are to be taken into account; and safety regulations which are in effect are to be observed as well.
[0003] The problem (object) lying at the basis of the invention is to provide a dashboard which can be used in vehicles which are equipped with airbags and can be manufactured simply and with any desired shaping, which has as low a weight as possible, which satisfies all safety regulations and which is capable of being recycled to the greatest possible extent.
SUMMARY OF THE INVENTION
[0004] The solution of this problem takes place through the features of claim 1 and in particular in that a base part is provided which has a region which is removable by an inflating airbag and which forms a part of the surface of the base part which points to the passenger space in the installed state, with the base part being manufactured of a plastic of low density, preferably of a foamed plastic, in particular of expanded polypropylene (EPP).
[0005] Through the use of a plastic of low density for the base part the total weight of the dashboard can be kept low.
[0006] Moreover, the provision of the removable region at the base part enables the dashboard in accordance with the invention to be used in motor vehicles which are equipped with airbags. Through the integration of the outlet for the inflating airbag into the base part in the form of a removable region the entire dashboard can be manufactured economically in only one work step. Furthermore, through the use of only a single material for the dashboard its recycling capability is improved.
[0007] In accordance with a preferred exemplary embodiment of the invention expanded polypropylene (EPP) is used as the material for the base part.
[0008] Through the use of this material the manufacturing costs for the dashboard can be kept low and the stability criteria required in respect to the safety regulations in effect can nevertheless be observed. Moreover, with EPP as a material for the dashboard, the latter can be manufactured in any form desired so that all present and future design requirements can be fulfilled with the invention.
[0009] In accordance with a further preferred embodiment of the invention the surface of the base part which points to the passenger space in the installed state is provided with a cover in the form of a plastic foil manufactured of a thermoplastic polyolefine (TPO), or made of a modified multiple component material.
[0010] The use of a foil of this kind enables the surface of the base part which points to the passenger space to be provided with the respective desired surface properties. Since in accordance with this embodiment a combination of materials from one material family takes place, the advantageous properties of the EPP which is used for the base part and in particular the recycling capability of the entire dashboard are not impaired.
[0011] In accordance with a further preferred embodiment of the invention weakenings of the base part in the form of incisions and/or depressions are provided at the rear side of the base part, which are invisible from the passenger space in the installed state. Through this the dashboard in accordance with the invention can also be used in vehicles without an airbag without giving the false impression by airbag cover contours which are visible from the passenger space that the respective vehicle is equipped with an airbag.
[0012] Through the provision of a structure element which is designed as a reinforcement and/or a carrier structure for the base part in accordance with a further preferred exemplary embodiment of the invention, with the base part and the structure element preferably being firmly connected to one another, in particular being welded, the stability of the dashboard in accordance with the invention is increased and a simple installation of the dashboard in the vehicle is enabled.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0014] [0014]FIG. 1 is a part of a dashboard designed in accordance with the invention in a sectioned side view.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] In the embodiment in accordance with the figure the dashboard in accordance with the invention comprises a base part 10 which is manufactured of expanded polypropylene (EPP), with it being possible in principle for another plastic of low density, e.g. a foamed plastic, to be used.
[0016] The surface of the base part 10 which points to the passenger space—in the figure upwardly and to the right—in the installed state is covered with a plastic foil 11 which is manufactured of a thermoplastic polyolefine (TPO), but can in principle consist of another material, e.g. of a modified multiple component material.
[0017] The base part 10 has a removable region 12 , the outline of which is determined by material weakenings which are provided in the form of V-shaped depressions 16 on the rear side of the base part 10 and which are not visible from the passenger space in the installed state. These depressions 16 can for example be produced through the pressing in of a corresponding tool into the not yet completely hardened plastic material of the base part 10 , through which the base part 10 has a higher density in the region of the side walls which extend at an inclination and bound the depressions 16 than does the bordering material.
[0018] Furthermore, the base part 10 has skin coverings 17 at side walls which extend at an inclination and bound the depressions 16 and at regions of its rear side which border on the depressions 16 .
[0019] The depression 16 which in the installed state is nearer to the windshield of the motor vehicle and is on the left in the figure is of lesser depth than the other depressions 16 , which extend up to the TPO foil 11 . The distance between the lowest position of the left depression 16 and the TPO foil 11 amounts to for example 1.5 mm.
[0020] The base part 10 is supported by a box-shaped structure element 18 which serves as a carrier structure and of which the side wall sections 23 , 24 and support sections 25 , 26 can be recognised in the figure.
[0021] The base part 10 is firmly connected to the structure element 18 at the sections 25 , 26 which extend parallel to the base part 10 by vibration welding, with it being possible in principle for the connection to take place in a different way. The structure element 18 is manufactured of a material which is different from that of the base part 10 .
[0022] In its region which faces the windshield of the motor vehicle in the installed state the base part 10 can be supported by a further, non-illustrated structure element.
[0023] The removable region 12 of the base part 10 is designed as an airbag cover which contacts the structure element 18 only in the region of the skin coverings 17 and is spaced from a receding region 26 a of the section 26 of the structure element 18 .
[0024] The sections 23 , 24 of the structure element 18 which point away from the base part 10 form a shot channel 22 for an inflating airbag which in the installed state is arranged in a non-illustrated airbag module beneath the removable region 12 of the base part 10 , which serves as an airbag cover.
[0025] When in the event of a collision the airbag is inflated, spreads out through the shot channel 22 and presses against the removable region 12 , the base part 10 is broken open at those weakenings which are designed as depressions 16 which extend up to the TPO foil 11 and thus as desired breaking locations. The removable region 12 can then open and is pivoted around in the direction of the windshield of the vehicle as a result of its connection to the base part 10 in the region of the left depression 16 in the figure.
[0026] The weakening 16 of the base part 10 facing the windshield of the vehicle, i.e. the material of the base part 10 and the TPO foil 11 in the region of the left depression 16 in the figure, thus act as a hinge region at which the removable region 12 is anchored so that the removable region 12 can not be flung through the interior of the vehicle.
[0027] Alternatively, a separate airbag cover can also be provided which is firmly connected at the rear side of the base part 10 to the removable region 12 and is formed in a single piece with the structure element 18 . For example an airbag cover of this kind can be connected to the section 23 of the structure element 18 which faces away from the base part 10 via a hinge region of reduced material strength.
[0028] It is also possible to provide an airbag cover as a separate component and to anchor it at the structure element 18 by means for example of a retention band which is manufactured of nylon.
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The invention relates to a dashboard for motor vehicles comprising a base part having a region which can be removed by an inflating airbag and which forms a part of the surface of the base part which points to the passenger space in the installed state, with the base part being manufactured of a plastic of low density, preferably of a foamed plastic, in particular of expanded polypropylene (EPP).
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FIELD OF THE INVENTION
The present invention pertains to a thread cutting device for sewing machines with a thread catcher. The thread catcher being actuated by an axially moveable drive mechanism to perform a first movement step catching the needle thread and the shuttle thread, and a second movement step whose direction is opposite to the first movement step in which the threads are pulled out and fed to a stationary cutting blade. A thread tensioning mechanism is provided for the needle thread and a releasing member for opening the thread tensioning mechanism during the thread pull operation. The releasing member being actuated by a cam rigidly attached to the drive mechanism.
BACKGROUND OF THE INVENTION
A thread cutting device, in which an axially displaceable drive mechanism catches the needle thread and the shuttle thread in one of its directions of movement and pulls them out and feeds them to the cutting blade in its other direction of movement, has become known from a realized sewing machine design. To control the releasing mechanism for the thread tension, a cam actuating the release mechanism is fastened on the drive mechanism. Even though this measure ensures a very simple drive of the tensioning mechanism, it causes opening of the thread tensioning mechanism during the movement of the drive mechanism in both directions of movement. This leads to difficulties in catching the loop under critical thread conditions and also to unequal thread ends after the cutting process.
SUMMARY AND OBJECTS OF THE INVENTION
It is an object of the present invention to design the releasing mechanism for thread tensioning in a thread cutting device with a thread catcher actuated by an auxiliary moveable drive mechanism which performs a first movement step catching the needle thread and the shuttle thread and a second movement step whose direction is opposite to the first movement step wherein the threads are pulled out and fed to a stationary cutting blade. A thread tensioning mechanism is provided for the needle thread and a releasing member for opening the thread tensioning mechanism during the thread pull operation. The releasing member being actuated by a cam rigidly attached to the drive mechanism so that the thread tensioning mechanism is opened only during the afterpull of the needle thread.
According to the invention, a thread cutting device is provided for sewing machines with a thread catcher. The thread cutting device being actuated by an axially moveable drive mechanism. The thread catcher performs a first movement step catching the needle thread and the shuttle thread and a second movement step whose direction is opposite to that of the first movement step in which the threads are pulled out and fed to a stationary cutting blade. A thread tensioning mechanism is provided for the needle thread and a releasing member is provided opening the thread tensioning mechanism during the thread pull operation. The releasing member can be actuated by a cam rigidly attached to the drive mechanism. A one way coupling is provided for the releasing member which is in action during the second movement step of the drive mechanism, the one way coupling being provided between the drive mechanism and a linkage connected to the releasing member.
With the control according to the present invention, the thread tensioning mechanism now remains closed during the penetration of the thread catcher into the needle thread loop, so that the stability of the loop is preserved when it is being caught by the thread catcher. The thread tensioning mechanism is opened only at the beginning of the afterpull of the needle thread and closes only when no more thread is pulled.
An embodiment of simple design of the one-way coupling is provided according to the invention in which the one-way coupling has a lever yielding in one direction. The lever pivoting during the first movement step of the drive mechanism and remaining rigid during the second movement step of the drive mechanism.
The measure according to the invention in which the cam is limited by a cam section rising in a wedge shaped manner at one end and by a radially dropping cam section at the other end leads to slip-free opening of the thread tensioning mechanism and to immediate closing of the thread tensioning mechanism after a sufficient amount of needle thread has been pulled in.
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
In the drawings:
FIG. 1 is a partially cut-away sectional view showing a sewing machine with a control of the thread cutting device and of the thread tensioning mechanism according to the invention;
FIG. 1a is a sectional view showing the thread tensioning mechanism in detail;
FIG. 2 is a top view of part of the drive of the thread cutting and tensioning device shown in FIG. 1; and
FIGS. 3 through 5 show various positions of the cam and of the one-way coupling for controlling the thread tension according to the invention.
FIG. 6 is a schematic representation of the shuttle together with the cut-off device;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the base plate 1 of a sewing machine, under which the horizontal shuttle drive shaft 2 is mounted. The shaft is driven by a lower main shaft 4 via a step-up gear 3. The shuttle 5 is fastened at the front end of the shuttle drive shaft 2. It cooperates with the needle 6 that can be moved up and down and fastened in a needle bar 6a which is only schematically indicated. A thread cutting device 7, whose design and mode of operation are described in U.S. Pat. No. 3,173,392, is arranged under the base plate 1. The thread cutting device 7 has a thread catcher 8, which is arranged coaxially with the shuttle 5 and cooperates with a cutting blade 9 fastened on the lower side of the base plate 1. The thread catcher 8 is fastened on a supporting arm 10 which is connected to a ring 11 that loosely surrounds the shuttle drive shaft 2. The ring is secured in the axial direction and is mounted freely rotatably in loop 12 that is fastened under the base plate 1. A connecting rod 13 is hinged to the supporting arm 10, and the connecting rod 13 is connected to an arm of an angle lever 14 which is supported by a bearing block 15 that forms an integral part of the housing. The other arm of the angle lever 14 is connected to a drive mechanism 17 for the thread catcher 8 via a bar 16.
To drive the thread catcher 8, a cam 18, which has a control groove 19 as well as a control segment 20, is fastened on the main shaft 4. A drive mechanism 21, designed as an axially displaceable shaft, is mounted in a support 22 fastened under the base plate 1 in parallel to the main shaft 4 (cf. FIG. 2). A control lever 24, provided with a roller pin 23 as well as a releasing lever 25, is fastened on the drive mechanism 21. A pawl 28 equipped with a locking lug 26 and a stop 27 is loosely mounted on a sleeve 30 fastened in a side wall 29 of the support 22 and is secured against axial displacement by the side wall 29 of the support 22 as well as by an end flange 30a of the sleeve 30. A spring 31 wound around and is supported by the drive mechanism 21, which abuts the control lever 24 at one end 3a and is supported by the pawl 28 at the other end 3b causes the pawl to swivel in the direction toward the control segment 20 of the cam 18 and the roller pin 23 out of the control groove 19. At the same time, the spring 31 acts as a compression spring and displaces the drive mechanism 21 into its right-hand end position, shown in FIG. 1, in which the roller pin 23 is opposite the control groove 19 when the sewing machine is in the lowered needle position.
An electromagnet 32, whose armature 33 is connected to an arm 35 of a starting lever 36 via an eye 34, is fastened in the support 22. The starting lever is mounted in the support 22 and is pivoted upward by a torsion spring 37 until a pivoted-down projection 38 comes into contact with the locking lug 26 of the pawl 28 or--with the pawl in the pivoted-down position--until a stop 39 comes into contact with a setscrew 40 fastened adjustably in the support 22.
Before the threads are cut, they must be pulled out over a length sufficient for the subsequent stitch formation. This takes place with the needle thread tensioning mechanism released. The thread tensioning mechanism 42 (FIG. 1a) for the needle thread consists of a sleeve 43 with a longitudinally slotted setscrew 44 fastened in the machine housing, wherein tensioning disks 45, 46 are arranged on the setscrew and the disks are compressed by a tension spring 48 adjustable by means of a knurled nut 47 in order to exert a decelerating force on the needle thread. A releasing pin 49 is arranged in the sleeve 43 longitudinally displaceably, by means of which the tensioning disk 45 can be lifted off from the tensioning disk 46 against the action of the tension spring 4 in order to open the thread tensioning mechanism 42.
A cam 50, whose surface is designed as a cam curve having a curve section 51 rising in the shape of a wedge at one end and a straight and then radially falling curve section 52 at the other end, is used to actuate the releasing pin 49, and consequently to release the thread tensioning mechanism 42. A one-way coupling 53, which is arranged on a lever arm 54 mounted on the support 22, cooperates with the cam 50. The one-way coupling 53 consists of a segment-shaped lever 55, which is mounted pivotably on lever arm 54 and cooperates with the cam 50, as well as a stop 57, which is in contact with a pin 59 fastened in the lever arm 54 under the action of a torsion spring 58.
The lever arm 54 is rotated by a torsion spring 60 until a lateral contact surface 54a or the one-way coupling 53 comes into contact with the cam 50. The torque exerted by the torsion spring 60 considerably exceeds the torque exerted by the torsion spring 58. The lever arm 54 is connected to an angle lever 62 mounted on the machine housing via a bar 61. A push rod 63, which carries at its front end a releasing member 65 provided with an oblique surface 64 (FIG. 1a), is hinged to the angle lever.
Assuming that the sewing machine is running and the roller pin 23 is in its position outside the cam groove 19 of the cam 18 rotating together with the main shaft 4, the thread catcher 8 with its drive member 21 is in its starting position, and the thread tensioning mechanism 42 for the needle thread is closed, the device operates as follows: At the end of the seam, the sewing machine is briefly stopped by a needle positioning device in the lowered needle position, which is the starting position for thread cutting. The cam groove 19 in the cam 18 now assumes a position in which the roller pin 23 on the control lever 24 can be moved into the cam groove 19 by a single swiveling movement. The cam 50 and the one-way coupling 53 are in the position shown in FIG. 3, in which the thread tensioning mechanism 42 is closed.
By actuating a switch while depressing the pedal of the sewing machine for the reverse direction, the electromagnet 32 is briefly energized and the drive motor of the sewing machine is turned on immediately thereafter. The starting lever 36 is pulled down by the armature 33 of the electromagnet 32 and it pushes the roller pin 23 into the cam groove 19 via the releasing lever 25 and the control lever 24. At the same time, the spring 31 pivots the pawl 28, whose locking lug 26 lies against the projection 38 on the starting lever 36 and thus locks the position of the roller pin 23 pushed into the cam groove 19.
During the subsequent revolution of the main shaft 4 in the direction of arrow A, which is necessary for the thread cutting, the cam groove 19, extending in the axial direction, displaces the drive mechanism 21--via the control lever 24--from its resting position to the left, corresponding to a first section of the cam groove 19. The drive mechanism 21 now moves the thread catcher 8 via the angle lever 14 and the connecting rod 13 and into the widened needle thread loop caught by the shuttle 5 and thus catches the leg of the needle thread loop leading to the fabric to be sewn, as well as the shuttle thread, in the known manner.
During its displacement to the left, the cam section 52 hits the lever 55 and rotates same against the force of the torsion spring 58, so that the lever arm 54 remains in its resting position determined by the contact between the contact surface 54a and the cam section 52 during the displacement of the drive mechanism 21 to the left, and while the wedge-shaped curve section 51 passes by, the lever 55 again returns into its resting position, in which it is in contact with the pin 59.
After the loop of the needle thread has fallen off from the shuttle 5, the drive mechanism 21 is moved to the right as a consequence of the curved design of the cam groove 19 (FIG. 5). The wedge-shaped cam section 51 of the cam 50 now moves toward the lever 55 of the one-way coupling 53 and thus pivots the lever arm 54, which releases the thread tensioning mechanism 42 for the needle thread via the bar 51, the angle lever 62 and the push rod 63 in such a way that the releasing pin 49 is axially displaced by the oblique surface 64 of the releasing member 65, as a result of which the tensioning disk 45 is lifted off from the tensioning disk 46 against the force of the tension spring 48.
At the same time, the thread catcher 8 pulls thread from the shuttle thread reserve and the needle thread reserve due to the movement of the drive mechanism 21 to the right until the cutting blade 9 fastened on the lower side of the base plate 1 cuts off both threads shortly before the end of this movement.
Immediately thereafter, the cam section 52 of the cam 50 moves past the lever 55 of the one-way coupling 53, and the lever 55 can drop in behind the cam section 52 under the pressure of the torsion spring 60, so that the lever arm 54 can come into contact with its lateral contact surface 54a with the axially parallel surface of the cam section 52 of the cam 50. This dropping off of the lever 55 from the cam section 52 brings about immediate closure of the thread tensioning mechanism 42 via the tensioning release linkage.
During the further residual rotation of the main shaft 4 until the sewing machine is turned off in the raised needle position, the segment 20 pivots the pawl 28 over the stop 27, so that the locking lug 26 again releases the starting lever 36. The starting lever is pivoted upward by the torsion spring 37 until it comes into contact with the projection 38 at pin 40. As a result, the spring 31 is able to push the control lever 24 away from the cam 18, so that the roller pin 23 is lifted out of the cam groove 19. The sewing machine will then be stopped with the thread lever in the raised position and is ready for the next sewing operation.
While a specific embodiment of the invention has 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.
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A thread cutting arrangement for sewing machines including an arrangement in which the tension of the thread is released in both directions of movement of an axially moveable drive mechanism such that the thread tensioning mechanism is opened when the needle thread is caught. The movement of the drive mechanism is transmitted via a one-way coupling so that the opening of the thread tensioning mechanism is limited to the duration of the after pawal of the needle thread.
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BACKGROUND OF THE INVENTION
This invention relates generally to liquid drainage systems used on site for footings, open trenches or nitrification fields used as discharge points for septic tanks, and more particularly to a novel drainage system which is easy to install and which maximizes the size of a storage chamber or area for the liquid until it can be absorbed by or percolated into the surrounding soil.
In the past conventional drainage systems have typically comprised a horizontally extending perforated conduit placed within a drainage trench and surrounded by a quantity of loose aggregate material such as rock or crushed stone and covered with compacted soil. The space between the conduit and ground occupied by the aggregate serves to define a drainage cavity in fluid communication with the perforations of the conduit. An example of such a drainage system is found in the nitrification field of conventional ground absorption sewage disposal systems wherein effluent is discharged form a septic tank through the perforated vent pipe of a nitrification line which is surrounded by aggregate material such as rocks or crushed stone. The nitrification field creates a storage chamber or area for the sewage affluent until it can be absorbed by the soil.
These conventional systems suffer a number of drawbacks as discussed in U.S. Pat. No. 5,015,123 (owned by the assignee of this invention), and the novel drainage system described and claimed in the '123 patent represents a substantial improvement over the conventional system. The description of that improved system as set forth in the '123 patent is incorporated herein by reference in its entirety. Briefly, that system utilizes pre-assembled drainage line units illustrated in FIG. 2 of the patent in which loose aggregate in the form of lightweight materials is provided in surrounding relationship to a perforated conduit and bound thereby by a perforated sleeve member. These units used in combination with pre-assembled units illustrated in FIG. 3 of the patent which do not include the perforated pipe replace the gravel system used in the conventional systems as illustrated in FIGS. 4 b and 4 c of the patent to provide the storage chamber or area for the effluent until it can be absorbed by the soil. The system of the '123 patent represents a substantial improvement over the prior conventional gravel system for the reasons set forth in the '123 patent and has enjoyed substantial commercial success.
Recently, another drainage system has been proposed which includes a pair of drainage pipes such as those illustrated in FIG. 2 of the '123 patent extending longitudinally within the trench and laterally spaced from each other to define an open storage chamber and a cover placed on top of and spanning the laterally spaced pipes to prevent top dirt fill from falling down into the storage chamber. While this system conceptionally shows some promise, the design of the cover has not been strong enough to support the weight of the top fill dirt and bends and deflects downwardly to decrease the size of the storage chamber and reduce the overall efficiency of the drainage system.
Thus, there is a need in this most recent proposal for a cover which has sufficient strength and stability to support the weight of the top fill dirt and thereby avoid the problem associated with prior covers. The cover of this invention as described and claimed herein below was developed to perform that task.
SUMMARY OF THE INVENTION
Accordingly, the primary object of this invention is to provide a drainage system which includes a pair of longitudinally extending drain pipes placed within a drainage trench laterally spaced from each other to define a liquid storage chamber therebetween and a novel cover placed on top of the drain pipes. The cover is sufficiently strong and stable to support the weight of the fill dirt placed on top thereof, thereby substantially maintaining the chamber at its original size for storage of the drainage liquid until it can be absorbed by the soil defining the bottom of the trench.
Another object of the invention is to provide the above drainage system wherein the novel cover includes two side portions extending longitudinally over and generally conforming to the shape of the drain pipes and a center portion connecting the two side portions to maintain the drain pipes in laterally spaced relationship, the cover further including reinforcing elements extending between the side portions and the center portion to prevent downward deflection of the center portion under the weight of the top soil. As a result the size of the chamber is maintained to create maximum storage area for the liquid drainage until it can be absorbed by or percolated into the soil at the bottom of the trench.
A further object of the invention is to provide various embodiments of the novel cover which can be used in the above described drainage system and wherein all of the embodiments contain reinforcement elements which prevent downward deflection of the cover under load.
Still another object of the invention is to provide a novel cover as described above wherein the cover includes a plurality of vented openings which allows the system to breathe to thereby retard development of the clogging mat within the chamber, that is the mechanical loss of infiltrative capacity at the soil surface interface due to suspended solids, bacteria growth and ferrous sulfide precipitation.
Other objects and advantages of the invention will become apparent from reading the following detailed description of the invention wherein reference is made to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an end perspective of a fragmentary portion of the drainage system and cover of the invention illustrated with pre-assembled drainage units such as those illustrated in FIG. 2 of U.S. Pat. No. 5,015,123;
FIG. 2 is a fragmentary end section illustrating the drainage system placed within a drainage trench;
FIG. 3 is a top perspective view of a first embodiment of the novel cover which may be employed in the system of FIG. 1;
FIG. 4 is a top plan view of the cover illustrated in FIG. 3;
FIG. 5 is a side view of the cover taken along line 5 — 5 of FIG. 4;
FIG. 6 is an end view of the cover taken along line 6 — 6 of FIG. 4;
FIG. 7 is a view similar to FIG. 2 with the drainage system employing a second embodiment of the novel cover of the invention;
FIG. 8 is a top perspective view of the second embodiment of the cover shown in FIG. 7;
FIG. 9 is a top plan view of the cover illustrated in FIG. 8;
FIG. 10 is a side view of the cover taken along line 10 — 10 of FIG. 9;
FIG. 11 is an end view of the cover taken along line 11 — 11 of FIG. 9;
FIG. 12 is a top perspective view of the prior art cover referred to above under the Background of the Invention;
FIG. 13 is a side perspective view taken along line 13 — 13 of FIG. 12; and
FIG. 14 is a bottom view of the prior art cover illustrated in FIG. 12 .
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 generally illustrate the drainage system 20 with which the invention is concerned and include a pair of horizontal perforated drain pipe units 22 and 24 placed within and extending longitudinally along trench 26 and laterally spaced from each other to provide the central open chamber 28 . While drain pipe units 22 and 24 may be of various types, they are preferably pre-assembled drainage units such as those illustrated in FIG. 2 of U.S. Pat. No. 5,015,123 and include a central perforated pipe 30 surrounded by a plurality of lightweight plastic aggregate 32 held in place by a surrounding net 34 .
A cover 40 constructed according to the first embodiment of FIGS. 3-6 extends across the top of drainage units 22 and 24 and includes a retaining section 41 having side portions 42 and 44 which conform in shape and size to the outer surface and configuration of pipe units 22 and 24 , and a center portion 46 connected to the side portions and functioning to maintain the pipe units 22 and 24 in laterally spaced relation to form the center chamber 28 . In a typical installation the width of trench 26 may be 24 inches and the depth may be approximately 22 inches. Units 22 and 24 may be approximately 10 inches in diameter and the perforated pipe 30 within the units may be approximately 4 inches in diameter. When the storage system 20 is placed within the trench the distance between the top of the cover and the top of the trench will be approximately 10 to 11 inches and the space defined thereby will be filled with top soil 38 which was removed from the trench originally. In such an installation, assuming the density of the soil to be about 96 pounds per cubic feet, the weight or load imposed upon cover 40 and system 20 will be about 100 pounds per square foot.
The prior art plastic cover 50 illustrated in FIGS. 12, 13 and 14 and described hereinabove, included a pair of elongated continuous side sections 51 and 52 of generally circular configuration to conform to the outside surface of drainage units 22 and 24 and an inverted V-shaped center section 53 joined to sections 51 and 52 along sharp junction lines 54 and 55 . Recessed depressions 56 are provided in center section 53 to prevent the flattening at the apex of that section under load. Each of the side sections 51 and 52 include a plurality of downwardly projecting lugs or dimples 57 which penetrate into the outer surface of units 22 and 24 and help to hold those units in their laterally spaced relation in the same manner as shown in FIG. 2 .
In storage systems such as this liquid is fed into one end of the perforated pipes 30 from a collection basin or from a septic tank and passes outwardly through the perforations in the pipe and the lightweight aggregate into chamber 28 where it is collected and stored until it can be absorbed by or percolated into the soil defining the trench. It is desirable that the liquid or effluent storage area defined by units 22 and 24 and space 28 substantially maintain its original size so as to maximize the efficiency of the drainage system.
Even though the prior art cover illustrated in FIGS. 12-14 was about 0.125 inches thick, it encountered substantial downward deflection under load of the top soil such as bending along the junction lines 54 and 55 and the tendency of the side sections 51 and 52 to flatten out under load. As a result the size of chamber 28 and the overall size of the storage area defined by the units 22 and 24 and chamber 28 decreased to reduce the drainage capacity and overall efficiency of the system.
Accordingly, applicants have developed the novel covers of FIGS. 3-6 and FIGS. 7-11 incorporating the invention which overcome the problems associated with the prior art design of FIGS. 12-14.
The first embodiment of the invention includes the one-piece cover 40 illustrated in FIGS. 1-6. Cover 40 is molded of plastic, preferably of high density polyethylene plastic and is constructed so as to be light in weight but yet strong enough to resist downward deflection under the weight of the top fill soil 38 placed therein to fill the upper portion of trench 26 . For example in an installation such as in trench 26 shown in FIG. 2, the thickness of the cover may be about 0.080-090 inch, the width W may be about 21¼ inches and the length L may be any desired length for example, 63 inches long. The one piece cover 40 includes pipe retaining sections 41 and reinforcing sections 62 which alternate in corrugated undulating fashion along the length of the cover forming peaks and valleys defined by sections 62 and 41 , respectively. Each section 41 includes side portions 42 and 44 which are shaped and configured to correspond to the outer shape of pipes 22 and 24 and are connected together by the central radiused portion 46 . For example, in the configuration shown in FIG. 2 side portions 42 and 44 are formed on the radius of about 5 inches and the center portion is formed on a radius of about 4½ inches. Each reinforcing section 62 is formed on a single large radius to provide a crowned arch extending along the full width of the cover with each arch 70 being integrally joined to adjacent sections 41 by downwardly and outwardly tapering side walls 72 and 74 , the upper edges 76 of which are radiused to avoid any sharp stress points. Similarly, the junction lines 78 at which walls 72 and 74 join sections 41 are radiused to avoid any stress points. The width of sections 41 and 62 along the longitudinal direction is essentially the same. For example about 3½ to 4 inches.
The radius on which arches 70 are formed is about 38½ inches, large enough so that the top surface of the arch at the longitudinal center of the cover is spaced about 1 inch above the center of the portion 46 and a hollow space 76 is created beneath the bottom surface 78 of the arch so that that bottom surface does not engage the pipes 22 and 24 in the drainage system as shown in FIG. 2 .
Each portion 42 and 44 includes retaining lugs 80 which project downwardly from the bottom surface thereof and as illustrated in FIG. 2 are pressed into the outer surface of pipe assemblies 22 and 24 to help retain those pipes in spaced relationship within trench 26 .
When placed in use as illustrated in FIG. 2, portions 42 and 44 of sections 60 engage the top of laterally spaced pipes 22 and 24 with the center section 68 overlying chamber 28 . The sections 41 and 62 cooperate to completely cover pipes 22 and 24 and central chamber 28 to prevent any of the fill dirt 38 from falling down into the chamber. In addition the crowned arches 70 forming sections 62 and the tapered side walls 72 and 74 provide substantial strength and rigidity to the cover so that it is able to support the weight of the top soil and resist any significant downwardly deflection which would decrease the size of chamber 28 and the total liquid storage area defined by chamber 28 and pipes 22 and 24 .
Cover 40 may also be provided with a plurality of vent holes 100 in sections 41 which allow the drainage system to breathe. This helps prevent the development of clogging mat in chamber 28 . The sides of the holes 100 is smaller than the particles of soil 38 to prevent soil from falling into chamber 28 .
A second embodiment of the invention is illustrated in FIGS. 7-11. The novel cover 100 mounted in place on pipe units 22 and 24 as illustrated in FIG. 7, similarly includes a plurality of retaining sections 102 and reinforcing sections 104 arranged in alternating fashion along the length of the cover to form valleys and peaks, respectively, in the same way as the construction of the first embodiment of the invention. Sections 102 include radiused sections 106 , 108 and 110 joined along lines 112 , with each of the sections 106 , 108 and 110 being formed on the same radius, for example, 4.985 inches, to substantially conform to the outer radius of pipe units 22 and 24 .
Each of the reinforcing sections 104 includes a plurality of radiused crowned arches 114 , 116 and 118 longitudinally aligned with portions 106 , 108 and 110 respectively. Crowned portions 114 , 116 , and 118 are formed on essentially the same radius as portions 106 , 108 and 110 but on a raised center line so that the top surface of those portions extend above the top surfaces of portions 106 , 108 and 110 , for example about 1 inch thereabove, so as to provide the corrugated or undulating configuration of cover 100 . Arches 114 , 116 and 118 are connected to portions 106 , 108 an 110 by way of side walls 120 and 122 which taper downwardly and outwardly at an angle of about 5 degrees from sections 104 to sections 102 .
The raised crown arches 114 , 116 and 118 of section 104 provide a hollow space 130 therebelow so that the bottom surfaces of those crowned arches do not contact the pipe units when installed in place.
The width of sections 102 in the longitudinal direction is slightly larger than the width of sections 104 . For example, the width of sections 102 may be about 3½ inches whereas the width of sections 104 may be about 2½ inches.
As shown in FIG. 7, cover 100 mounts on pipe units 22 and 24 and functions in much the same way as cover 40 shown in FIG. 2 . The raised crown arches 114 , 116 and 118 provide strength and ridgity to the thin walled cover 100 and resist downward deflection of the cover under the weight of the top fill soil which is on top of the cover. Consequently the size of the liquid storage area defined by pipe units 22 and 24 and chamber 28 is not reduced during use and the efficiency of the drainage system is maximized.
It is apparent that the novel reinforced covers 40 and 100 are substantial improvements over the prior art cover illustrated in FIGS. 12-14 which experiences substantial bending and deflection under the weight of a top fill soil thereby causing the reduction in the size of the liquid storage area including chamber 28 . In contrast, the covers 40 and 100 are substantially thinner but yet are significantly stronger and experience virtually no downward deflection thereby avoiding any reduction in size of chamber 28 .
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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A drainage system for delivering fluid from a source of fluid for absorption into the ground, comprises a trench, a pair of perforated drainage conduits extending longitudinally in said trench and laterally spaced from each other to define an open chamber therebetween. The conduits are connected at one end to the source for receiving fluid from the source and delivering fluid to the chamber. A longitudinally extending cover overlies said conduits and prevents soil from falling into the chamber. The cover includes side portions which engage the conduits and a center portion connected to the side portions and maintains the conduits in laterally spaced relationship. The cover also includes reinforcing arches extending between the side portions and the center portion to resist downward deflection of the cover under the weight of the top soil. Vent holes in the cover permit the system to breathe.
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RELATED APPLICATIONS
[0001] This patent arises from a continuation of U.S. patent application Ser. No. 12/494,932 (now U.S. Pat. No. 8,490,227), which was filed on Jun. 30, 2009, which is a continuation of U.S. patent application Ser. No. 11/063,811 (now U.S. Pat. No. 7,568,242), which was filed on Feb. 23, 2005. Priority to both U.S. patent application Ser. Nos. 12/494,932 and 11/063,811 is claimed. Both U.S. patent application Ser. Nos. 12/494,932 and 11/063,811 are hereby incorporated by reference in their entireties.
FIELD OF THE DISCLOSURE
[0002] This disclosure relates generally to childcare products, and, more particularly, to play yards and methods of operating the same.
BACKGROUND
[0003] In recent years, portable play yards have become very popular. Portable play yards typically include a frame, a flexible enclosure supported by the frame, and a removable floor board or mat. The frame is largely or completely contained within the flexible enclosure so that there are few if any loose parts when the frame is collapsed or when the frame is erected. When collapsed, the portable play yard typically has a compact form factor to enable easy transport and storage of the play yard. Sometimes, the floorboard is wrapped around the collapsed frame to prevent the frame from inadvertently leaving the collapsed state.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a perspective view of an example play yard constructed in accordance with the teachings of the invention.
[0005] FIG. 2 is a perspective view of the example play yard of FIG. 1 shown without the enclosure.
[0006] FIG. 3 illustrates the example play yard of FIG. 1 with the removable floor board raised to expose the lower frame.
[0007] FIG. 4 illustrates the example play yard of FIG. 1 in a semi-folded state with arrows indicating the direction in which the joints of the frame of the play yard move to collapse the play yard.
[0008] FIG. 5 is a side view of the example play yard of FIG. 1 in a semi-folded state.
[0009] FIG. 6 is a perspective view of the example play yard of FIG. 1 in a fully folded state.
[0010] FIG. 7 is side view of the example play yard of FIG. 1 in the fully folded state.
[0011] FIG. 8 is a cross-sectional view of an end cap of the example play yard taken along line 8 - 8 of FIG. 1 and illustrating the pivotable connection of an upper frame rail to the end cap.
[0012] FIG. 9 is a cross-sectional view taken along line 9 - 9 of FIG. 8 .
[0013] FIG. 10 is an enlarged side view of a post of the example play yard of FIG. 1 .
[0014] FIG. 11 is a cross-sectional view of the post taken along line 11 - 11 of FIG. 10 .
[0015] FIG. 12 is an exploded perspective view of another example post of the example play yard of FIG. 1 .
[0016] FIG. 13 a is a perspective view of another example post that may alternatively be used with the example play yard of FIG. 1 showing the post prior to receiving the enclosure.
[0017] FIG. 13 b is a perspective view similar to FIG. 13 a , but showing the enclosure coupled to the post.
[0018] FIG. 14 is a cross-sectional view of the post taken along line 14 - 14 of FIG. 13 b.
DETAILED DESCRIPTION
[0019] An example play yard 10 is shown in FIG. 1 . The play yard 10 is portable in that it is intended to be collapsible from an erected position such as the example position shown in FIG. 1 to a collapsed position such as the example position illustrated in FIGS. 6-7 . When the play yard 10 is in the erected position, it provides an enclosure for a small child or infant. The play yard 10 has a smaller form factor when it is in the collapsed position then when it is in the erected position. Therefore, the play yard 10 may be easily stored or transported when collapsed.
[0020] As shown in FIG. 1 , when in the erected position, the illustrated play yard 10 has a rounded rectangular shape. In particular, the illustrated play yard 10 has four sides 12 , each of which is bowed outward away from the center of the play yard 10 . In addition, the play yard 10 of FIG. 1 includes four corner posts 14 joining the sides 12 that define the rounded rectangular shape. Like the sides 12 , the corner posts 14 are bowed outward away from the center of the play yard 10 . However, whereas the sides 12 bow about a generally vertical axis, the corner posts 14 curve about a generally horizontal axis. As a result of the bowed sides 12 and corner posts 14 , the play yard 10 defines a rounded rectangular volume.
[0021] The illustrated portable play yard 10 includes a frame 22 (see FIGS. 2 and 3 ) and an enclosure 23 supported on the frame 22 . The frame 22 includes a collapsible lower frame 24 (see FIG. 3 ) and a collapsible upper frame 26 (see FIG. 2 ). The upper frame 26 is suspended above the lower frame 24 by the corner posts 14 . Each of the corner posts 14 is connected between a foot 28 and an end cap or bracket 30 . Each foot 28 is coupled to the lower frame 24 . Each end cap 30 is coupled to the upper frame 26 .
[0022] As shown in FIG. 1 , in the illustrated play yard 10 two of the feet are implemented as conventional wheels and two of the feet 28 are implemented as stationary supports to facilitate movement of the erected play yard 10 when desired and to prevent unwanted rolling of the play yard 10 when movement is not desired. However, persons of ordinary skill in the art will appreciate that a different number of feet 28 (e.g., 0, 1, etc.) may be implemented by wheels and/or stationary supports, if desired.
[0023] The lower frame 24 of the illustrated play yard 10 includes four outer sides which, when the lower frame is in the erected position, together define a generally rectangular perimeter. Each of the outer sides comprises a pair of rails 32 joined by a central joint 34 . One end of each of the rails 32 is pivotably coupled to one of the feet 28 . The opposite end of each of the rails 32 is pivotably coupled to one of the central joints 34 . The pivotable couplings enable the sides of the lower frame 24 to be moved between the erected position and the collapsed position. As shown in FIGS. 4 and 5 , the joints 34 move upward and translate inward when the play yard 10 is moved from the erected position to the collapsed position.
[0024] For the purpose of selectively locking the lower frame 24 in the erected position and for providing support for the center of the play yard 10 , the lower frame 10 is further provided with a central assembly 40 . The central assembly 40 is pivotably coupled to the central joints 34 of two opposite sides of the lower frame 24 . More specifically, the central assembly 40 includes two rails 42 and a central hinge 44 . In the illustrated example, one end of each rail 42 is pivotably coupled to a respective one of the central joints 34 of the long sides of the play yard 10 . The opposite ends of the rails 42 are coupled to the central hinge 44 of the central assembly 40 .
[0025] The central hinge 44 includes a conventional lock mechanism to selectively permit or prevent movement of the central assembly 40 and, thus, the lower frame assembly 24 from the erected position to the collapsed position. The lock mechanism comprises a handle 46 . When the handle 46 is pivoted into a generally horizontal position (see FIG. 3 ), a sleeve associated with the handle 46 substantially prevents the rails 42 of the central assembly 40 from pivoting upward. As a result, the central assembly 40 and, thus, the lower frame 24 cannot be collapsed. When the handle 46 is pivoted into a generally vertical position (See FIG. 4 ), the sleeve associated with the handle 46 does not prevent the rails 44 of the central assembly 40 from pivoting upward. As a result, the central assembly 40 and, thus, the lower frame 24 may be collapsed by lifting the handle 46 .
[0026] To provide support for the center of the play yard floor when the play yard 10 is in the erected position, the central assembly 40 includes a pair of centrally located feet 48 . To provide further lateral support for the lower frame 24 , a pair of opposed outrigger feet 50 are coupled to opposed ones of the central hinges 34 (see FIGS. 3 and 4 ). Like the feet 28 , the outrigger feet 50 and the centrally located feet 48 are positioned to engage a ground surface supporting the play yard 10 when the play yard 10 is in the erected position.
[0027] The upper frame 26 of the illustrated play yard 10 includes four outer sides which, when the upper frame 26 is in the erected position, together define a rounded rectangular (i.e., four sided) perimeter. The rounded rectangular shape may be an oval, a half-oval, or any combination of rounded and straight sides. However, at least one of the sides is preferably rounded. It is even more preferable that at least two opposite sides are rounded to provide symmetry.
[0028] In the illustrated example, each of the outer sides comprises a pair of outwardly bowed rails 52 joined by a central joint 54 . One end of each of the rails 52 is pivotably coupled to one of the end caps 30 . The opposite end of each of the rails 52 is pivotably coupled to one of the central joints 54 . The pivotable couplings enable the sides of the upper frame 26 to be moved between the erected position and the collapsed position.
[0029] Each of the central joints 54 is provided with a releasable lock to enable selective collapsing of the upper frame 26 . The construction of the releasable lock forms no part of the present invention and will not be discussed in detail here. Persons of ordinary skill in the art are aware of the numerous types of joint locks that are used in portable play yards. Any of those known locks may be employed in the illustrated play yard 10 . For example, the releasable locks described in U.S. Pat. No. 6,250,837, which is hereby incorporated herein by reference, may be used in this role.
[0030] It is desirable for the form factor of the play yard 10 to be as small as possible when the play yard 10 is folded into the collapsed position of FIG. 6 . A small form factor translates into less packaging costs for the manufacturer and smaller storage requirements for the end user. Because the rails 52 of the upper frame 26 are outwardly bowed to create the rounded rectangular perimeter, the central joints 54 extend further away from the center of the play yard 10 when the upper frame 26 is in the erected position than would the central joints of a conventional rectangular frame. Therefore, if the central joints 54 are permitted to move directly downward when the upper frame 24 is moved from the erected position to the collapsed position, the joints 54 would increase the form factor of the collapsed play yard 10 .
[0031] Therefore, to reduce the form factor of the collapsed play yard 10 , the rails 52 of the upper frame 26 are coupled to the end caps 30 such that the centers of each side of the upper frame 26 (e.g., the central joints 54 ) move inward and downward as the upper frame 26 moves from the erected position to the collapsed position, as indicated by the arrows in FIGS. 4 and 5 . (The inward component of this motion is in addition to the inward translation caused by moving the posts 14 toward one another as shown in FIG. 6 ). As a result, when the upper and lower frames 24 , 26 are in the collapsed positions shown in FIG. 6 , the joints 54 are positioned inward of the posts 14 . Positioning the joints 54 inward of the posts 14 when the play yard 10 is in the fully collapsed position creates a smaller, more compact structure, which eases storage and transportation.
[0032] To produce the desired inward and downward movement of the centers of the rails 52 as the upper frame 26 is collapsed, the rails 52 of the upper frame 26 are pivotably coupled to the end caps 30 by mechanical fasteners 60 that are positioned at an angle α from the horizontal. In the example of FIGS. 8 and 9 , each mechanical fastener 60 penetrates an end cap 30 and a corresponding one of the rails 52 of the upper frame 26 . Each mechanical fastener 60 , thus, defines an axis of rotation for a corresponding one of the rails 52 . Selecting the angular orientation of the mechanical fasteners 60 , thus selects the pivoting motion of the corresponding rails 52 .
[0033] Preferably, all of the mechanical fasteners 60 are positioned at the same angle α, but persons of ordinary skill in the art will readily appreciate that different angular orientations could optionally be used for different sides of the upper frame 26 if different pivoting motions are desired for those different sides. For example, if it is desirable to have sides that extend different distances from the center of the play yard when the play yard is erected, but which still close in to substantially the same distance from the center of the play yard when the play yard is collapsed such that the collapsed play yard has a generally rectangular form factor, the fasteners of the differently positioned sides would be positioned at different angular orientations to achieve the different movements of the differently extending sides. Similarly, in the illustrated example, the angle α is approximately 11 degrees from the horizontal plane, but other angles may be selected to obtain a desired movement of the centers of the rails 52 . The mechanical fasteners may be implemented by bolts, screws, rivets, etc.
[0034] To further enlarge the volume of the play yard 10 and to enhance its rounded appearance, the posts 14 that support the upper frame 26 above the lower frame 24 are curved. In the illustrated example, the posts 14 include a body having a generally straight upper section 64 , a generally straight lower section 66 , and a curved central section 68 (see FIG. 10 ). The upper section 64 of each post 14 is coupled to a respective one of the end caps 30 by one or more mechanical fasteners (e.g., rivets). The lower section 66 of each post 14 is coupled to a respective one of the feet 28 by one or more mechanical fasteners (e.g., rivets). Preferably, the curved section 68 of each post is oriented to bow away from the center of the play yard 10 about a generally horizontal axis. The posts 14 , like the rails 32 , 52 of the lower and upper frames 24 , 26 , may be constructed of metal (e.g., steel, aluminum, etc.) or of extruded plastic tubes.
[0035] As mentioned above, the illustrated play yard 10 includes an enclosure 23 that is supported by the frame 22 . Preferably, the enclosure includes five flexible sides, namely, a bottom and four sides. The top is open. The enclosure 23 may be made of fabric, plastic, mesh and/or any other material which is sufficiently strong and durable to define the enclosure volume throughout the desired useful life of the play yard 10 and which is flexible enough to be folded. In the illustrated example, the enclosure 23 is a fabric structure including mesh side panels. The illustrated enclosure 23 includes upper sleeves which receive the rails 52 of the upper frame 26 and lower sleeves which receive the rails 32 of the lower frame 24 . In other words, the sides of the enclosure 23 are stretched between the upper and lower frames 24 , 26 .
[0036] Unlike traditional play yards, the posts 14 are not covered or encased in the enclosure 23 . Instead, the enclosure 23 of the illustrated play yard is coupled to the inner surface of the posts 14 . As a result, the outward facing surfaces, (particularly of the curved sections 68 ), of the posts 14 are completely exposed.
[0037] In order to facilitate coupling of the enclosure 23 to the posts 14 , each of the corners of the enclosure 23 is sewn, glued, fused or otherwise fastened into a sleeve which receives a flexible cylindrical member to define a corner bead 70 as shown in FIGS. 11 and 12 . The flexible cylindrical member may be implemented by a wire, a rope, a foam or plastic tube, etc. Further, each post 14 defines a channel 72 for receiving a respective one of the corner beads 70 .
[0038] In a presently preferred implementation, each channel 72 is defined by a track 74 which is coupled to the exterior of a respective one of the posts 14 . Because the tracks 74 are coupled to the inner surfaces of the curved posts 14 , the tracks 74 are curved in a manner that complements the post shape. In the example of FIGS. 11 and 12 , the track 74 includes a backing 76 which is secured to a respective one of the posts 14 via mechanical fasteners 78 (e.g., rivets, screw, etc.). The channel 72 is defined adjacent the backing 76 by opposed arms 80 . Each of the opposed arms 80 has a first end coupled to the backing 76 and a second free end. The free ends of the arms 80 are curved toward one another to define a slit having a width through which the corner bead 70 may not pass. In the illustrated example, four sets of opposed arms 80 are employed, but other numbers of arms 80 (e.g., 1, 2, 3, 5, etc.) might likewise be appropriately employed. The backing 76 and the arms 80 of the illustrated example are integrally formed, since the track 74 is made of molded plastic.
[0039] In the example of FIGS. 11 and 12 , the tracks 74 are preferably fastened to their corresponding posts 14 , and the corner beads 70 are then threaded down into the channels 74 defined by their respective tracks 74 . To facilitate assembly, it may be easier to thread the corner beads 70 of the enclosure 23 into their respective channels 74 before assembling the end caps 30 and the upper frame 26 to the posts 14 .
[0040] An alternative post 14 is shown in FIGS. 13 a , 13 b and 14 . In the example of FIGS. 13 a , 13 b and 14 , a post 114 is extruded to define a channel 172 . The channel 172 is located within the post 114 and is in communication with a slot 175 . The channel 172 follows the shape of the post 114 . Thus, in the illustrated example, the channel 172 is curved like the post 114 . The enclosure 23 is joined to the post 114 by threading the corner bead 70 down into the channel 172 as shown in FIG. 13 a . As shown in FIGS. 13 b and 14 , the enclosure 23 passes through the slot 175 when the bead is threaded into the channel 172 . However, the slot 175 and the corner bead 70 are sized such that the corner bead 70 may not pass through the slot 175 . Although the post 114 requires a more complicated manufacturing process than the post 14 , the post 114 has the advantage of not requiring the track 74 .
[0041] In order to provide a rigid, comfortable support for a child or infant located within the play yard 10 , the play yard 10 is further provided with a floor board 90 . When the illustrated play yard 10 is erected, the floor board 90 is located within the enclosure 23 on top of the lower frame 24 in a generally horizontal plane (assuming, of course, that the surface on which the play yard 10 is erected is generally horizontal). The illustrated floor board has a rounded rectangular outer perimeter substantially corresponding to the rounded rectangular shape of the upper frame 26 . Since the lower frame 24 has a generally rectangular outer shape, portions of the floor board 90 extend outwardly of (i.e., overhang) the lower frame 24 .
[0042] Other than its shape, the floor board 90 of the illustrated example is conventional. For example, the illustrated floor board 90 includes one or more foam pads secured to one or more boards. The pad(s) and board(s) are encased in a plastic sleeve as is conventional in portable play yards sold today such as the Travelin' Tot® play yards sold by Kolcraft Enterprises. Seams are defined between adjacent boards of the floor board 90 to facilitate folding of the floor board 90 in discrete sections. In the illustrated example, the floor board 90 includes four boards and is foldable in fourths. The floor board 90 may, thus, be wrapping around the collapsed play yard 10 for transport and/or storage.
[0043] The floor board 90 may be removably secured to the floor of the enclosure 23 by any suitable fasteners. In the illustrated example, the floor board 90 is secured to the floor of the enclosure 23 by Velcro® strips. Alternatively, the floor board 90 may be held in place by gravity without the benefit of fasteners.
[0044] Although certain example methods, apparatus and articles of manufacture have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the claims either literally or under the doctrine of equivalents.
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Play yards and methods of operating the same are disclosed. A disclosed example includes a collapsible upper frame, a collapsible lower frame, and posts to support the upper frame above the lower frame. The posts include respective tracks. The example also includes a foldable, frameless enclosure operatively coupled to the upper frame, the lower frame and the posts. The enclosure has a plurality of sides and a bottom to define an enclosure volume. The enclosure also has a plurality of corner beads dimensioned for receipt in a respective one of the tracks to secure the enclosure to the posts.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 62/237,207, filed Oct. 5, 2015, the entire disclosure of which is hereby incorporated by reference herein.
FIELD
[0002] The present disclosure relates to split bearings, split bearing cartridge assemblies, and split housed bearing assemblies.
BACKGROUND
[0003] Split bearings and split bearing assemblies are generally known in the art. They are often selected for use due to the relative ease with which they may be replaced on a shaft. However, certain deficiencies remain with the split bearing assemblies currently in the field that can lead to costly repairs and downtime. An object of the present disclosure is to address the deficiencies of existing split bearing assemblies.
SUMMARY
[0004] In one embodiment of the present disclosure, there is provided a split bearing cartridge assembly for mounting on a shaft. The split bearing cartridge assembly may comprise a split inner race fixedly securable to the shaft and providing a first rolling element engaging surface; a plurality of rolling elements retained within a cage, wherein the cage is securable to allow rolling of the rolling elements around the first rolling element engaging surface; and, a split outer race rotatably securable to the rolling elements, wherein the split outer race provides a second rolling element engaging surface for the rolling elements. A split bearing container is also provided for substantially encapsulating the split inner race, split outer race, rolling elements and cage. In this aspect, sealing means are also provided for sealing between the split inner race and openings of the bearing container located axially outwardly from the rolling elements.
[0005] In another embodiment of the disclosure, a split housed bearing assembly for supporting a shaft is provided. The split housed bearing assembly comprises a split inner race fixedly securable to the shaft; a plurality of rolling elements retained within a cage; a split outer race rotatably securable to the rolling elements; a split bearing container for substantially encapsulating the split inner race, split outer race, rolling elements and cage; and a split housing for housing the split bearing container. First and second sealing means are provided for sealing between the split inner race and first and second openings, respectively, of the bearing container.
[0006] The rolling elements of the split bearing cartridge assembly may be rollers, and more specifically, cylindrical rollers. The seals of the assembly may be rotary seals and of a triple labyrinth construction. The split inner race of the cartridge assembly may extend axially beyond the first and second openings of the split bearing container. The split housing may be, a split pillow block housing, a split flange housing
[0007] In another aspect of the present disclosure, a split housing may be provided for housing the aforementioned split bearing cartridge assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For illustration purposes, the following figures have been included to help the reader better understand the preferred embodiments of the disclosure:
[0009] FIG. 1 , which is an exploded perspective view of a split bearing cartridge assembly in accordance with the present disclosure;
[0010] FIG. 2 , which is a perspective view, in partial section, of a split bearing cartridge assembly in accordance with the present disclosure;
[0011] FIG. 3 , which is an enlarged view of detail A of FIG. 2 , with a variant split outer race;
[0012] FIG. 4 , which is a perspective view, in partial section, of a split inner race in accordance with the present disclosure;
[0013] FIG. 5 , which is a perspective view of a split inner race clamp ring in accordance with the present disclosure;
[0014] FIG. 6 , which is a perspective view of an assembled cage and rolling element assembly in accordance with the present invention;
[0015] FIG. 7 , which is a top view of the assembled cage and rolling element assembly of FIG. 6 ;
[0016] FIG. 8 , which is a perspective view, in partial section, of a split outer race in accordance with the present disclosure;
[0017] FIG. 9 , which is a perspective view, in partial section, of a split housed bearing assembly in accordance with the present disclosure;
[0018] FIG. 10 , which is an alternate perspective view of the split housed bearing assembly of FIG. 9 ;
[0019] FIG. 11 , which is a perspective view, in partial section, of another split housed bearing assembly in accordance with the present disclosure; and
[0020] FIG. 12 , which is an alternate perspective view of the split housed bearing assembly of FIG. 11 .
DETAILED DESCRIPTION
[0021] Preferred embodiments of the present disclosure will now be described in more detail with reference to the aforementioned figures. It is noted that the majority of the elements of the split bearing cartridge assembly and split housed bearing assembly are split elements, that is to say that they are formed in two parts to be joined to form a single working element when installed. In the figures, each of the parts of a split element have been identified with numerals including a lettered suffix, whereas there are no numerals to identify the element as a whole. For example, in FIG. 1 , each part of the split inner race 120 a , 120 b are identified whereas there is no numeral to identify the inner race as a whole. Throughout this disclosure, whole elements may be described with reference to the appropriate numeral without the lettered suffix (e.g. 120 for the split inner race as a whole) and it should be understood that such a reference is a reference to the ensemble of the corresponding suffixed numerals (e.g. 120 a and 120 b for the separate components of the split inner race).
[0022] FIG. 1 shows, in exploded view, a split bearing cartridge assembly 100 in accordance with a preferred embodiment of the present disclosure. A split bearing container 110 , made up of two parts 110 a , 110 b , is provided as an enclosure for the other elements of the split bearing cartridge assembly 100 . The two parts of the split bearing container 110 a , 110 b can be secured to one another using fastening means such as bolts 114 located on the exterior of the split bearing container. The skilled person would appreciate that other suitable fastening means may be used to allow selective assembly and disassembly of the split bearing container 110 .
[0023] The split bearing container 110 , when assembled, substantially encapsulates the other split bearing elements of the assembly, which include a split inner race 120 , a split cage 130 (the bottom half of the split cage is not shown in FIG. 2 ), a plurality of rolling elements 136 , and a split outer race 140 .
[0024] With reference to FIGS. 2 and 4 , a split inner race 120 may be affixed to a shaft 150 so that the split inner race 120 and the shaft 150 rotate together. In the illustrated embodiment, the split inner race 120 is affixed to the shaft 150 through the use of split clamp rings 122 , 124 . The two components of the split clamp rings 122 a , 124 a may be fixed to their respective counterparts 122 b , 124 b ( FIG. 5 ) using capscrews (hidden lines 527 in FIG. 5 show the path of the capscrews) or other fastening means of the like that allow for selective assembly and disassembly of the split clamps rings 122 , 124 . The split inner race 120 is formed with recesses 126 for accommodating the split clamp rings 122 , 124 . The recesses 126 are appropriately positioned within the split inner race 120 so that, when assembled, the split clamp rings 122 , 124 also serve to substantially prevent axial movement of the split cage 130 and rolling elements 136 ( FIGS. 6 and 7 ) with respect to the split inner race 120 .
[0025] With reference to FIGS. 2, 6 and 7 , the split cage 130 and rolling elements 136 may be manufactured and assembled in accordance with methodology known in the art, such as described in US Patent 5 , 743 , 659 to the Applicant, which is hereby incorporated by reference. Once the split clamp rings 122 , 124 have been installed, thus securing the split inner race 120 to the shaft 150 , the split cage 130 (including the rolling elements 136 ) may be assembled such that the rolling elements 136 engage with the central landing portion 128 of the split inner race 120 . The central landing portion 128 of the split inner race 120 provides one of the surfaces with which the rolling elements 136 engage when in operation.
[0026] With reference to FIGS. 2 and 8 , a split outer race 140 may be positioned around the rolling elements 136 within the split bearing cartridge assembly 100 . A portion of the inside surface 144 of the split outer race 140 provides the second surface with which the rolling elements 136 engage when in operation. Accordingly, when in operation, the rolling elements 136 will roll between the central landing portion 128 of the split inner race 120 and a portion of the inside surface 144 of the split outer race 140 . The split bearing container 110 is provided with a channel 118 for accommodating the split outer race 140 . When assembled, the split outer race 140 sits in the channel 118 thus preventing axial movement of the split outer race 140 within the split bearing container 110 .
[0027] The split outer race 140 shown in FIG. 2 may be substituted for the split outer race 340 shown in FIG. 3 . Whereas the geometry of the split outer race 140 in FIG. 2 allows the shaft 150 , split inner race 120 and split cage 130 and rolling elements 136 to float, use of the split outer race 340 shown in FIG. 3 will produce a fixed or held bearing. The bearing is considered to be fixed or held because the tabs 342 provided on the outer race 340 serve to restrict the axial movement of the rolling elements 136 , split cage 130 , split inner race 110 and clamp rings 122 , 124 . Typically, where thermal expansion of the shaft 150 in expected, it is desirable for the shaft to be supported by a floating bearing at one end and a fixed bearing at the other end.
[0028] With continued reference to FIG. 2 , split seals 160 , 162 serve to help contain lubricant within the split bearing container 110 as well as prevent foreign contaminants from entering the split bearing container 110 and ultimately reaching and damaging the split cage 130 and rolling elements 136 . Lubricant may be introduced into the split bearing cartridge assembly 100 via lubrication fitting 164 . The lubricant may be a lithium-based grease or any other suitable lubricant known to those skilled in the art. The split seals 160 , 162 are rotary seals (e.g. triple labyrinth seals made predominantly of aluminum), and act to substantially seal the openings of the split bearing container 110 on either side of the rolling elements 136 . The split bearing container 110 may be provided with fingers 116 at each of its openings for engaging with the split seals 160 , 162 to help maintain a seal where the split seals 160 , 162 meet the split bearing container 110 . As best illustrated in FIG. 2 , the split inner race 120 extends axially such that the split seals 160 , 162 ride on an outer surface of the split inner race 120 .
[0029] As is generally known in the art, over time, the seals of a housed bearing unit may wear grooves into the shaft upon which they are installed. When installing a replacement split bearing cartridge assembly or split housed bearing assembly (as will be described in more detail below) on a shaft that has sustained damage at the areas of seal contact, the effectiveness of the seals of the replacement unit may be compromised due to poor contact between the new seals and the damaged surface of the shaft. This, in turn, may lead to an increased risk of premature failure of the replacement bearing unit. Conversely, when replacing a failed housed bearing unit with a split bearing cartridge assembly or split housed bearing assembly according to the present disclosure, the split inner race 110 extends far enough axially to seal against undamaged portions of the shaft when the split inner race 110 is tightly clamped over the shaft. The outer surface of the extended portions of the split inner race 110 provide a clean smooth surface for the split seals 160 , 162 to ride on, thereby greatly reducing, if not eliminating, the risk of premature failure associated with sealing on a damaged shaft. Furthermore, subsequent damage caused by the split seals 160 , 162 in the split bearing cartridge assembly of the present disclosure will be sustained by the split inner race 110 , which is inexpensive to replace as compared to the shaft.
[0030] A split housed bearing assembly 900 in accordance with the present disclosure will now be described with reference to FIGS. 9 and 10 . In FIG. 9 , the split bearing cartridge assembly 100 of FIGS. 1 and 2 is supported by a split housing 970 . The split housing selected to illustrate the embodiment shown in FIGS. 9 and 10 is commonly referred to as a split pillow block housing and includes a base portion 970 a and a mating portion 970 b . The base portion 970 a may be secured to stable surface, for example a structurally secure steel beam, through the use of bolts 974 . With the base portion 970 a secured, the shaft 150 , which may be raised and suspended above its eventual resting position to facilitate assembly of the split bearing cartridge assembly 100 , may be lowered into its desired position with the split bearing cartridge assembly seated in the base portion 970 a of the housing. The mating portion 970 b may then be positioned atop the base portion 970 a and secured to the base portion 970 a using capscrews 978 or other suitable fastening means known to those skilled in the art.
[0031] The outer surface 982 of the central portion of the split bearing cartridge assembly may be arcuate to mate with a similarly arcuate inside surface 986 of the base portion 970 a and mating portion 970 b of the split pillow block housing. The corresponding arcuate mating surfaces 982 , 986 permit some misalignment of the split bearing cartridge assembly 100 within the split housing 970 . A pin 190 may be inserted into the outside of the split bearing container 110 to restrict the degree to which the cartridge 100 may misalign within the split housing 970 .
[0032] A split pillow block housing, such as the one shown in FIGS. 9 and 10 is commonly used where the plane of the stable surface to which the housed unit is to be secured is parallel to the axis of the shaft. Another embodiment of the present disclosure involves a split flanged housing 1170 and will now be described with reference to FIGS. 11 and 12 . This type of flange housing may be used where the plane of the stable surface to which the housed unit will be secured and the axis of the shaft are orthogonal.
[0033] Split housed bearing assembly 1100 comprises the split bearing cartridge assembly 100 of FIGS. 1 and 2 supported by a split flanged housing 1170 . The split flanged housing 1170 may be made up of a first portion 1170 a and a mating portion 1170 b that come together and support the split bearing cartridge assembly 100 in a similar fashion to the embodiment illustrated in FIGS. 9 and 10 . The first and mating portions 1170 a , 1170 b may be secured together using capscrews 1178 or other suitable fastening means known in the art. In order to provide support for the shaft upon which the housed bearing assembly 1100 will be installed, the split flange 1170 may be secured to a stable surface by the use of bolts (not shown) through bolt holes 1172 provided in the split flange 1170 . Although there are four bolt holes 1172 in the embodiment illustrated in FIG. 12 , any suitable number of bolt holes may be used provided the split housed bearing assembly can support the shaft once secured to the stable surface.
[0034] The present disclosure does not require any specific boundary dimensions for the split bearing cartridge assembly and split housed bearing assembly; however, selecting the boundary dimensions to correspond with existing housed bearing units being used in the field may be desirable in order to facilitate interchangeability.
[0035] Although the preceding description relates to particular preferred embodiments of the disclosure only, the skilled reader will appreciate that modifications are possible within the scope of the appended claims.
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The disclosure provides an improved split bearing cartridge assembly and split bearing housed bearing assembly. The split bearing cartridge assembly comprises a split inner race fixedly securable to a shaft, a plurality of rolling elements retained within a cage, a split outer race rotatably securable to the rolling elements, a split bearing container for substantially encapsulating the split inner race, split outer race, rolling elements and cage, and first and second sealing means for sealing between the split inner race and first and second openings, respectively, of the bearing container. The split bearing cartridge assembly may be combined with a split housing resulting in an improved split housed bearing assembly.
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BACKGROUND OF THE INVENTION
The present invention. relates to a method and apparatus for ejecting material from a liquid. The invention employs technology the same as or similar to that described in WO97/27057, and, more particularly, it relates to the application of a differential voltage to the electrodes of a printhead.
In order to control the ejection of material the electrical potential gradient at an ejection location needs to be varied from below a threshold to above a threshold. This has been achieved by applying a voltage pulse to an ejection electrode. However, there are limitations in the availability of compact electronic drive circuits which are able to provide the required voltage pulses, and this presents particular problems in small printheads. Also, in printheads containing an array of ejection locations, capacitive coupling between proximate ejection locations can adversely effect ejection. This cross-talk can be reduced if lower voltages are used, and it is therefore desirable to use the smallest possible voltages to cause ejection.
EP-A-0 761 443 discloses an array printer having multiple ink outlets in which matrix addressing of the ink outlets is achieved by applying a voltage to individual ejection electrodes and an inverse voltage to common control electrodes in order to achieve ejection from specific ink outlets.
SUMMARY OF THE INVENTION
According to the present invention there is provided a method ejecting material from a liquid within a chamber of a multi-chamber ejection device having respective ejection and secondary electrodes associated with each chamber, the method comprising:
controlling the application of first voltage pulses to a respective ejection electrode associated with the chamber and second voltage pulses to a respective secondary electrode associated with the chamber, such that when a voltage pulse is applied to the ejection electrode a voltage pulse, inverted with respect to the pulse applied to the ejection electrode, is applied to the secondary electrode.
It should be understood that, in the context of this invention, the word “inverted” is intended to define voltage pulses which may have either opposite signs, or voltage pulses with voltages that rise and fall in an opposing manner.
It should also be understood that, although there is no limitation to the pulses being of equal and opposite magnitude, it is preferable that the moduli of the change in voltage of the voltage pulses are equal.
According to the present invention there is also provided apparatus for ejecting material from a liquid, comprising
a plurality of chambers for containing the liquid; respective ejection and secondary electrodes associated with each chamber;
control means for applying first voltage pulses to a respective ejection electrode associated with a chamber and second voltage pulses to a respective secondary electrode associated with the chamber;
the control means controlling the first and second voltages such that, when a voltage pulse is applied to the ejection electrode, a voltage pulse, inverted with respect to the pulse applied to the ejection electrode, is applied to the secondary electrode.
Voltage pulses may be applied to multiple ejection electrodes and multiple secondary electrodes.
BRIEF DESCRIPTION OF THE DRAWINGS
A number of embodiments of the invention will now be described with reference to the accompanying drawings, in which:
FIG. 1 is a partial perspective view of a portion of a printhead incorporating ejection apparatus according to the present invention;
FIG. 2 is a view similar to FIG. 1 showing further and alternative features of the ejection apparatus;
FIG. 3 is a partial sectional view through a cell of FIG. 1;
FIG. 4 is a graphical illustration of voltages that may be applied to the one electrode;
FIG. 5 is a graphical illustration of voltages that may be applied to the another electrode;
FIG. 6 is a plan view of an ejection apparatus similar to that illustrated in FIG. 1;
FIG. 7 is a close up plan view of a cell of the ejection apparatus of FIG. 6;
FIG. 8 is a plan view of an alternate ejection apparatus showing a modified electric field; and
FIG. 9 is a close up plan view of a cell of the alternate ejection apparatus showing a modified electric field.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, part of an array-type printhead 1 , as described in our earlier application PCT/GB97/00186, is illustrated, the printhead comprising a body 2 of a dielectric material such as a synthetic plastics material or a ceramic. A series of grooves 3 are machined in the body 2 , leaving interposing plate-like lands 4 . The grooves 3 are each provided with a ink inlet and ink outlet (not shown, but indicated by arrows I & O) disposed at opposite ends of the grooves 3 so that fluid ink carrying a material which is to be ejected (as described in our earlier application, WO97/27057) can be passed into the grooves and depleted fluid passed out.
Each pair of adjacent grooves 3 define a cell 5 , the plate-like land or separator 4 between the pairs of grooves 3 defining (for all but the cells immediately adjacent the ends of the array) an ejection location for the material and having an ejection upstand 6 . In the drawing two cells 5 are shown, the left-hand cell 5 having an ejection upstand 6 which is of generally triangular shape and the right-hand cell 5 having a truncated upstand 6 ′. The cells 5 are separated by a cell separator 7 formed by one of the plate-like lands 4 and the corner of each separator 7 is shaped or chamfered as shown so as to provide a surface 8 to allow the ejection upstand 6 to project outwardly of the cell beyond the exterior of the cell as defined by the chamfered surfaces 8 . The truncated upstand 6 ′ is used in the right-hand, end cell 5 of the array (and similarly in the end cell at the other end—not shown) to reduce end effects resulting from the electric fields which in turn result from voltages applied to ejection electrodes 9 provided as metallised surfaces on the faces of the plate-like lands 4 facing the upstands 6 , 6 ′ (ie. the inner faces of each cell separator). Although the end cells are not used for ejection, the truncated upstand 6 ′ acts to pin the liquid meniscus which in turn reduces end effects during operation, which might otherwise distort the ejection from the adjacent cell. The electrode 9 in the end cells is held at a suitable bias voltage which may be the same as a bias voltage applied to the ejection electrodes 9 in the operative cells as described in our earlier applications mentioned above. As can be seen from FIG. 3, the ejection electrodes 9 extend over the side faces of the lands 4 and the bottom surfaces 10 of the grooves 3 . The precise extent of the ejection electrodes 9 will depend upon the particular design and purpose of the printer. An isolation groove 14 , to provide a measure of protection against electrical shorting between adjacent cells 5 , is provided in some cases, if required.
FIG. 2 illustrates two alternative forms for side covers of the printer, the first being a simple straight-edged cover 11 which closes the sides of the grooves 3 along the straight line as indicated in the top part of the figure. A second type of cover 12 is shown on the lower part of the figure, the cover still closing the grooves 3 but having a series of edge slots 13 which are aligned with the grooves. This type of cover construction may be used to enhance definition of the position of the fluid meniscus which is formed in use and the covers, of whatever form, can be used to provide surfaces onto which the ejection electrode and/or secondary or additional electrodes can be formed to enhance the ejection process.
FIG. 2 also illustrates an alternative form of the ejection electrode 9 , which comprises an additional metallised surface on the face of the land 4 which supports the upstand 6 , 6 ′. This may help with charge injection and may improve the forward component of the electric field.
FIG. 3 illustrates a partial sectional view through one side of the one of the cells 5 of FIG. 1, with a secondary electrode 19 being shown located on the chamfered face 8 on the cell separator lands 4 and therefore disposed substantially alongside the ejection upstand. In a further embodiment (not shown) the secondary electrode may be formed, at least in part, on the face of the cell separator land 4 (and thus rearwardly of the ejection upstand), with land 4 (and thus rearwardly of the ejection upstand), with the ejection electrode also on the face, but separated therefrom.
Referring now to FIGS. 4 and 5 voltage pulses A and B, for example, are applied to the electrodes 9 and 19 respectively. The electrical potential between the electrodes 9 , 19 must change sufficiently for ejection to be achieved. When the voltage pulses are applied, the difference in the voltages V 1 and V 4 applied to the electrodes 9 and 19 is large and can be sufficient to cause ejection. However, it can be appreciated that lower voltage changes may be applied to each of the electrodes 9 , 19 than would need to be applied to the ejection electrode 9 , if the ejection electrode 9 was the only electrode used to facilitate ejection.
For example, the initial voltage V 2 , V 3 applied to each of the electrodes 9 , 19 may be 800V, and when ejection is desired the voltage on the ejection electrode 9 may be increased to V 1 =1150V and the voltage on the secondary electrode 19 may be decreased to V 4 =450V. Thus a localised net effect is a change of 700V at the ejection location, but the largest actual voltage change applied is only 350V. However, if the ejection electrode 9 was the only electrode used to facilitate ejection a voltage change of a full 700V would need to be applied to it. This is disadvantageous as it results, for example, in a less localised electric field causing capacitive coupling between ejection locations.
Alternatively, if both electrodes are in contact with the ink and the secondary electrode 19 is otherwise insulated, the voltages applied to the electrodes initially may be V 2 =750V to the ejection electrode 9 and V 3 =1100V to the secondary electrode 19 . When ejection is desired the voltages are switched, i.e. the voltage on the ejection electrode 9 is increased to V 1 =1100V and the voltage on a secondary electrode 19 is decreased to V 4 =750V. This embodiment relies on particles in the ink becoming charged creating a mean voltage level such that when the voltages on the electrodes are switched the net effect on the particles to be ejected is that they see twice the potential.
So, in both examples, the actual voltage changes used to cause ejection are only 350V, which is half the voltage change that would need to be applied to only the ejection electrode 9 if that were the only voltage to be changed. It can also be appreciated that only fairly simple circuitry is required to apply pulses of this nature.
In the printhead illustrated in FIG. 6, lines of equipotential 23 illustrate the electric field generated when ejection is caused from two neighbouring cells 5 A and 5 B by applying an electric pulse of 600V to the primary electrodes 9 in those cells only. It can be seen from FIG. 7, which is a close up view of the cell 5 B, that the electric field illustrated by the lines of equipotential 23 is not orthogonal to the desired droplet trajectory, which is the shortest path between the cell 5 B and the substrate 21 .
It will be appreciated that the resulting asymmetry in the field, as shown in FIG. 7, will act to drive the drops off the desired trajectory to one side and it has been found in this example that the field at the ejection location makes an angle of about 6° with the desired droplet trajectory. Such a deviation results in a placement error of approximately 100 microns at a head-substrate gap of 1.0 mm.
In another example, as shown in FIG. 8, pairs of secondary electrodes 19 are provided on a support 20 lying between the ejection electrodes 9 and a substrate 21 . The electrodes 19 are, in this example, generally planar and lie on faces of the support 20 parallel to the ejection electrodes 9 . Secondary electrodes 19 transverse to this plane or with any other shape or orientation can work equally well. Between the secondary electrodes 19 of each pair is a hole 22 , each of which is disposed directly in front of an ejection upstand 6 of a corresponding cell 5 A, 5 B, 5 C. The holes 22 may (as shown) take the form of slits or notches, and it can be appreciated that the support 20 is an integral unit with the illustrated sections joined together out of the plane of the figure. The holes 22 may alternatively be circular and there may then be a single secondary electrode 19 around the circumference of each hole. The secondary electrodes 19 are provided on the sides or around the periphery of the holes 22 such that they are proximate to ejected material passing through the holes 22 .
In operation, a voltage pulse is applied to an ejection electrode 9 and an inverted pulse is applied, in this example, to a pair secondary electrodes 19 of a corresponding hole 22 . In this example the pulse and inverted pulse are applied simultaneously. The benefits of this approach become clear when the effects of ejection in a cell 5 A on a neighbouring cell 5 B is considered.
FIGS. 8 and 9 show the field pattern when the primary electrode 9 is driven by a +300V pulse and the corresponding secondary electrodes 19 are driven by a synchronised −300V pulse. While the field is not everywhere symmetrical, the field at the ejection tip now lies parallel to the desired droplet trajectory. Thus, unlike the situation in which there are no secondary electrodes 19 or they are not charged, the field generated by a combined positive pulse from the primary electrode 9 and a simultaneous inverted pulse from the secondary electrodes 19 does not result in significant distortion of the field at neighbouring ejection cells 5 and such distortion that there is is not asymmetrical. With such an arrangement both the dot size and dot position become largely independent of the pattern in which neighbouring electrodes are driven.
In such an arrangement it is possible to drive all the cells 5 synchronously with a high duty cycle whilst maintaining a high image quality. This is particularly advantageous for high speed, high quality printing.
It has been found that for optimum performance the relative magnitude of the voltage pulse applied to the ejection electrode 9 and the voltage pulse applied to the secondary electrodes 19 should be varied dependant on the precise geometry of the apparatus. For a given geometry pulse magnitudes are varied so as to ensure that the field in each driven cell is parallel to the desired droplet trajectory, as illustrated in FIG. 9 .
A similar arrangement can also enable use of matrix addressing. Here ejection is obtained only when a pulse is applied to the ejection electrode 9 and an inverted pulse is applied to the secondary electrode 19 , but one or the other pulse may be applied to groups of cells 5 , without causing ejection. Such schemes permit a reduction in the total number of electronic drive devices required to drive a multi-channel apparatus.
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The invention relates to a method of ejecting material from a liquid within a chamber ( 5 ), comprising: controlling the application of first voltage pulses (A) to a first electrode ( 9 ) associated with the chamber and second voltage pulses (B) to a second electrode ( 19 ) associated with the chamber, such that when a voltage pulse (A) is applied to the first electrode ( 9 ) a voltage pulse (B), inverted with respect to the pulse (A) applied to the ejection electrode ( 9 ), is applied to the second electrode ( 19 ).
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is the U.S. National Phase Application under 35 U.S.C. § 371 of International Application No. PCT/NO2014/050088, filed Jun. 2, 2014, designating the U.S. and published as WO 2015/041537 on Mar. 26, 2015, which claims the benefit of Norwegian Patent Application No. 20131253, filed Sep. 8, 2013, which is hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for characterization of a fluid media or composition of fluid media by measuring a parameter related to electrical permittivity of the fluid. More particularly, the invention for characterization of a fluid relates to measuring a frequency of oscillation of an electrical relaxation oscillator oscillating at a frequency that is determined by an electrical capacitance of an electrical capacitor adapted for the fluid media or composition of fluid media to form part of a dielectric between two respective capacitor plate forming elements, whereby the electrical capacitance is made dependent on a permittivity of the fluid media or composition of fluid media.
BACKGROUND
A substantial number of commonly used and well known industrial processes involve transporting various media in pipes, and storage or separation of these in tanks or vessels, in particular pressurized tanks or vessels holding media under high pressure and at elevated temperatures. Determination of the type and character of the media contained in the tank or vessel by electronic means is a substantial element for managing and controlling such processes.
In several applications it is of importance that measurements can be made through a wall of a pressurized container. This applies to various industries, such as e.g. to the petroleum industry or the food industry. In the petroleum industry, it will be advantageous to be able to determine the relative composition of water, hydro carbons in various states, and gas using a probe positioned in the interior of a vessel or installed in a pipe wall. Similarly, a plurality of sensor devices according to the invention could advantageously be located at different levels in a tank, pipe, or vessel, to determine the composition of the media contained therein at corresponding levels, such as e.g. in a separator tank for processing and separating the various phases in a multi-phase flow from a hydrocarbon well. Thereby, that the level of water, gas, and oil within the tank may be determined on a continuous basis, and without interrupting a process involving the media. Typically, there will be considerable dynamics in a separator container when processing a production stream, such that distinct levels or clear interfaces between the various phases of the media contained in may not be formed. By applying electrical measurements based on a variation of electrical capacitance of an electrical capacitor of which the media in the pressurized container forms at least a part of a dielectric between the plates of the capacitor, the condition that the respective dielectric constant, herein also referred to as the electrical permittivity, of water, oil, and gas phases are widely different from each other is exploited, such that the relative portions of the different phases in a mixture at levels of interest within the container may be inferred.
In known solutions where relative portions of the different phases in a mixture at levels of interest within the container are inferred from electrical measurements based on a variation of electrical capacitance value C of an electrical capacitor as a function of the effective dielectric constant of the media to which the capacitor is exposed, the electrical capacitor of electrical capacitance value C is coupled with an inductive element of electrical inductance value L to form an electrical resonator having a resonance at angular frequency w that generally is generally given by w=(C*L) −1/2 . The angular frequency w at resonance, which is measured to infer the relative portions of the different phases in the media composition, hence, varies not only proportionally with the square root of the electrical capacitance value C of the electrical capacitor, but also proportionally with the square root of the electrical inductance value L of the inductor. Accordingly, the stability and accuracy of the frequency w to be measured as a function of the capacitance value C of the capacitor that is exposed to the media in the tank or container, greatly depends on the degree to which the inductance value L of the inductor may be controlled and kept stable for a measurement period, and sensitivity of the inductor to stimuli due to mechanical vibration and other environmental conditions that have an effect on the inductance value L of the inductor. In the case of monitoring the processing of a hydrocarbon well stream, or other fluid that is streaming or being pumped to a tank or container, typically at high or rapidly varying velocities, rapidly varying and powerful mechanical impulse and vibration noise is generated and inevitably coupled to the resonator circuit of the sensor, and requires complex or intricate mechanical, electrical and signal processing designs in order for the noise to filtered out or compensated for in the signal for measuring the frequency of the resonator.
Accordingly, there is a need for an improved apparatus and method for measuring a parameter related to electrical permittivity of a fluid or fluid media composition in a container.
The invention is in part enabled by the recent development of semiconductor based miniaturized circuitry, allowing for the provision of an ultra-accurate power supply using commercially available electronic components.
SUMMARY OF THE INVENTION
The invention provides an apparatus for determining a value of a parameter related to electrical permittivity of a fluid media or a composition of fluid media to be characterized in a first container. The apparatus advantageously comprises an electronic sensor comprising a first electrical capacitor formed by at least one electrode on a first side of a dielectric barrier and at least a first part of an electrically conducting housing surrounding at least a circumference part of the dielectric barrier and being sealingly attached thereto, the housing being adapted for being sealingly attached to wall of one of the first container or a second container so as to allow the fluid media or the composition of fluid media to be characterized to occupy a space between the first part of the housing and a second side of the dielectric barrier opposite to the first side, and an electronic relaxation type first oscillator circuit arranged on a first miniature circuit board being fit to the housing and connected with the first electrical capacitor, an electrical power supply connected to the first oscillator circuit and being adapted to supply electrical power to the first oscillator, and a first frequency measuring device coupled to the first oscillator circuit for providing a measured first oscillator frequency representing the electrical permittivity. The first oscillator circuit is arranged to oscillate at the first oscillator frequency dependent on an electrical capacitance of the first electrical capacitor and an electrical resistance of a first electrical resistor. The first oscillator circuit includes an electronic inverter circuit formed by a first integrated advanced high-speed CMOS electronic Schmitt trigger circuit. The electrical power supply is an ultra-stable electrical power supply adapted to supply electrical power to the first oscillator circuit at an ultra-stable supply voltage.
According to a first aspect, the electronic inverter circuit included in the first oscillator circuit an embodiment of the apparatus of the invention is formed by a NAND gate having one gate output connected to a first terminal of the first resistor and at least two gate inputs whereof a first gate input is connected to the electrode of the first capacitor and a second terminal of the first resistor.
In an apparatus of the invention according to the first aspect, a second one of the at least two gate inputs is connected to an electrical control line so as to provide a start/stop input of the first oscillator circuit.
According to second aspect of the apparatus of invention, the electrical resistance of the first electrical resistor is selected for the first oscillator frequency to be in a range from about 2 MHz to 100 MHz.
In an apparatus of the invention according to the second aspect, the electrical resistance of the first electrical resistor is selected for the first oscillator frequency to be in a range from about 10 MHz to 20 MHz.
According to third aspect of the apparatus of invention, the first integrated advanced high-speed CMOS electronic Schmitt trigger circuit is part of a miniature surface mount integrated circuit.
In an apparatus of the invention according to the third aspect, the first integrated advanced high-speed CMOS electronic Schmitt trigger circuit is a monolithic-silicon-on-sapphire integrated circuit.
In an apparatus of the invention according to the third aspect, the first integrated advanced high-speed CMOS electronic Schmitt trigger circuit contains a plurality of integrated advanced high-speed CMOS electronic Schmitt trigger circuits, and a second one of the plurality of integrated advanced high-speed CMOS electronic Schmitt trigger circuits is connected to a temperature stable second electrical capacitor and a temperature sensitive second electrical resistor to form a relaxation type second oscillator circuit being arranged to oscillate at a second oscillator frequency dependent on a temperature stable electrical capacitance of the second electrical capacitor and a temperature dependent electrical resistance of the second electrical resistor, and the apparatus further comprising a second frequency measuring device coupled to the second oscillator circuit for providing a measured second oscillator frequency representing a temperature of the apparatus, and a temperature compensating means adapted to modify the measured first oscillator frequency representing the electrical permittivity in response to the measured second oscillator frequency.
According to a further aspect of the apparatus of invention, the housing is a thick walled, hollow cylindrical housing with a substantially circular cross section, the dielectric barrier is positioned to seal off a first end of the cylindrical housing, the first miniature circuit board is positioned on the second end of the cylindrical housing, and the at least one first electrode being connected to the first oscillator circuit on the first miniature circuit board by a substantially straight electrical conductor positioned centrally in the cylindrical housing.
According to a yet further aspect of the apparatus of invention, the dielectric barrier is a ceramic substrate sealingly brazed at to the housing at the circumference part.
According to the invention, electrical capacitance measurements are made using a capacitive electronic sensor comprising a first electrical capacitor formed by at least one electrode on a ceramic substrate located proximal to a composition of media contained in a pressurized container and an electrically conducting housing surrounding part of the electrode on a ceramic substrate, and an electronic relaxation type oscillator being connected to the first electrical capacitor and arranged to oscillate at a frequency that is dependent on the electrical capacitance of the first electrical capacitor and comprising an integrated electronic Schmitt trigger circuit being fed with electrical power by an ultra-accurate power supply, to provide a stable, reliable, and accurate measurement of a characteristic parameter of the composition of the media.
In an embodiment of the invention, the electronic circuitry forming the electronic oscillator is arranged on a circuit board being attached and located in close proximity to the electrically conducting housing surrounding part of the electrode on a ceramic substrate.
In a further embodiment of the invention, a microprocessor or microcontroller is arranged on the circuit board, in close proximity to the.
The present invention provides a method of providing the apparatus of the invention, and methods of providing the apparatus of the invention according to respective aspects disclosed above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a generalized in part circuit schematic and in part block schematic illustration of a sensor device embodiment of the present invention;
FIG. 2 is a cross section view illustrating a part of a sensor device sub assembly adapted for an embodiment of the present invention; and
FIG. 3 is a perspective view illustration of a probe device comprising a plurality of embodiments of the sensor device of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following, a sensor apparatus according to the present invention is explained by way of exemplary embodiment, first with reference to FIG. 1 which provides a generalized illustration of the sensor and its application, in part in a schematic circuit presentation and in part in a block schematic presentation. With regard to its application, the sensor of the invention is illustrated in a cross section view as being installed in a wall 400 of a pressure carrying pipe or container, with the possibly pressurized medium or media, illustrated by “cloud” 300 , to be characterized by the sensor in located to the left of the wall 400 carrying sensor. The term high pressure as referred to in this explanation indicates that the medium 300 held in the container, which could be a tank, a pipe, or other vessel, is at a pressure that is either significantly higher or lower than the pressure of the volume in which other elements of the sensor are located. Accordingly, the area located to the right of the wall 400 is for convenience referred to as a low pressure area in which at least the electronic circuitry 200 of media dependent oscillator 210 is arranged, optionally, together with a co-located temperature dependent oscillator 220 . The sensor generally comprises a wall mounted mechanical sub assembly comprising a cylindrical metal sensor housing 105 sealingly mounted in the wall 400 . A window 110 of a pressure resistant solid dielectric material is sealingly attached to the housing, to provide a basis for forming an electric capacitor illustrated by Cm in which the medium 300 also will from part of the dielectric, and to ensure that the medium 300 does not leak from the high pressure side to the low pressure side. Advantageously, the dielectric window is made from a ceramic material, such as e.g. zirconium oxide, that provides high mechanical strength and over a broad temperature range, and a suitable dielectric permittivity. Accordingly, the side of the window facing the high pressure side is generally free, while the side of the window on the low pressure side carries over a large part of the surface an electrode 115 of a material of good electrical conductivity. Thereby an electric capacitor is formed by the electrode 115 and the housing 105 . In cases where the wall 400 is of an electrically conducting material, such as e.g. steel or other metal, the wall 400 provides an electrical extension of the housing 105 and serves also to form part of the electrical capacitance illustrated by Cm in which the medium 300 serves as a dielectric together with the dielectric window 110 . The electrode 155 has an very short electrical connection 120 to other elements of a highly stable and noise insensitive electronic relaxation oscillator, in particular as the electrical connection 120 is arranged to connect the electrode 155 to the Schmitt trigger input integrated circuit U 1 providing an inverting output which is fed back to the input by the resistor R 1 . Thus, the inverting output of the Schmitt trigger inverter being fed back to its input provides a 180 degree phase shift for astable operation to alternately charge and discharge the capacitor Cm, and the time constant provided by the stable resistance value of resistor R 1 and the medium 300 dependent capacitance value of sensor capacitance Cm determine the time for the voltage over the capacitor Cm to reach the very accurate and stable upper and lower thresholds, respectively, of the Schmitt trigger input of the integrated circuit U 1 determine the oscillation frequency of this astable circuit. The medium 300 dependent capacitor Cm has in embodiments of the invention typically a further capacitor C 1 connected in parallel, which could be provided by a stray capacitance between the housing 105 , or other conductive parts in its proximity which in the drawing of FIG. 1 has been illustrated by an electrical earth symbol. Advantageously, a separate capacitor C 1 is provided, in order to provide better control of that value, so as to provide an oscillation frequency of the astable relaxation oscillator 210 which is in a range from about 2 MHz to about 100 MHz. In respect of the present invention, it has been found that for probes comprising embodiments of the sensor apparatus of the present invention using an advantageous monolithic integrated silicon-on-sapphire AHC (advanced high speed CMOS) Schmitt trigger input integrated inverter or NAND gate circuit, adjusting values of R 1 and C 1 for the relaxation oscillator to operate at a frequency in the range from about 20 MHz to about 30 MHz has proven to provide a surprisingly highly stable oscillator frequency output as a function of electrical permittivity of the medium 300 on the high pressure side, over a wide range of temperatures, i.e. from room temperature up to temperatures in a range from 200 to 300 degrees C. It has been found that accuracy and stability of the capacitance sensor comprising the relaxation oscillator using a monolithic integrated silicon-on-sapphire AHC (advanced high speed CMOS) Schmitt trigger input integrated inverter or NAND gate circuit, is further enhanced significantly by providing an ultra-stable electrical power supply 250 for feeding the integrated Schmitt trigger circuit with a supply voltage that is stable to within 3 ppm. In advantageous embodiments of the present invention, the elements R 1 and U 1 , and, optionally, C 1 , are mounted on a common miniature circuit board connected by a short wire 120 the electrode 115 of the capacitive sensor 100 , so as to keep the elements of the relaxation oscillator thermally well coupled to each other. The miniature circuit board is advantageously arranged on and attached to an end part of the capacitive sensor sub assembly 100 .
In FIG. 1 is also illustrated the provision of a further relaxation oscillator 220 , formed by at least a temperature stable capacitor C 2 , a Schmitt trigger input integrated inverter or NAND gate circuit having its input connected to the temperature stable capacitor C 2 , and a temperature dependent feedback resistor R 4 connected between the input of the integrated Schmitt trigger circuit and its inverted output, providing astable operation at a temperature dependent frequency of oscillation. The further relaxation oscillator 220 is advantageously also arranged on the same miniature circuit board as the media dependent relaxation oscillator 210 , to provide on its output a frequency readable to a processor U 5 for use by the processor to provide a temperature compensating processing of an output of from the media 300 dependent relaxation oscillator 210 . Advantageously, the same miniature circuit board is also providing a first I/O (input/output) circuit U 3 for providing a digital indication of the medium 300 dependent oscillation frequency of the Schmitt trigger input integrated circuit relaxation oscillator 210 . Advantageously, the same miniature circuit board is also providing a second I/O (input/output) circuit U 4 for providing a digital indication of the temperature dependent oscillation frequency of the Schmitt trigger input integrated circuit relaxation oscillator 220 . Additional resistor R 2 and R 3 shown in FIG. 1 are optional, and may be included for advantageously controlling the precision, accuracy, dynamic range, or resolution, at which temperature is to determined by way of the oscillation frequency of the relaxation oscillator 220 . Advantageously, the Schmitt trigger input integrated inverter or NAND gate circuits employed for both relaxation oscillators 210 and 220 are provided by a single chip integrated monolithic silicon-on-sapphire integrated advanced high-speed CMOS (AHC).
The electrode 115 could be plate shaped, which is connected to an oscillator circuit 210 . The impedance and frequency characteristic of the oscillator circuit are also influenced by both the geometry of the sensor sub assembly and circuit board design, and the surrounding medium. This is being exploited to determine the dielectric constant, permittivity, of the medium 300 which surrounds or is close to the electrode 115 . It is also disclosed that the circuit contains a temperature sensitive resistor R 4 .
The nomenclature is otherwise like what it according to common practice may be indicated in electrical circuits. FIG. 2 shows in a schematic representation main features of a physical sensor sub assembly arrangement wherein the invention may put to use. In the cross section view in FIG. 2 , details illustrated of the sub assembly of the sensor 100 are the cylindrical housing 105 , the housing “front” part 106 to which the dielectric window 110 is sealingly attached at its circumference, the plate shaped electrode 115 being arranged on the “inwards” side of the dielectric window 110 , the metal rod or wire 120 connected to a central part of the “inward” face of the electrode 115 for connecting the electrode 115 to the input of the Schmitt trigger input AHC integrated silicon-on-sapphire inverter or gate circuit, and the “rear” part 107 of the cylindrical housing 105 on which there is an arrangement for attaching the common miniature circuit board onto which at least the media 300 dependent relaxation oscillator 210 is amounted. The centrally drawn broken line indicates a central axis of the circular cylindrical shape of the sensor housing 105 , hence also a line in the cross section plane of the view of FIG. 2 . The arrangement comprises a pressure proof vessel 105 in which a ceramic window 110 has been installed. On the window has been placed an electrode 115 which is connected to an oscillator 210 which is further collocated with a temperature detecting element R 4 which in turn is connected with an analog-to-digital converter. A connection from the electronic elements of the sensor arranged in a pressure proof container would as ordinary be a cable connection to a penetrator device (not shown) from which a connection is arranged to a display and control unit (not shown). The window 105 will be in close contact with the medium 300 , the properties of which are to be measured.
FIG. 3 shows in a perspective view one of several possible arrangements of a plurality of the Schmitt trigger relaxation oscillator based sensors in a “profiler” probe for determining a profile of a multi-phase medium in a tank, comprising a longitudinal probe housing with a probe housing wall 400 to be positioned vertically in a pressure tank, a plurality of sensors 100 according to the invention in two vertical rows of 12 sensors each in a staggered arrangement for providing a ½ sensor vertical spacing resolution in sensing characteristics of a medium 300 located at the face of each sensor 100 window, a flange 410 for attaching the probe sealingly to a wall of the pressure tank, and an external housing for accommodating electronics and other means that need not be co-located with each sensor device 100 , such as the ultra-stable electronic power supply for the integrated advanced high-speed CMOS electronic Schmitt trigger circuit relaxation oscillator 210 and the processor for processing measurements made by each sensor device 100 of the probe.
The invention resides in an improvement of known art in that the oscillator is made significantly less sensitive to noise by it being provided with a Schmitt trigger. Thereby achievable measurement accuracy is improved and calibration is simplified.
The stability of the integrated advanced high-speed CMOS electronic Schmitt trigger circuit relaxation oscillator based sensor according is further improved by combining it with the ultra-stable power supply, advantageously accommodated in a housing located separate from the sensor device.
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In an embodiment, an apparatus for determining a value of a parameter related to electrical permittivity of a fluid includes capacitor formed by at least one electrode on a first side of a dielectric barrier and at least a part of an electrically conducting housing surrounding the barrier. The housing is adapted for being sealingly attached to a container so as to allow the fluid to be characterized to occupy a space between the housing and a side of the barrier, and an electronic relaxation type oscillator circuit is arranged on a miniature circuit board being fit to the housing and connected with the capacitor. An electrical power supply is connected to supply electrical power to the oscillator at an ultra-stable supply voltage, and a frequency measuring device coupled to the oscillator circuit for providing a measured oscillator frequency representing the electrical permittivity dependent on capacitance and resistance.
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This invention relates to an improvement in rain gutter attachment and deals particularly with a section which may be interposed in a rain gutter when it is being made or reconstructed, and which will result in an effective means of removing the water from rain gutters. While particularly designed for use in countries where the rain gutters have a tendency to freeze and thaw, it is also effective for use in rain gutters which have a tendency to fill up with leaves so that they do not drain properly.
BACKGROUND OF THE INVENTION
In my previous U.S. Pat. No. 3,889,474 issued June 17, 1975, I describe a rain gutter attachment which fits into a notch formed in the forward side of the rain gutter, and which included a pair of outlets, located one above the level of the other. While this structure has proven to be very satisfactory, it has been found in action practice to have certain disadvantages. The main disadvantage lies in the fact that the structure requires that a notch be cut in the forward wall of the rain gutter, and that attachment brackets for connecting the attachment to the rain gutter had to be riveted or screwed with metal screws to the forward surface of the rain gutter. The main objection to this construction that in new installations, the notch had to be cut into the new section of rain gutter either before or after it was installed. Cutting a notch in the new rain gutter at the time of its installation was objectionable to many persons even though they recognized the advantage of the construction. A feature of the present invention resides in the provision of a structure which avoids these previous objections.
SUMMARY OF THE INVENTION
The present structure, while having certain advantages, is quite similar in effect to the construction previously produced. However, the step of cutting one or more notches in the rain gutter, and the securing of the brackets to the gutter has now been eliminated. Instead in forming new rain gutters on new structures, or reconstructing the rain gutters of old buildings, a section is inserted in the rain gutter which includes end portions which conform to the shape and contour of the remainder of the gutter, so that the attachment may be inserted into the conventional rain gutter at any point along its length by use of the conventional slip joints which were commonly used to connect the sections of a gutter in end abutting relation. These slip joints include an outer member which conforms to the outer shape of the conventional gutter, and an inner member having edges spaced inwardly from the inner surfaces of the outer member to accommodate the gutter sections therebetween. The manner of connecting the inner and outer slip joint members in parallel relation may vary with different constructions. However, one form of construction commonly used includes an outer member which conforms to the shape of the outer surface of the rain gutter, an inner member which is secured in fact contact with the center portion of the outer member and which is provided with offset edges which extend in spaced parallel relation to the inner surface of the outer member so as to accommodate a gutter section or other fitting therebetween. By the term other member, I mean to imply end caps or the like instead of an adjoining section.
A further feature of the present invention resides in the provision of a hose connection which may be supplied when desired to direct water into the rain gutter in order to clean it out and to cause the leaves in the gutter to be directed down the downspouts. By this means, most of the leaves and other debris collecting in the rain gutter may be directed to the downspouts, thereby eliminating much of the necessity of manually cleaning out the rain gutters when the downspouts become clogged up at their entrances.
A further feature of the present invention resides in the provision of a deflector which may be provided within the rain gutter adjoining the lowermost of the openings leading to a downspout. It has been found through the use of this deflector, twigs and material of this type which are within the rain gutter will normally tend to be deflected toward the rear side of the rain gutter, and will accordingly be turned by the flow of fluid within the rain gutter to be directed longitudinally of the downspout, and will not usually lie crosswise of the downspout in a manner to block the entrance thereto.
A feature of the preferred form of the invention lies in the provision of an inner flange encircling each outlet opening, and an outer flange in parallel spaced relation thereto. These flanges are preferably spaced apart a sufficient distance so that a sealant material may be inserted therebetween, before the elbow or other downspout member is attached thereto, causing the sealant material to flow on either side of the elbow or downspout member. Rivets or metal screws are then applied between the flanges, and through the downspout member to hold this member securely in position.
An additional feature of the present invention resides in the provision of a cover on the solar heating box encircling the downspouts. It has been found in actual practice that when this solar heating box is subjected to sunlight the temperature within the box greatly exceeds the outside temperature, thereby increasing the flow of fluid through the downspout. By providing heat to this particular area, much of the tendency for the downspouts to freeze up is eliminated, this being particularly true where the solar heat box contains elbows which tend to freeze up more quickly than the vertical portions of the downspouts which are normally exposed to the sun. Actual tests have proven that the temperature within the solar heating box is several degrees warmer than the outside temperature, and this is particularly true if the heating box is provided with a black or otherwise dark surface.
These and other objects and novel features of the present invention will be more clearly and fully set forth in the following specification and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a rain gutter attachment illustrating one form of construction thereof.
FIG. 2 is a perspective view of the section of rain gutter which is inserted into the rain gutter line.
FIG. 3 is a diagrammatic view of the blank showing the general construction of the rain gutter sections shown in FIG. 2.
FIG. 4 is a sectional view through one of the outlets for the rain gutter, the position of the section being indicated by the line 4--4 of FIG. 2.
FIG. 5 is a sectional view through the rain gutter showing one side of the solar heat box.
FIG. 6 is a sectional view showing the hose connection which may be provided at the top of the solar heat box.
FIG. 7 is a perspective view of a slightly different form of construction in which the downspouts extend angularly outwardly from the building. This construction is employed particularly where the eaves do not project well beyond the wall of the house or other structure.
FIG. 8 is a sectional view through the rain gutter, showing in elevation the solar heat box connected thereto and the downspouts extending angularly and outwardly therefrom.
FIG. 9 is an elevational view of the plate which may be attached to the flat portion of the rain gutter and showing inner and outer spaced flanges between which the downspout member may be anchored.
FIG. 10 is a sectional view through the rain gutter, and through portions of the upper outlet and elbow connected thereto.
FIG. 11 is a cross sectional view generally indicated by the line 11--11 of FIG. 10, but showing flanges secured to the outer spaced flanges for securing the outer spaced flanges to the flat outer surface of the central flat portion of the attachment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The rain gutter section which is inserted in line with the other sections is formed as perhaps best illustrated in FIGS. 2 and 3 of the drawings. Quite obviously this section is designed to fit the cross sectional shape of perhaps one of the most commonly used types of rain gutters at present on the market. The rain gutter section A is provided with a substantially vertical rear wall 10 which is normally folded along the fold line indicated by the dotted line 11 to a flange 12 which is usually folded to substantially 180° to extend in parallel relation to the rear wall 10. The rear wall 10 is connected along the fold line 13 to the bottom wall 14 which is normally supported at slight slant to the horizontal in order to slope toward the downspout area of the rain gutter. As this is common practice, it is not described in detail.
The forward edge 15 of the gutter bottom 14 is connected along the line 15 to the front wall which is indicated in general by the numeral 16. In the particular form illustrated the front wall 16 includes a vertical portion 17 connected to the bottom portion 14, and S-shaped portion 19 extending outwardly from the upper edge of the vertical portion 17, a vertical flange portion 20 secured to the upper edge of the S-shaped portion 19, a horizontal flange 21 extending horizontally toward the rear wall 10 and a reversely turned flange 22 secured to the edge of the horizontally extending portion 21 and which is bent outwardly beneath the flange 21 in order to present a rounded edge. While not being confined to the particular arrangement illustrated, this shape of gutter is customarily used in this part of the country, and the flange 20 and inturned flange 22 fill the purpose of reinforcing the construction, and preventing injury to the persons installing or cleaning out the rain gutter A. Obviously, the application's attachment could be used in rain gutters of almost any form, and the particular form illustrated is designed to merely illustrate the manner in which a gutter section may be formed rather than to limit the design to a particular type of construction.
As is perhaps best illustrated in FIG. 2 of the drawings, the ends 23 and 24 are designed to be of the same cross sectional shape as the rain gutter itself, and accordingly, the additional section A may be inserted by slip joints such as C which are well known in the art, and which are usually used for connecting the adjoining ends of rain gutter sections. No claim is made to the member C as they are well known in the art, and are commonly used for connecting the adjoining ends of rain gutter sections together.
The rain gutter section A differs from most such sections in having a flat center portion 25 to facilitate the attachment of the solar heat chamber B which will be described. As illustrated in FIGS. 1 and 5 of the drawings, the solar heat chamber B includes parallel side walls 26, a bottom wall 27, and a front wall 29. In preferred form, a cover 30 is equipped with peripheral flanges such as 31, and front and rear flanges such as 32 and 32' form a cover for the solar heat box B, and provide a means of access to the interior thereof. By removal of the cover, the interior of the solar heat box B is readily available.
In the form of construction illustrated in FIGS. 1 through 6 elbows such as 33 and 34 are in communication with the spouts 35 and 36 which are extending forwardly from the flat portion 25 and which are shown in FIG. 2 as extending through the apertures 37 and 39 in the flat portion 25 of the attachment. The purpose of this entire arrangement is to provide communication between the rain gutter 10 and the downspouts, of which the elbows 33 and 34 are elements.
In the present application and claims, it is desired to point out that the downspout members may either extend angularly outwardly from the house or other building or may comprise angles which are connected to vertical downspouts in the event the vertical downspouts do not interfere with the drainage of water. Usually, in portions of the country which are subject to severe cold, the eaves extend well beyond the building so that a sidewalk may extend beneath the eaves to protect persons entering or leaving the building. However, in some instances, the roof terminates closely adjacent the house wall. In such a case, it is preferable to extend the downspouts outwardly and downwardly to a point spaced from the house so that the water collected may be delivered to points spaced away from the house walls sufficiently so that water will not drain into the basement.
In the construction which has been described, the side walls 26 of the solar heat housing are provided with outwardly extending flanges 42 which are riveted or otherwise secured as indicated at 43 to the flat portion 25 of the rain gutter attachment A. As is also evident from FIG. 5 of the drawings, a deflector 44 is provided above the hose connection 45 so that the water from the hose connection will be deflected into the rain gutter. Also as indicated in FIGS. 2 and 4 of the drawings, a deflector 46 is attached to the inner surface of the flat portion 25 of the gutter section 10 which seems to serve a unique purpose. In other words, twigs or other such material which flow toward the outlets through the rain gutter 10 have a tendency for the forward ends thereof to be deflected toward the center of the gutter, and the water flowing through the gutter has a tendency to turn such twigs into the lower outlet 37 to be directed to the downspouts.
FIGS. 7 and 8 of the drawings indicate a very similar construction, but in which the downspouts extend outwardly and downwardly from the box B. This requires a somewhat different shape of box in which the forward wall 47 is somewhat taller from the creased line 34 and includes apertures 49 and 50 through which the straight portions 51 and 52 of the downspouts extend. While not shown in the drawings, this type of construction is used on housings or buildings where the edges of the roof terminate close to the house, and in which there is a sidewalk extending close to the house. The downwardly inclined downspout portions 51 and 52 are provided with elbows which turn downwardly so that liquid from the rain gutters may be deposited at a desired distance from the house. In actual practice, an ornamental grill or other covering member is supported by posts spaced on either side of the vertical downspouts so as to provide an ornamental appearance which will not detract from the appearance of the house. The vertical downspouts usually terminate in spaced relation to the ground so that any water freezing in these portions of the downspouts will drop downwardly to the ground when the sun heats these members. In view of the fact that this is a somewhat different arrangement from that previously described, it has not been illustrated except for the fact that the downspout portions 51 and 52 incline outwardly and downwardly from the rain gutter 10. A cover 53 serves the same capacity of the cover 30 which has been previously described, and acts to close the upper end of the solar heat box B.
FIGS. 9 and 10 of the drawings show a somewhat improved construction which has been found somewhat easier to produce than that previously described. As is shown, the structure still involves the flat plate 25 forming a part of the rain gutter. However, in the construction shown in these figures, in place of the separate discharge members 35 and 36, out turned flanges 60 are provided encircling the lower opening 37, and similar out turned flanges 61 are provided encircling the upper apertures 39. These out turned flanges 60 and 61 form the same purpose as the spouts 35 and 36. However, a plate 62 is secured to the outer surface of the flat portion 25 of the rain gutter section 10, and the plate 60 is apertured to conform with the apertures 37 and 39 and the plate portion 25. Flanges 63 and 64 are formed outwardly from the apertures in the plates 62 to provide flanges which are in spaced relation to the flanges 60 and 61. The end of the downspout member is inserted between these flanges and is preferably cemented in place. Rivets or metal screws are inserted through the apertures 65 and 66 in order to hold the elbows or downspout portions in position.
It should be explained that the downspout portions which have been described comprise either elbows such as are shown in FIGS. 1 through 5 of the drawings or straight lengths of downspouts as indicated in FIGS. 7 and 8. In any event, with the construction shown in FIGS. 9 and 10, the elbows or downspouts portions may be connected by rivets 67 to secure the downspout portion in place. FIG. 11 shows a construction which is very similar to that shown in FIGS. 9 and 10 except for the fact that in place of the plate 62, outwardly extending flanges such as 70 are provided to hold the outer flanges 63 and 64 in place. Here again, a sealing compound would be inserted between the flanges before the elbows or downspout members are inserted so as to thoroughly seal these members together before they are riveted or otherwise secured.
In view of the different variations of rain gutters and downspouts, it is difficult to explain the possibilities of the various forms of construction. In view of the fact that the downspouts and the elbows are normally of the same general periphery, any of the construction could be used, but actually the structure shown in FIGS. 9 through 11 are probably the easiest and hold the downspout portions most securely. In the following claims, in describing the words "downspout portions", it is desired to make it understood that the downspout portions could be either elbows or straight portions depending upon the particular situation.
In accordance with the Patent Statutes, I have described the principles of construction and operation of my Rain Gutter Attachment, and while I have endeavored to set forth the best embodiments, I desire to have it understood that obvious changes may be made within the scope of the following claims without departing from the spirit of my invention.
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A rain gutter attachment which includes a section capable of fitting between two sections of a rain gutter of conventional form. This attachment section includes a central flat outer surface having a pair of apertures therethrough, one aperture adjoining the bottom of the attachment center, and the other aperture above the level of the first and offset laterally therefrom. Elbows or straight sections of downspout are in communication with these apertures. A solar heat box is secured to the flat central portion of the attachment enclosing portions of the elbows or downspout sections.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a 35 U.S.C. §371 National Phase conversion of PCT/FR2010/052846, filed Dec. 21, 2010, which claims benefit of French Application No.09 59291, filed Dec. 21, 2009 and French Application No. 10 54674, filed Jun. 14, 2010, the disclosures of which are incorporated herein by reference. The PCT International Application was published in the French language.
TECHNICAL FIELD
The present invention relates to a flexible underwater pipe intended for transporting fluid in deep water. These fluids are notably gases or liquids, preferably hydrocarbons.
BACKGROUND OF THE INVENTION
Flexible pipes for transporting hydrocarbons generally comprise from the outside to the inside of the pipe:
an external polymeric sheath for protecting the whole of the pipe and notably for preventing seawater from penetrating into its thickness, tensile armor plies, a pressure vault, a internal sealing polymeric sheath, and optionally a metal carcass.
If the pipe comprises a metal carcass, it is said to be with a rough bore. If the pipe is without any metal carcass, it is said to be with a smooth bore. Generally, for transporting hydrocarbons, a pipe comprising a carcass is preferred while a pipe without any carcass will be suitable for transporting water and/or pressurized steam.
The metal carcass and the pressure vault consist of longitudinal elements wound with a short pitch, and they give the pipe its resistance to radial forces while the tensile armor plies consist of metal wires wound with long pitches in order to spread out axial forces.
The nature, the number, the dimensioning and the organization of the layers forming the flexible pipes are essentially related to their conditions of use and of installation. The pipes may comprise additional layers to those mentioned above.
In the present application, the notion of winding with a short pitch designates any helicoidal winding with a helix angle close to 90°, typically comprised between 75° and 90°. The notion of winding with a long pitch, as for it, covers helix angles of less than 55°, typically comprised between 25° and 55° for the armor plies.
These flexible pipes are notably suitable for transporting fluids, notably hydrocarbons in sea beds and this at great depths. More specifically, they are said to be of the unbonded type and they are thus described in the normative documents published by the American Petroleum Institute (API), API 17J and API RP 17B.
The flexible pipes may be used at great depth, typically down to 2,500 meters deep. They allow transport of fluids, notably of hydrocarbons, having a temperature attaining 130° C. typically and which may even exceed 150° C. and an internal pressure which may attain about 1,000 bars, or even 1,500 bars.
The constitutive material of the internal sealing polymeric sheath has to be chemically stable and capable of mechanically withstanding the transported fluid and its characteristics (composition, temperature and pressure). This material should combine ductility, durability (generally the pipe should have a lifetime of at least 20 years), mechanical strength, heat and pressure resistance characteristics. The materials should notably be chemically inert with regard to the chemical compounds making up the transported fluid.
Pipes comprising a sealing polymeric sheath based on polymer, notably on polyamide or polyethylene, may notably be used. However, the thermomechanical properties of polymers, notably of polyamides or polyethylenes, under the conditions of use mentioned earlier (high temperature and pressure, high acidity and presence of water) may be significantly reduced. In particular, polyamides may be degraded by hydrolysis. Further, it is difficult to use polyethylenes at temperatures above 65° C. Thus, many studies have been reported for attempting to improve these properties, in particular for improving their resistances to creep and to tension or compression. For this, the mobility of the polymer chains relatively to each other should be reduced by longer and/or more cross-linked polymer chains.
Thus, international application WO2007/078038 describes a thermoplastic resin, notably in polyamide, comprising nanoparticles of metal oxide, the surface of which is covered with silanes, allowing binding between the polyamide and the nanoparticles.
International application WO93/05086 describes a method for increasing the molecular mass of polyamides by an amidation process applying a catalyst of the phosphonic acid type in the presence of titanium dioxide comprising alumina.
International application WO2008/113362 describes a flexible pipe comprising a polymeric layer, notably based on polyamide, comprising a cationic clay, notably of the smectite type.
International application WO 03/078134 describes a flexible pipe comprising a layer based on polyethylene cross-linked with a peroxide.
International application WO 91/19924 describes a flexible pipe comprising a layer based on polyethylene cross-linked with a silane.
The mechanical properties of the modified polyamide or polyethylenes of these applications are affected. Nevertheless, these properties further have to be improved in order to allow transport of fluids under the extreme conditions mentioned above.
SUMMARY OF THE INVENTION
One of the objects of the present invention is therefore to provide a flexible underwater pipe comprising a layer based on a polymer having improved thermomechanical properties allowing its use for transporting fluids, such as hydrocarbons, notably at high pressure and at high temperature.
For this purpose, according to a first object, the object of the invention is a flexible underwater pipe intended for transporting fluids, notably hydrocarbons, comprising at least one layer comprising a polymeric resin comprising at least one polyhedral oligomeric silsesquioxane chemically bound to the polymer.
Polyhedral oligomeric silsesquioxanes (Polyhedral Oligomeric SilSesquioxane POSS) according to the invention, hereafter POSS, may be molecules with nanometric dimensions of formula (RSiO 1.5 ) x wherein x represents an integer greater than or equal to 6 and less than or equal to 12, x representing the degree of polymerization, and wherein R represents a substituent, it being understood that the groups R of each RSiO 1.5 group may be either identical or different from each other, at least one group R of the POSS being able to form a chemical bond with said polymer.
The POSSes have a <<cage-shaped>> structure comprising silicon and oxygen atoms, and wherein each silicon atom bears a substituent R.
When at least one of the R groups is an organic substituent, the POSSes are organic/inorganic hybrid entities.
The groups R may be of a very diverse nature. Each group R may independently of the other groups R be:
inorganic, for example a halogen, —SH, —OH or —NH 2 , or organic for example:
a group —OSi(R 7 )(R 8 )(R 9 ), wherein R 7 , R 8 and R 9 independently represent OH, an alkyl, an alkoxyl or a group
a group —OR 17 , wherein R 17 represents H or an alkyl,
a saturated, unsaturated (notably a vinyl group) or aromatic, linear, branched or cyclic hydrocarbon chain, optionally substituted with one or several groups, notably selected from a halogen or a group —OCOCl, —COCl, —SO 2 Cl, —COOR 1 , —COR 1 , —CR 1 R 2 Cl, —OR 1 , —OSi(R 7 )(R 8 )(R 9 ), —SR 1 , —NR 1 R 2 , —NR 1 COR 2 , —COR 1 NR 2 , —NR 1 —CO—NR 2 R 3 , —O—CO—NR 1 , —NR 1 , —CO—OR 2 , —CN, —NO 2 , —NCO,
wherein R 7 , R 8 and R 9 are as defined above and R 1 , R 2 and R 3 represent independently H or a saturated, unsaturated or aromatic, linear, branched or cyclic hydrocarbon chain, itself optionally substituted with or several of the groups selected from a halogen or a group —OCOCl, —COCl, —SO 2 Cl, —COOR 4 , —COR 4 , —CR 4 R 5 Cl, —OR 4 , —SR 4 , —NR 4 R 5 , NR 4 COR 5 , —COR 4 NR 5 , —NR 4 —CO—NR 5 R 6 , —O—CO—NR 4 , —NR 4 —CO—OR 5 , —CN, —NO 2 , —NCO,
wherein R 4 , R 5 and R 6 represent independently H or a saturated, unsaturated or aromatic, linear, branched or cyclic hydrocarbon chain, it being understood that at least one of the R groups of POSS is able to form a chemical bond with the polymer.
In the sense of the present application, a halogen is selected from fluorine, bromine, iodine and chlorine.
A hydrocarbon chain preferably comprises from 1 to 10 carbon atoms, notably from 2 to 6 carbon atoms. The preferred hydrocarbon chains are alkyl groups (preferably having from 1 to 10 carbon atoms, in particular 2 to 6 carbon atoms), alkenyl groups (preferably having from 2 to 10 carbon atoms, in particular from 2 to 6 carbon atoms), aryl groups (preferably having from 6 to 10 carbon atoms), arylalkyl groups (preferably having from 7 to 10 carbon atoms) or alkylaryl groups (preferably having from 7 to 10 carbon atoms). The vinyl group is the preferred alkenyl group, the phenyl group is the preferred aryl.
The alkyl groups preferably have from 1 to 10 carbon atoms, in particular from 2 to 6 carbon atoms. An alkoxyl group is an —O-alkyl group.
The following diagram illustrates four exemplary POSS structures suitable for the invention.
The definition of POSS in the sense of the application also comprises the POSSes of formula [(RSiO 1.5 ) x′ (XRSiO 1.0 ) x″ ], wherein:
R is as defined above, x′ and x″ represent independently of each other an integer, so that the sum of x′ and x″ is greater than or equal to 6 and less than or equal to 12, and X represents a substituent of the silicon, the groups X of each group XRSiO 1.0 may be identical or different from each other and identical or different from the R substituents, it being understood that at least one of the R and one of the X is able to form a chemical bond with the polymer.
These compounds, illustrated in the following diagram, correspond to POSSes wherein some of the Si—O—Si functions are broken (a partly open cage) as illustrated in the diagram below. The silicon atoms located at the opening of the cage are substituted with groups R and X. The silicon atoms of the cage are substituted with groups R.
For example, the following diagram represents POSSes wherein an Si—O—Si function is in a hydrolyzed form (X represents OH).
Typically, each group X may be, independently of the other groups X and groups R, a group which is:
inorganic, for example a halogen, —SH, —OH or —NH 2 , or organic, for example:
a group —OSi(R 7 )(R 8 )(R 9 ), wherein R 7 , R 8 and R 9 represent independently OH, an alkyl, an alkoxyl or a group,
a group —OR 17 , wherein R 17 represents H or an alkyl,
a saturated, unsaturated (notably a vinyl group), or aromatic, linear, branched or cyclic hydrocarbon chain, optionally substituted with one or several groups, notably selected from a halogen or a group —OCOCl, —COCl, —SO 2 Cl, —COOR 1 , —COR 1 , —CR 1 R 2 Cl, —OSi(R 7 )(R 8 )(R 9 ), —SR 1 , —NR 1 R 2 , —NR 1 COR 2 , —COR 1 NR 2 , —NR 1 —CO—NR 2 R 3 , —O—CO—NR 1 , —NR 1 —CO—OR 2 , —CN, —NO 2 , —NCO,
wherein R 7 , R 8 and R 9 are as defined above and R 1 , R 2 and R 3 represent independently H or a saturated, unsaturated or aromatic, linear, branched or cyclic hydrocarbon chain, itself optionally substituted with one or several of the groups selected from a halogen or a group —OCOCl, —COCl, —SO 2 Cl, —COOR 4 , —COR 4 , —CR 4 R 5 Cl, —SR 4 , —NR 4 R 5 , NR 4 COR 5 , —COR 4 NR 5 , —NR 4 —CO—NR 5 R 6 , —O—CO—NR 4 , —NR 4 —CO—OR 5 , —CN, —NO 2 , —NCO,
wherein R 4 , R 5 and R 6 represent independently H or a saturated, unsaturated or aromatic, linear, branched or cyclic hydrocarbon chain.
The inventors have discovered that polyhedral oligomeric silsesquioxanes chemically bound to a polymer allow reduction in the mobility of the polymer chains relatively to each other and therefore improvement in the thermomechanical properties of the polymer, in particular improvement in its resistance to creep and to tension or compression.
By a polyhedral oligomeric silsesquioxane <<chemically bound>> to the polymer, is meant that the polyhedral oligomeric silsesquioxane comprises at least one group capable of forming a chemical bond with the polymer. By <<group capable of forming a chemical bond>> is meant any atom, function capable of forming a chemical bond or any group bearing such an atom or such a function. The chemical bond is for example a covalent, ionic bond or a hydrogen bond. Preferably said at least one polyhedral oligomeric silsesquioxane is bound to the polymer through at least one covalent and/or hydrogen bond.
At least one of the groups R or X, as defined above, of POSS is therefore chemically bound to the polymer.
In a first embodiment, the chemical bond between the polymer and the POSS in the layer of the pipe is a covalent bond. This chemical bond may notably be a bond of the ester, amide, amine, ether, thioether, urea, imine, imide, sulfonamide, carbamate, phosphate, siloxane (Si—O—Si), silane (Si—C) or carbon-carbon type. This embodiment is particularly preferred since the covalent bonds are generally the most stable chemical bonds.
In a second embodiment, the chemical bond between the polymer and the POSS in the layer of the pipe is a hydrogen bond. This chemical bond exists in the presence of at least one hydrogen bond donor and at least one hydrogen bond acceptor, one being on the POSS and the other one being on the polymer. The acceptor is notably a fluorine, nitrogen or oxygen atom and the donor is an acid H, typically such as an H atom born by an amine or an alcohol, but also an amide, a urea, a carbamate . . . .
In a third embodiment, the polymer and the POSS of the layer of the pipe are both bound through a covalent bond and a hydrogen bond.
The polymer of the layer of the flexible pipe is a polymer capable of chemically binding to the POSS, typically through hydrogen and/or covalent bonds. The polymer may comprise in its backbone, groups capable of chemically binding to the POSS. It may also comprise functional side chains. Functional side chains are for example side chains bearing COOH, NH 2 , OH, epoxide, nitrile, anhydride or trialkoxysilane groups. The polymer is preferably an organic polymer (i.e. comprising carbon atoms), and in particular the backbone of which is organic.
In a first embodiment, the polymer of the layer of the flexible pipe is a polyamide optionally comprising functional side chains notably as defined above. The polyamides are advantageous since they may be used at high temperatures, generally above 100° C. The polyamide of the layer of the flexible underwater pipe may be a homopolyamide or a copolyamide, such as for example polyamide 6, polyamide 4.6, polyamide 6.6, polyamide 11, polyamide 12, polyamide 12.12, polyamide 10.12, polyamide 6.10, polyamide 6.12, polyamide 6.9, polyamide 9.9, polyamide 9T, polyamide 12T, polyamide 10T, polyamide 12I, polyamide 12T, polyamide 12T.12, polyamide 10T.12, polyamide 12T.106, polyamide 10T.106, polyamide 6.66, polyamide 6.612, polyamide 6.66.610, polyamide 6.66.12, polyamide 6.6T, polyamide 6T.6, polyamide 6T.12, polyamide 6T.6I, polyamide 6I.6T, polyamide 6.6I, polyamide 6T.66, polyamide 6T.66.12, polyamide 12.MACMI, polyamide 66.6I.6T, polyamide MXD6.6, MXD10, a polyphthalamide, polyarylamide, polyesteramide, polyetheresteramide, polyetheramide or mixtures thereof.
Preferably, the polyamide is selected from polyamide 11, polyamide 12, polyamide 6.12 and polyphthalamide.
When the polymer of the layer of the flexible pipe is a polyamide, the polyamide and the POSS of the layer of the pipe may be bound through a covalent bond and/or a hydrogen bond.
In a second embodiment, the polymer of the layer of the flexible pipe is a polyethylene optionally comprising functional side chains. Polyethylene polymers are of interest since they are not degraded by hydrolysis and are inexpensive. Functional side chains are for example side chains bearing COOH, NH 2 , OH, epoxide, nitrile, anhydride or trialkoxysilane, preferably trialkoxysilane groups, notably function side chains bearing groups of formula —Si—(OR 10 )(OR 11 )(OR 12 ), wherein R 10 , R 11 and R 12 are independently alkyl groups, preferably n-propyl, isopropyl, ethyl or methyl, more preferably methyl. For example, the polyethylene may comprise side chains of formula —CH 2 —CH 2 —Si—(OR 10 )(OR 11 )(OR 12 ), wherein R 10 , R 11 and R 12 are as defined above, in particular side chains of formula —CH 2 —CH 2 —Si—(OMe) 3 , which are more preferred since the Si—OMe functions are easily hydrolyzable into silanol functions Si—OH.
The polyethylene polymers comprising functional side chains are either commercial polymers or may be prepared by techniques known to one skilled in the art. For example, the polyethylene polymers comprising side chains of formula —CH 2 —CH 2 —Si—(OR 10 )(OR 11 )(OR 12 ) may be prepared by reaction between polyethylene and the vinyl silane derivative of formula CH═CH—Si—(OR 10 )(OR 11 )(OR 12 ) in the presence of peroxide (Sioplast process).
A flexible pipe comprising a layer comprising a polyethylene resin comprising at least one POSS chemically bound to the polyethylene may advantageously be used at higher temperatures than a flexible pipe comprising a layer comprising a polyethylene resin, and in particular at temperatures compatible with a use for transporting hydrocarbons.
When the polymer of the layer of the flexible pipe is a polyethylene optionally comprising functional side chains, the polyethylene and the POSS of the layer of the pipe are generally bound through a covalent bond.
In a third embodiment, the polymer of the layer of the flexible pipe is a homopolymer or copolymer of polyvinylidene fluoride optionally comprising functional side chains. A homopolymer or copolymer of polyvinylidene fluoride is notably a bearer of fluoride functions with which the POSS is capable of forming hydrogen bonds.
The layer comprising a polymeric resin comprising at least one POSS chemically bound to the polymer of the flexible underwater pipe may also comprise additives, such as antioxidants, plasticizers and any other fillers such as carbon black for example.
The layer comprising at least one layer comprising a polymeric resin comprising at least one POSS chemically bound to the polymer may notably be the sealing internal polymeric sheath in a flexible underwater pipe as defined above, but it may also be an intermediate layer located between two other layers.
In an embodiment, the flexible underwater pipe further comprises the following layers:
an external polymeric sheath, at least one tensile armor ply, optionally a pressure vault, and optionally a metal carcass.
According to a second object, the invention relates to a method for preparing the aforementioned flexible underwater pipe, comprising the following steps:
a) forming a polymeric resin comprising at least one polyhedral oligomeric silsesquioxane comprising the mixture of a polymer and of at least one polyhedral oligomeric silsesquioxane, for which at least one of the silicon atoms is substituted with a group capable of forming a hydrogen and/or covalent bond with said polymer, b) extruding in order to form a layer comprising said resin, c) assembling the layer obtained in step b) with at least one other layer.
The method generally comprises a subsequent step d) for cross-linking the assembly obtained during step c). This cross-linking is generally achieved by putting said assembly in the presence of water (or of humidity) at high temperatures, notably from 85 to 99° C., preferably from 95 to 98° C., for example by immersion in hot water or by circulation of hot water. The duration of the cross-linking step d) is variable, and notably depends on the thickness of the layer comprising the polymeric resin comprising POSS.
The polymer applied in the method is as defined above.
Said group capable of forming a hydrogen and/or covalent bond with said polymer is preferably selected from the R and/or X groups defined hereinbefore and capable of forming a hydrogen and/or covalent bond with said polymer, notably such that said R and/or X is(are) selected from a halogen, —SH, —OH, —NH 2 , a group —OSi(R 7 )(R 8 )(R 9 ), wherein R 7 , R 8 and R 9 represent independently OH, an alkyl, an alkoxyl, or a group
or a group —OR 17 , wherein R 17 represents H or an alkyl, an unsaturated hydrocarbon chain (notably a vinyl group) or a saturated, unsaturated or aromatic, linear, branched or cyclic hydrocarbon chain, substituted with one or several groups selected from a halogen, or a group —OCOCl, —COCl, —SO 2 Cl, —COR 1 , —CR 1 R 2 Cl, —OR 1 , —OSi(R 7 )(R 8 )(R 9 ), —SR 1 , —NR 1 R 2 , —NR 1 COR 2 , —COR 1 NR 2 , —NR 1 —CO—NR 2 R 3 , —O—CO—NR 1 , —NR 1 —CO—OR 2 , —CN, —NO 2 , —NCO,
wherein R 7 , R 8 and R 9 represent independently H or an alkyl and R 1 , R 2 and R 3 represent independently H or a saturated, unsaturated or aromatic, linear, branched or cyclic hydrocarbon chain, itself optionally substituted with one or several of the groups selected from a halogen or a group —COCl, —OCOCl, —SO 2 Cl, —COOR 4 , —COR 4 , —CR 4 R 5 Cl, —OR 4 , —SR 4 , —NR 4 R 5 , NR 4 COR 5 , —COR 4 NR 5 , —NR 4 —CO—NR 5 R 6 , —O—CO—NR 4 , —NR 4 —CO—OR 5 , —CN, —NO 2 , —NCO,
wherein R 4 , R 5 and R 6 represent independently H or a saturated, unsaturated or aromatic, linear, branched or cyclic hydrocarbon chain.
In a first embodiment of the method, said groups R and/or X of the POSS capable of forming a covalent bond with the functions of the polymer is(are) selected from a halogen, —OH, —COOH, —NH 2 , —SH, a —OSi(R 7 )(R 8 )(R 9 ) group, —OR 17 , wherein R 7 , R 8 , R 9 and R 17 are as defined above or a saturated, unsaturated, aromatic, linear, branched or cyclic hydrocarbon chain substituted with one or several groups selected from a halogen or a group —COCl, —OCOCl, —SO 2 Cl, —COOH, —CR 1 R 2 Cl, —OH, —SH, —NR 1 H, —CN, —NCO,
wherein R 1 , R 2 et R 3 are as defined above.
Said more preferred R and/or X capable of forming a hydrogen and/or covalent bond with said polymer is(are) selected from:
a group —OH, —COOH or —NH 2 , preferably —OH, a group —OR 17 wherein R 17 represents an alkyl, preferably a methyl, since the —Si—OMe group (the silicon stemming from the cage of the POSS) is advantageously easily hydrolyzable into a silanol Si—OH function, a group —OSi(R 7 )(R 8 )(R 9 ), preferably a group
or a group —OSi(OMe) 3 , for which the Si—OMe functions are advantageously easily hydrolyzable into a silanol Si—OH function,
a vinyl group —CH═CH 2 , a group of formula —(CH 2 ) 3 —NH—(CO)—CH═CH—COOH.
Thus, in this first embodiment, during step a), at least one covalent bond is formed between the polymer and the POSS.
As an illustration, a substituent of the POSS bearing:
a halogen function may form an amine bond with an amine function of the polymer (by nucleophilic substitution) notably when the polymer is a polyamide, an alcohol function may form an ester bond with a carboxylic acid function of the polymer, notably when the polymer is a polyamide, a thiol function may form a thioester bond with a carboxylic acid function of the polymer, notably when the polymer is a polyamide, an epoxide function may form an ester bond with a carboxylic acid function of the polymer and/or an amine bond with an amine function of the polymer, notably when the polymer is a polyamide, an amine function may form an amide bond with a carboxylic acid function of the polymer, notably when the polymer is a polyamide, a carboxylic acid, acyl chloride or anhydride function may form an amide bond with an amine function of the polymer, notably when the polymer is a polyamide, an isocyanate function may form a urea bond with an amine function of the polymer, notably when the polymer is a polyamide, a chloroformate function may form a carbamate bond with an amine function of the polymer, notably when the polymer is a polyamide, a sulfonyl chloride function may form a sulfonamide bond with the amine function of the polymer, notably when the polymer is a polyamide, a hydroxyl function may form a siloxane bond with a trialkoxysilane group of the polymer, notably when the polymer is a polyethylene comprising side chains bearing trialkoxysilane groups, an alkoxyl function may form a siloxane bond with a trialkoxysilane group of the polymer, notably when the polymer is a polyethylene comprising side chains bearing trialkoxysilane groups, a function —OSi(R 7 )(R 8 )(R 9 ) wherein R 7 , R 8 and R 9 represent independently OH or an alkoxyl may form a siloxane bond with a trialkoxysilane group of the polymer, notably when the polymer is a polyethylene comprising side chains bearing trialkoxysilane groups, a vinyl group may form a carbon-carbon bond with a polyethylene.
The POSSes of the following formulae (I), (II), (III), (IV), (V), (VII), (VIII), (IX), (X), (XI), (XII), (XIII) and (XIV) may for example be applied during step a) of the first embodiment:
wherein R represents a saturated, unsaturated or aromatic, linear, branched or cyclic hydrocarbon group or a group as defined for R and/or X in the first embodiment of the method.
Preferably, in the aforementioned formula (I), R represents
and in the aforementioned formulae (II), (III), (IV) and (V), R represents an alkyl, for example an isobutyl group, these POSSes are advantageously commercially available.
The compounds of formula (VII) and (VIII) are commercially available.
Preferably, when the polymer is a polyamide optionally comprising side chains, the POSSes of formulae (I), (II), (III), (IV) or (V) are applied during step a).
Preferably, when the polymer is a polyethylene comprising side chains bearing trialkoxysilane groups, notably comprising a group —Si—(OR 10 )(OR 11 )(OR 12 ), wherein R 10 , R 11 and R 12 are as defined above, in particular side chains of formula —CH 2 —CH 2 —Si—(OR 10 )(OR 11 )(OR 12 ), wherein R 10 , R 11 and R 12 are as defined above, the POSSes of formulae (VII), (VIII), (IX) or (X) are applied during step a).
Preferably, when the polymer is a polyethylene, the POSSes of formulae (XI), (XII), (XIII) or (XIV) are applied during step a).
POSSes for which at least one of the silicon atoms is substituted with a substituent bearing a group capable of forming a covalent bond with a polymer, and in particular bearing one of the aforementioned groups, may notably be prepared by following the methods described in the international application WO 01/10871.
The mixing of step a) may notably be achieved by mixing the polymer in the molten state (<<melt mixing>>), by compounding, extrusion, reaction extrusion (i.e. by performing steps a) and b) simultaneously). Except when step a) is performed by reactive extrusion, the mixture of step a) may be used either as a master mixture or as a main matrix for forming the layer comprising the polymeric resin.
Generally, in step a) of the method when the mixture of the polymer and of the POSS forms the main matrix, 1 to 10% by weight, preferably 1 to 5% by weight, of POSS are used based on the total weight of the mixture. When the mixture of the polymer and of the POSS is used as a master mixture, the POSS mass percentage in the polymeric resin may attain 30% or even 50%.
During step a) of the method, additives may be added, in particular the aforementioned ones.
In this first embodiment, the method may comprise a chemical coupling step for forming a covalent bond between said group and the functions of the polymer, for example by hydrolysis or a radical reaction.
This chemical coupling step may for example be a hydrolysis, notably an acid hydrolysis. For example:
if the polymer is a polyethylene comprising side chains bearing a trialkoxysilane group, preferably of formula —CH 2 —CH 2 —Si—(OR 10 )(OR 11 )(OR 12 ), with hydrolysis, it is possible to hydrolyze the trialkoxysilane group into a silanol group, capable of binding to at least one hydroxyl group borne by a POSS with formation of a siloxane bond (Si—O—Si), if the polymer is a polyethylene comprising side chains bearing a trialkoxysilane group, preferably of formula —CH 2 —CH 2 —Si—(OR 10 )(OR 11 )(OR 12 ), with hydrolysis, it is possible to hydrolyze the trialkoxysilane group into a silanol group and if the POSS comprises at least one trialkoxysilane group hydrolyzable into a silanol group, the thereby formed silanol groups on the POSS and the polymer may fuse together with formation of a siloxane bond, if the polymer is a polyethylene comprising side chains bearing a trialkoxysilane group, preferably of formula —CH 2 —CH 2 —Si—(OR 10 )(OR 11 )(OR 12 ), with hydrolysis it is possible to hydrolyze the trialkoxysilane group into a silanol group and if the POSS comprises at least one alkoxyl group hydrolyzable into a silanol group (the alkoxyl group being borne by a silicon atom of the cage of the POSS), the silanol groups on the POSS and the polymer may fuse together with formation of a siloxane bond.
The polymer may also be prepared during step a). For example, when the polymer is a polyethylene polymer comprising side chains of formula —CH 2 —CH 2 —Si—(OR 10 )(OR 11 )(OR 12 ) wherein R 10 , R 11 and R 12 are as defined above, the step a) may comprise the following steps:
a 1 ) melting a polyethylene polymer, a 2 ) adding a vinylsilane derivative of formula CH═CH—Si—(OR 10 )(OR 11 )(OR 12 ), a peroxide initiator and at least one polyhedral oligomeric silsequioxane, for which at least one of the silicon atoms is substituted with a hydroxyl, trialkoxysilane or alkoxyl group in order to obtain a polyethylene comprising functional side chains, a 3 ) mixing with polyethylene, a catalyst for the cross-linking reaction, an antioxidant and a stabilizer,
it being understood that steps a 2 , a 3 and b) may be carried out simultaneously.
The peroxide initiator may notably be dicumyl peroxide or 1,1-(t-butylperoxy) 3,3,5-trimethylcyclohexane (Lupersol L231).
The catalyst of the cross-linking reaction may notably be dibutyl tin laurate (DBTL) or dioctyl tin laurate (DOTL).
The antioxidant may notably be a hindered phenolic compound such as Irganox® (Ciba-BASF) or Hostanox® (Clariant) compounds.
The stabilizer may notably be a hindered amine light stabilizer (HALS), such as Chimassorb®, Tinuvin® or Irgastab® (Ciba-BASF).
The mixture of polyethylene, of the catalyst of the cross-linking reaction, of the antioxidant and of the stabilizer is a master mixture for the polyethylene comprising side chains of formula —CH 2 —CH 2 —Si—(OR 10 )(OR 11 )(OR 12 ).
The POSSes bearing at least one hydroxyl, trialkoxysilane or alkoxyl group are added during step a 2 , simultaneously or separately with the vinylsilane derivative. Indeed, it is generally preferred to avoid adding POSS during step a 3 ) in order to avoid a chemical reaction between the cross-linking reaction catalyst and the POSS and therefore their degradations.
The steps a 1 ), a 2 ) and a 3 ) are then followed by step b) (extrusion), c) (assembly with other layers) and d) (cross-linking) as defined above.
Step d) then comprises the aforementioned hydrolysis step allowing formation of the siloxane bonds.
The chemical coupling step may also be a radical reaction. For example, if the polymer is a polyethylene and if the POSS bears at least one vinyl group, the POSS may be grafted to the polyethylene by a radical reaction and with formation of carbon-carbon bonds.
Step a) then comprises the steps a 1 , a 2bis and a 3bis and the method comprises the following steps:
a 1 ) melting a polyethylene polymer, a 2bis ) adding to the molten polyethylene polymer, a peroxide initiator and at least one polyhedral oligomeric silsesquioxane, for which at least one of the silicon atoms is substituted with a hydroxyl, trialkoxysilane or alkoxyl group in order to obtain a premix, a 3bis ) mixing with polyethylene, a catalyst for the cross-linking reaction, an antioxidant and a stabilizer, b) extruding for forming a layer comprising said resin, c) assembling the layer obtained in step b) with at least one other layer, d) cross-linking the assembly obtained at the end of step c),
it being understood that steps a 2bis , a 3bis and b) may be carried out simultaneously. For example the POSS may be added during the extrusion through a side feeder on the extruder.
The peroxide initiator, the catalyst for the cross-linking reaction, the antioxidant, the stabilizer may notably be those defined above.
The cross-linking of step d) is generally carried out under the same conditions as defined above. Step d) then comprises the aforementioned radical reaction step allowing the formation of carbon-carbon bonds between the vinyl group of the POSS and polyethylene. If the POSS comprises, in addition to the vinyl function, a group —OSi(R 7 )(R 8 )(R 9 ), step d) further comprises a hydrolysis step allowing the formation of siloxane bonds.
A different method may be applied when the polymer is a polyethylene and the POSS bears at least one vinyl group, wherein the polyethylene polymer is prepared during the method. The method then comprises a step for polymerization of ethylene and POSS bears at least one vinyl group. This method is however more complex to apply than the method comprising the steps a 1 ), a 2bis ), a 3bis ), b), c) and d) as defined above.
The following embodiments are preferred when the polymer is polyethylene:
the POSS bears at least one vinyl group, notably two vinyl groups, the POSS bears at least one vinyl group and a siloxane group (preferably of formula —OSi(R 7 )(R 8 )(R 9 ) wherein R 7 , R 8 and R 9 are as defined above), notably bearing two vinyl groups and a siloxane group or bearing a vinyl group and two siloxane groups, the POSS bears at least one vinyl group and an alkoxyl group, notably two vinyl groups and one alkoxyl group.
The chemical coupling step may be catalyzed, notably by heat, radiation and/or a catalyst.
For example, if the polymer bears a carboxylic acid function, the esterification reaction between the hydroxyl function of a POSS, for which at least one of the silicon atoms is substituted with a substituent bearing a hydroxyl group and the carboxylic acid function of a polymer may be catalyzed by a base. It is within the skill of one skilled in the art to adapt the chemical coupling conditions (temperature, pressure, use of a catalyst, reaction time) in order to allow generation of the covalent bond.
In another example, the aforementioned steps for hydrolysis of alkoxysilane or trialkoxysilane silane groups into silanol groups when the POSS bears at least one trialkoxysilane or alkoxyl group and/or the polymer comprises trialkoxysilane groups, may be catalyzed with an acid. Also, the condensation step between the POSS and the polymer in order to form a siloxane bond may be catalyzed with an acid, or even with an acid and with heat.
When the POSS has only one silicon atom bearing a substituent R or X capable of forming a covalent bond, a polymer comprising a modified functional group, the molecular mass of which is increased, is obtained.
When the POSS has two silicon atoms bearing a substituent R or X capable of forming a covalent bond, the POSS may react with two distinct polymer chains, which allows an increase in the molecular mass of the obtained polymer.
When the POSS has more than three silicon atoms bearing a substituent R or X capable of forming a covalent bond, the POSS may react with three distinct polymer chains, which allows an increase in the molecular mass of the obtained polymer and in the generation of cross-linking points.
The larger is the number of silicon atoms of the POSS substituted with a substituent R or X capable of forming a covalent bond, the more the molecular mass of the polymer increases. Preferably POSSes comprising at least two silicon atoms substituted with a group capable of forming a covalent bond are used during step a). More preferably, POSSes comprising at least three silicon atoms substituted with a group capable of forming a covalent bond are used during step a). POSSes comprising as many substituents R and/or X capable of forming a covalent bond as there are silicon atoms, may be used, when each silicon atom of the POSS bears a group capable of forming a covalent bond. Generally, POSSes comprising less than four silicon atoms substituted with one or more groups R and/or X capable of forming a covalent bond are used during step a).
By increasing the molecular mass and/or the number of cross-linking points, it is possible to reduce the mobility of the chains of polymers relatively to each other and thereby obtain a polymer having improved thermomechanical properties. A flexible underwater pipe comprising such a polymer is therefore adapted so as to be used for transporting fluids under high pressure and at a high temperature.
In a second embodiment of the method, said group(s) R and/or X capable of forming a hydrogen bond is(are) selected from —OH, —NH 2 , —SH, —OR 17 , a saturated, unsaturated or aromatic, linear, branched or cyclic hydrocarbon chain, substituted with one or more groups selected from a group —F, —COOR 1 , —OR 1 , —SR 1 , —NR 1 R 2 , —NR 1 COR 2 , —COR 1 NR 2 , —NR 1 , —CO—NR 2 R 3 , —CN, —NO 2 wherein R 1 , R 2 and R 17 are as defined above, with the polymer. Thus, during step a), at least one hydrogen bond is formed between the polymer and the POSS.
The POSSes of the following formulae (I), (II), (III) and (VI) may for example be applied during step a) of the second embodiment:
wherein R represents a saturated, unsaturated or aromatic, linear, branched or cyclic hydrocarbon chain or a group as defined for R and/or X in the second embodiment of the method.
Preferably, in the aforementioned formula (I), R represents
and in the aforementioned formulae (II), (III) and (VI), R represents an isobutyl group. These POSSes are advantageously commercially available.
These POSSes indeed have at least one of the silicon atoms, substituted with a substituent bearing a group capable of forming a hydrogen bond, as illustrated in the following diagram:
There again, POSSes, for which at least one of the silicon atoms bears a substituent R capable of forming a hydrogen bond with a polymer, and in particular bearing one of the aforementioned functions, may notably be prepared by following the methods described in international application WO 01/10871.
This second embodiment is particularly adapted when the polymer is a polyamide optionally comprising functional side chains.
When a crystalline polymer is applied for carrying out step a) of the method, for example a polyamide 11, a polyamide 12 or a polyamide 6.12, generally the layer obtained at the end of step b) also has a crystalline nature. The presence of POSS in the polymeric resins does not affect the crystalline nature of the obtained layer.
The extrusion step b) may be carried out by any method known to one skilled in the art.
Generally, the resin obtained at the end of step a) is dried, typically in an oven at a temperature of more than 70° C., generally for several hours, for examples four hours at 80° C., before feeding a single screw, a twin screw extruder, a reactive extruder (and in this case, steps a) and b) are simultaneous since the mixing between the POSS and the polymer and the extrusion are accomplished in the same tooling) or a co-extruder allowing a layer to be made, comprising a polymeric resin comprising at least one POSS chemically bound to the polymer.
The layer comprising the resin obtained at the end of step b) is typically tubular, generally has a diameter from 50 mm to 600 mm, preferably from 50 to 400 mm, a thickness from 1 mm to 150 mm, preferentially from 40 to 100 mm and a length from 1 m to 10 km.
The method comprises step c) for assembling the layer obtained during step b) with at least one other layer in order to form the flexible underwater pipe, notably with an external polymeric sheath, a tensile armor ply, optionally a pressure vault, and optionally a metal carcass.
In an embodiment, the extrusion of the mixture obtained in step a) is accomplished on another layer, typically the carcass, in order to obtain an assembly (carcass/layer in polymeric resin comprising at least one POSS chemically bound to the polymer) which will then be added and calendered with at least one other layer during step c), typically a pressure vault, tensile armor plies and an external polymeric sheath. This embodiment notably allows the making of rough bore flexible pipes.
According to another embodiment, the extrusion of the mixture obtained in step a) is independent and the layer obtained at the end of step b) is then added and calendered with at least one other layer during step c), typically a pressure vault, tensile armor plies and an external polymeric sheath. This embodiment notably allows the making of smooth bore flexible pipes.
The layers are assembled so as to form a flexible underwater pipe of the unbonded type, as described in the normative documents published by the American Petroleum Institute (API), API 17J and API RP 17B.
According to a third object, the object of the invention is a flexible underwater pipe which may be obtained by the aforementioned method.
The presence of POSS chemically bound to the polymer in a polymeric resin used as a layer of the flexible underwater pipe according to the invention has, in addition to improvements in the thermomechanical properties of the resin, the following advantages:
the thermomechanical properties of the resin may be adapted depending on the percentage of POSS introduced into the resin and on the POSS used, more particularly depending on the nature of R and/or X and therefore on the nature of the bond with the polymer (covalent or hydrogen bond and nature of the covalent bond (ester, amide, sulfonamide, . . . )), on the number of R and/or X substituents of the POSS capable of forming a chemical bond with the polymer, the resin is homogeneous since the POSSes are miscible in polymeric resins by selecting the R and X groups, the resin may be obtained by using conventional devices and techniques for mixing and extruding, the cage structure comprising silicon and oxygen atoms of the POSSes is chemically stable over time, the water uptake of the resin is reduced since the POSSes make the resin more hydrophobic, swelling of the resin is reduced, the elongation at break of the resin is increased while maintaining the modulus, the impact resistance and the permeation.
These advantages allow the use of the flexible underwater pipe for transporting fluids. Thus, according to a fourth object, the object of the invention is the use of the aforementioned flexible underwater pipe for transporting fluids, notably gases or liquids, preferably hydrocarbons.
BRIEF DESCRIPTION OF THE DRAWINGS
Other particularities and advantages of the invention will become apparent upon reading the description made hereafter of particular embodiments of the invention, given as an indication but not as a limitation, with reference to the FIGURE.
The FIGURE is a schematic partial perspective view of a flexible pipe according to the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates a pipe according to the invention comprising, from the outside towards the inside:
a so-called sealing external polymeric sheath 10 (called an external sheath), an external tensile armor ply 12 , an internal tensile armor ply 14 wound in the direction opposite to that of the external ply 12 , a pressure vault 18 for spreading out the radial forces generated by the pressure of the transported fluid, a so-called sealing internal polymeric sheath 20 comprising a polymeric resin comprising at least one POSS according to the invention, and an internal carcass 22 for spreading out the radial crushing forces.
Because of the presence of the internal carcass 22 , said pipe is said to be with a rough bore. The invention may also be applied to a pipe said to have a smooth bore, not comprising any internal carcass.
Also, there would be no departure from the scope of the present invention by suppressing the pressure vault 18 , provided that the helix angles of the wires forming the armor plies 12 , 14 are close to 55° and in the opposite direction.
The armor plies 12 , 14 are obtained by winding with a long pitch an assembly of wires in a metal or composite material, with a generally substantially rectangular section. The invention would also apply if these wires had a section with circular or complex geometry, for example of the self-stapled T type. In FIG. 1 , only two armor plies 12 and 14 are illustrated, but the pipe may also comprise one or several additional pairs of armors. The armor ply 12 is said to be external since here it is the last, starting from the inside of the pipe, before the external sealing sheath 10 .
The flexible pipe may also comprise layers not shown in FIG. 1 , such as:
a holding layer between the external polymeric sheath 10 and the tensile armor plies 12 and 14 , or between two tensile armor plies,
one or several anti-wear layers in a polymeric material in contact either with the internal face of the aforementioned holding layer, or with its external face, or with both faces, this anti-wear layer giving the possibility of avoiding the wear of the holding layer in contact with metal armors. The anti-wear layers, which are well known to one skilled in the art, are generally made by a helicoidal winding of one or several strips obtained by extrusion of a polymeric material based on polyamide, on polyolefins, or on PVDF (polyvinylidene fluoride). It is also possible to refer to document WO2006/120320 which describes anti-wear layers consisting of strips in polysulfone (PSU), polyethersulfone (PES), polyphenylsulfone (PPSU), polyetherimide (PEI), polytetrafluoroethylene (PTFE), polyetheretherketone (PEEK) or polyphenylene sulfide (PPS).
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The disclosure relates to a flexible underwater pipe intended for transporting fluids, notably hydrocarbons, comprising at least one layer comprising a polymeric resin comprising at least one polyhedral oligomeric silsesquioxane chemically bound to the polymer.
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This application claims the benefit, under 35 U.S.C. §365 of International Application PCT/EP03/50216, filed Jun. 5, 2003, which was published in accordance with PCT Article 21(2) on Dec. 24, 2003 in English and which claims the benefit of European patent application No. 02364030.3, filed Jun. 13, 2002.
The invention concerns a communication device and a communication method.
BACKGROUND OF THE INVENTION
The invention can be applied for example in the field of home networks.
Typically, a home network allows communication, connection, interoperability between video equipments for personal or recorded video displaying, video games, . . . but mainly it should give to the user the opportunity to communicate easily with the external world.
Video programs, images, music, text pages, information data can be accessed from numerous sources provided by different heterogeneous means of transmission.
For example, television can be broadcasted from satellite, terrestrial, cable, LMDS (Broadcast Network) or delivered by Internet (Broadband Network). That is also true for music or web pages. There is no limit in mixing technologies.
A first approach to connect and adapt the home network to the outside world is to use a residential gateway that has numerous means of reception, a bridge that translates the transport protocol of the incoming data to the protocol supported by the home network.
A solution, commonly proposed, is to provide a box with slots (commonly PCI slots) in which the proper daughter boards are inserted according to the accesses requested by the user.
Such a solution is proposed in the patent application WO 00/11840 filed in the name of Mitsubishi on Aug. 12, 1999 entitled “home gateway”.
This solution presents a lot of drawbacks that are commonly not admitted in consumer products:
In consumer products, opening the box is performed by servicing people only. Allowing consumer to add boards by himself is not admitted. The basic platform that will receive add-on board(s) has features that will never be used, but they must be paid by the consumer, making the product less competitive for low-end configuration. More complicated the product is, more expensive it is. Connectors, oversize power supply, large case . . . don't characterize low cost product. An open system can be tampered more easily, paving the way to the hackers for unauthorized acts.
Patent applications WO 99/57839 entitled “method and apparatus for user and device command and control in a network” filed on May 7, 1999 and WO 01/13374 entitled “device communication and control in a home network connected to an external network” filed on Aug. 17, 2000, both filed in the name of Samsung, describe a system interconnecting several external sources to a local area network. Each module provides a connection with an external data source. However, such modules do not modify the incoming stream in order to enable the cohabitation of several streams on the local area network and in particular do not adapt the incoming streams data rate to the limited bandwidth of a local area network.
BRIEF SUMMARY OF THE INVENTION
The invention proposes a communication device comprising
several external data sources, at least a local area network connecting peripherals, means enabling to establish connections between the local area network and the external data sources, means for controlling the incoming data from the external sources and sending them to the local area network in order to reduce the bandwidth occupation on the local area network.
According to the invention, the device comprises:
means for updating signalization tables comprised in the incoming data, means for inserting the modified signalization tables in the stream sent to the local area network.
Such a device controls the incoming data and thus, when the local area network is connected to many external sources, the invention is particularly suitable as it improves the simultaneous transfers of data from the different external sources.
According to a preferred embodiment, the communication device is intended to establish one connection with an external source upon request of peripherals of the local area network.
The connection with an external source is then made when requested, this can enable to save bandwidth on the local area network. Moreover, thanks to the means for controlling the incoming data, the bandwidth occupation is optimized for serving as many as possible requests from the peripherals.
According to a preferred embodiment, the communication device comprises filtering means intended to remove some data coming from the external sources to create a single program transport stream or a partial multiple program transport stream for the local area network from the multiple program transport stream selected from the external source.
A way to reduce the bandwidth is to remove the unnecessary information from the incoming data stream. When the incoming data stream comprises transport streams composed of several programs, some of the programs may not be requested by peripherals on the local area network. Thus a way to reduce the bandwidth is to remove the programs having packet identifiers not requested by the peripherals.
According to a preferred embodiment, the communication device comprises
means for updating signalization tables comprised in the incoming data, means for inserting the modified signalization tables in the stream sent to the local area network.
When the incoming data is composed of several audio and video streams, the selection of one or more audio or video programs implies also the modification of the tables describing the content of the stream. The tables are modified and then reinserted in the modified stream.
According to a preferred embodiment, the filtering means are intended to remove packets containing non-requested packet identifiers from the multiple transport streams to create single transport streams.
According to a preferred embodiment, the communication device has means to guarantee a copy protection of the data coming from the external source.
Content protection is a key concern in providing audio video data to subscribers.
Some audio video digital programs, music, data are free, some others are in the copyright. These ones are mostly scrambled.
When a customer has paid rights, he can display and record the analog pictures.
In a network, every data of any type can be stored, modified, transmitted, duplicated without significant distortion thanks to the powerful features of the digital equipments that are interconnected.
Royalties must me preserved on one hand and, in the other hand, some copy permission could be granted to the customer.
For the customer, copy permission could be as simple as an instant display or as permissible as a full ownership. Access control level is granted by the owner of the material and the rights are managed by the access control of the gateway module.
Thanks to the access control from the gateway module, all the data in the copyright that are available in the home network have been given the access by the copy protection system.
According to a preferred embodiment, the local area network is compliant with IEEE-1394 protocol.
According to a preferred embodiment, the communication device is intended to generate a data stream on the local area network compliant with DVB or DSS standard.
The invention also concerns a system comprising:
Several external data sources, At least a local area network connecting peripherals, A gateway enabling to establish connections between the local area network and the external data sources, the gateway
being distributed among some peripherals, called gateway modules, and comprising means for managing the introduction or the withdrawal of new gateways modules,
Each gateway module comprising means enabling it to establish a complete connection between the local area network and an external source, the other gateway modules having established or not a connection with an external source, Characterized in that each gateway module is a communication device according to claims 1 to 9 .
When the home network is compliant with the IEEE-1394 network, an other fact is often ignored by IEEE-1394 gateway designers:
The number of simultaneous accesses to the gateway is limited by the number of isochronous channels that can be opened, mainly due to hardware limitations. That feature depends on the IEEE1394 bus chipset. So, even many slots are populated, only one, two or, in any case, a finite number of them would be used simultaneously.
A modular gateway as proposed can enable the access to several isochronous channels as each module has its own IEEE-1394 interface and the controlling means enable the cohabitation of the different isochronous channels by sharing the bandwidth among the different gateway modules.
The invention also concerns a communication method between several external data sources and a local area network, said local area network connecting peripherals, comprising the step of:
enabling the set-up of connections between the local area network and the external data sources,
characterized in that it further comprises the step of:
controlling the incoming data from the external sources and sending them to the local area network in order to reduce the bandwidth occupation on the local area network, said method being preferably intended to be implemented in a device according to any embodiment of the invention.
The invention also concerns a computer program product comprising program instructions for executing the steps of the method for creating semantic browsing options according to the invention, when said program is loaded on a computer.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features of the invention will appear in the following description of exemplary embodiments made with reference to the attached drawing where:
FIG. 1 represents a communication device according to an embodiment of the invention,
FIG. 2 represents an example of a stream filtering process,
FIG. 3 represents a system implementing gateway modules according to an embodiment of the invention,
FIG. 4 represents the layers and the protocol stacks that control a device according to a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment illustrated by the different figures is based on a local area network compliant with the IEEE-1394 standard and the incoming stream is compliant with MPEG-2 standard.
On FIG. 1 , the device 1 comprises a receiver/demodulator module 2 connected to an external network 17 .
The external network 17 can be a broadcast network, such as a satellite, a terrestrial or a cable network. The receiver demodulator module 2 comprises radio frequency circuits, a QPSK (standing for “Quaternary Phase Shift Keying”, a COFDM (standing for “Coded Orthogonal Frequency Division Multiplexing”) or QAM (standing for “Quadrature Amplitude Modulation”) demodulator according to the type of chosen front end.
The external network can also be a broadband network such as an ADSL (standing for “Asymmetric Digital Subscriber Line”) network. It gives the means of communication according to the IP protocol for accessing the broadband network.
The receiver demodulator 2 is connected to a signal processor 3 .
The signal processor 3 comprises at least a stream filtering module 16 , a tables updating module 15 , a content protection module 14 and an IP bridging module 18 .
The filtering module is in charge of controlling the incoming data from the external network 17 , in order to save bandwidth on the IEEE-1394 network.
Saving bandwidth on the local area network is particularly important when several communication devices 1 are connected to the local area network. Each of the device being for instance connected to a different external network, enabling the end user to access several external networks such as ADSL, cable, satellite, . . . .
One limit in connecting a large number of devices 1 is the bandwidth of the IEEE-1394 network at a given time. When the client terminal, called also peripheral, is requiring a new stream, the local area network can afford the extra load or not.
The interoperability middleware takes care about the status of the home network and assists the user to optimize the network via the User Interface.
Very often, only a program from a multiple program stream is requested so the required bandwidth is reduced; if the incoming stream is compliant with MPEG-2, the stream can be reduced from 30 Mb/s (the whole multiple program) to 4 Mb/s. So, each time one program is requested, the stream is sorted to make a SPTS (Single Program Transport Stream) from the MPTS (Multiple Program Transport Stream).
The Program Tables are modified in relationship with the new content of the stream.
The SPTS is created by removing unused PIDs (standing for “Packet Identifiers”) from the MPTS without modifying the PTS/DTS (standing for “Presentation Time Stamp/Decode Time Stamp”), then the packets occupy the same temporal location making a stream with holes.
The resultant transport stream is DVB (standing for “Digital Video Broadcast”) or DSS (standing for “Digital Satellite System”) compliant so it is directly sent to the IEEE-1394 bus chipset that is designed for broadcasting isochronous DVB or DSS streams on the home network.
FIG. 2 , described later, represents an example of the filtered stream
The signal processor 3 comprises also a module 15 in charge of updating the tables of the incoming stream towards the filtered stream.
The transport stream tables of information describe the content of the stream. They are transmitted inside packets with a known packet identifier (PID).
These packets of data are sorted and temporary stored in a memory of the signal processor 3 , such as a FIFO (standing for “First-In First-Out”) memory.
When a predetermined number of packets are stored, they are transferred to the DRAM (standing for “Dynamic Random Access Memory”) 12 . The tables are then analyzed by a processor 6 , modified and updated. Then, they are transferred back to the memory of the signal processor 3 . As soon as a packet is ready, it is inserted into the stream in place of a hole in the stream. The holes are created by the filtering module when some packets containing non requested PIDs are removed from the MPTS stream.
The signal processor 3 comprises also an IP (standing for “Internet Protocol”) bridging module 18 .
IP bridging is performed according to the RFC 2374 December 1999 by P. Johansson that specifies how to use the IEEE Std-1394-1995 for a high performance serial bus, for the transport of Internet Protocol version 4 (Ipv4) datagrams; it defines the necessary methods, data structures and codes for that purpose. These include not only packet formats and encapsulation methods for datagrams, but also an Address Resolution Protocol (1394 ARP) and a Multicast Channel Allocation Protocol (MCAP). Both 1394 ARP and MCAP are specific to Serial bus; the latter permits management of serial bus resources when used by IP multicast groups.
The module 3 comprises also a content protection module 14 .
As explained earlier, the copy protection system enables the copyright protection of the programs and also enables, if allowed, the copy permission to the end user.
Such a content protection module is thus important in the field of audio video content where copy protection is a key concern.
In a preferred embodiment, the used copy protection system is associated with a smart card reader 11 . The smart card reader enables the user to be identified and informs also the device 1 of the rights of the user.
The signal processor module is connected to an IEEE-1394 port 13 composed of a link layer and of a physical layer. It is a standard interface to an IEEE-1394 network. Two IEEE-1394 ports are connected to enable the chaining of peripherals.
A flash memory 7 and a read only memory (ROM) 8 are connected to the IEEE-1394 port, to a processor 6 and to the signal processor 3 .
The flash memory 7 and the Rom memory 8 are used by the processor 6 to store the code instructions. A DRAM (standing for “Dynamic Random Access Memory”) 12 is also connected to the processor.
Device 1 also comprises a power supply unit 9 , and a clock module 10 in charge of providing clocks to the different modules of device 1 .
An I2C (standing for “Inter-Integrated Circuit”) interface is also connected to the receiver demodulator 2 and to the processor 6 . The registers of the tuner and the demodulator are programmed through the serial bus interface I2C.
A phone modem 5 , that performs the access to the external network, allows the connection with the broadcaster for interactive TV or the connection to a server for Internet services.
In the cable version, not represented, a modulator can be added to provide a return channel for data returned to a server by using the cable as a bi-directional link.
A firmware 19 is also running under the control of the processor and will be described with the help of FIG. 4 .
FIG. 2 represents an embodiment of a filtered stream.
The incoming stream is, in a preferred embodiment, a Multiple Program Transport Stream (MPTS) compliant with MPEG-2 standard.
Such a stream includes multiple programs. Among these programs, some of them may not be required by the peripherals located on the IEEE-1394 network. So the filtering module 16 of the signal processor 3 is in charge of removing the data packets, which are not required by the peripherals.
The MPTS stream comprises also the information tables represented by the SI (standing for “System Information”) packets. SI packets are extracted from the incoming MPTS stream and modified according to the newly created stream, called pseudo SPTS stream, which contains only the data packets, which are requested by the peripherals, the modified SI packets and holes instead of the removed packets.
FIG. 3 represents a system including several devices 1 according to a preferred embodiment of the invention.
A house 32 comprising a home network connected to external sources, 28 , 29 , 30 , 31 , is represented.
The home network comprises an IEEE-1394 network connecting several peripherals such as a home server 20 , a primary display 22 , a camcorder 23 , a digital recorder 21 , a personal computer 24 , a secondary display 26 and two wireless transmission modules 25 and 27 .
Four devices A, B, C, D, also called gateway modules, are each connected to an external source.
Modules A and B are respectively connected to satellite antennas 28 and 29 . Module C is connected to a terrestrial TV antenna 30 , module D is connected to an ADSL network 31 .
The gateway modules are, in a preferred embodiment, clustered in an attic or a cellar of the house. They are chained and only one optical fiber links the cluster to the rest of the network. Such an optical fiber enables to have a relatively long haul transmission or link between the cluster of gateways and the rest of the network. This can be of interest for a home installation purpose.
Such a system enables the connection to several external sources and the number of connections is not limited by the bandwidth of the network as each of the gateway modules has controlling means enabling it to optimize the amount of data sent to the local area network. Moreover, one great advantage of having each gateway connected to an external source is that each of the gateway module has an IEEE-1394 port and thus a sufficient number of isochronous channels can be handled simultaneously. The gateway is thus distributed, fully scalable, giving the end user the best freedom in building its own network. The global gateway function is the sum of small hardware devices controlled by clients in a home network. Clients can be the displays 22 or 26 , the home server 20 , the digital recorder 21 or the analog camcorder 23 .
FIG. 4 gives an illustration of the layers and the protocol stacks controlling the device 1 .
The firmware stack is running under control of a real time operating system.
At low level, the hardware adaptation layers are composed of several interfaces according to the external sources that are connected.
The hardware adaptation layers make the interface between the receivers and the upper protocol stacks.
The hardware interface in use is depending on the type of the gateway module: it depends on the external source the gateway module is connected to.
A module 37 controls the access to the IEEE-1394 local area network.
A module 35 controls the access to the broadcast network and a module 35 controls the access to the broadband network.
The upper layer is a kernel core in charge of the protocols supported by the gateway modules. The kernel core comprises:
a module 39 for managing the IEEE-1394 link, a module 38 dealing with the DVB, DSS, ATSC (standing for “Advanced Television System Committee”) transport streams. The protocol stack is compliant with the standardized specifications. a module 34 supporting main transport protocols like TCP (standing for “Transmission Control Protocol”), UDP (standing for “User Datagram Protocol”), RTP (standing for “Real time Transport Protocol”).
The upper layer called “user's libraries core” supports a proprietary interoperability protocol. In another embodiment HAVI (standing for “Home Audio Video interoperability”) or other protocol can also be implemented.
An API (standing for “Application Programming Interface”) is delivered for allowing an easy implementation of the user application. The user application includes the remote control of the gateway module, data processing . . .
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The invention concerns a communication device including several external data sources, at least a local area network connecting peripherals, means enabling to establish connections between the local area network and the external data sources, means for controlling the incoming data from the external sources and for sending them to the local area network in order to reduce the bandwidth occupation on the local area network. The device also includes means for updating signalization tables included in the incoming data and means for inserting the modified signalization tables in the transport stream sent to the local area network. It is applicable to IEEE 1394 networks.
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FIELD OF THE INVENTION
The invention has for its object an apparatus for the launching of movable discs or targets for trap shooting.
More precisely, the object of the invention is to provide an improvement in the supply of movable discs or targets.
This improvement relates to a device for distribution of said discs or targets, such that the storage space of these latter will be as limited as possible.
BACKGROUND OF THE INVENTION
The state of the art can be defined by the following documents:
FR-A-2,445,506 relates to a loader which comprises a transfer member situated in the plane of an intermediate reception stage and subjecting each target to linear displacement to directly above the throwing arm on the one hand, and guide means carried by the arm, on the other hand.
FR-A-2,419,500 relates to a loader which comprises a plate, a turret rotatably mounted on the plate and comprised by a magazine, a device for distribution with rollers mounted on the plate, a transfer assembly is suspended between the plate and the launching arm and a device for driving in synchronism the turret and the movable member of the transfer assembly.
FR-A-2,308,080 relates to an installation which comprises a target station and a trap shooting station, a transverse slideway perpendicular to the direction of shooting, a target carriage movable along the slideway between two end positions, and a transverse drive device to displace the carriage in both directions on the slideway.
Between the stations, is disposed a target transport system which is connected to one of the ends of the slideway, and the carriage can pass from the slideway to the system and inversely. The system comprises a longitudinal drive device for the displacement of the carriage in both directions between the stations.
FR-A-2,266,139 relates to a rollerway constituted by a profile whose web is vertical, carried by posts whose feet are secured to a profile whose web is disposed horizontally on the ground.
The same profile is used, a first time vertically to support the rolling rails and a second time to maintain the feet of the posts. The height of the vertical profile is adjustable. No screw or nut is necessary for mounting. Usable to displace movable targets, for retrieval of targets, but not limited thereto.
Finally, FR-A-2,114,069 relates to a projector for launching targets, comprising a magazine, a supply plate, a launching arm, a spring and means actuated by a motor to displace the plate and to cause the arm to turn while stretching the spring, the movement of the supply plate is controlled positively by means providing a cam on the external surface of a cylindrical rotatably member driven by the motor, said member comprising a drive finger which coacts with the launching arm to cause the latter to turn during the loading phase and the launching arm being mounted so as to turn freely relative to the cylindrical member in the course of the launching phase.
All these launching devices have devices for storing movable targets; these are generally stacks of said targets on each other.
These apparatus also have devices for receiving targets which are to be launched.
Among these two types of devices, the storage on the one hand and reception on the other hand, there exists a space through which the targets fall by gravity alone.
However, certain targets which are more fragile than others, because of their design or problems in production, will not withstand this drop through the air, and break, which gives rise to numerous problems.
As the prior art devices fail to solve the problems enumerated above because the use of gravity to cause the targets to fall is always used in the manner described for example, there have been proposed devices for transferring targets which have linear displacements.
SUMMARY OF THE INVENTION
The essential object of the present invention is to provide an improvement which still uses gravity, but with no risk of damage to the displaced targets.
To this end, the launching apparatus for targets for trap shooting whose speed and projecting distance are variable, is of the type using a rotatable drum into which are loaded movable targets; the movable targets are superposed on each other in columns, maintained by tubes or vertical rollers, displaced between an upper recessed retention plate or having radial arms for the storage of movable targets and a lower recessed retention plate for each column of targets, or having radial arms between each column of targets; said lower plate being in a position which is above and parallel relative to a fixed base plate which comprises a single recess so as to permit the passage of movable targets which are received on a launching plate disposed in front of an ejection arm, one or several motors ensuring the rotation of the drum and the movement of the ejection arm, characterized by the fact that said launching plate is comprised by a movable launching ramp articulated about a transverse pivotal axis.
The target launching apparatus is moreover characterized by the fact that the launching plate is comprised by a fixed launching ramp whose upper surfaces are at the same height below and parallel to the path of the assembly of the ejection arm and the movable and articulated launching ramp.
The apparatus is further characterized by the fact that the transverse pivotal axis is directed substantially in the direction of the axis of rotation of the ejection arm, such that the movable and articulated launching ramp pivots between two end positions, a position pivoted at an angle α in which one of the two ends of said movable launching ramp is facing and at the height of the recess provided in the base plate so as to receive at least one target from the rotatable drum, said target being adapted to be launched, and a launching position in which the movable launching ramp is at a height less than but parallel to the path of the assembly of the ejection arm.
The apparatus is also characterized by the fact that the movable and articulated launching ramp has in its lower portion a longitudinal swinging axis, said axis being substantially parallel to the tangent to the trajectory of the ejection arm at the level of the movable launching ramp, such that said movable and articulated launching ramp swings between two end positions, a launching position in which the movable launching ramp is at a height less than and parallel to the path of the ejection arm assembly, and a swung position in which the ramp is swung at an angle β about the swinging axis.
Another advantage of the use of the movable ramp is to facilitate the ejection of broken pieces of targets which, despite all precautions taken, will be present.
The movable articulated ramp coacts with a guide element which serves as a slideway.
This slideway is itself adjustable as to its arc and its radius.
It is itself arcuate or in the shape of a comma.
This slideway is itself secured to the launching plate.
In the case in which the targets used always have the same shape such as: diameter, thickness, the slideway is adjustable to a height suitable to coact with the edge of the target.
In practice, the targets will have several sources of manufacture, and various dimensions.
Moreover, it can be of interest to the trap shooter to launch small size targets such as "minis" whose dimensions are 90 mm in diameter, 24 mm thick, for a weight of 70 g, or "bees" whose dimensions are as follows: 60 mm diameter, 20 mm thickness and a weight of 36 g.
There can also be launched two targets at the same time which do not have the same sizes.
The slideway should therefore perform its guide function no matter what the size of the targets and no matter what the angle of the articulated movable ramp.
The invention overcomes this problem.
According to another embodiment, the guide slideway is
formed of two slideways, a fixed slideway and an articulated slideway.
The fixed slideway is parallel to the plane of the launching plate.
The articulated slideway remains parallel to the plane of the movable launching ramp.
The articulated slideway is in prolongation of the fixed slideway but it is articulated about a pivotal axis, its end in contact with the movable articulated launching ramp ensuring the simultaneous movement with said ramp.
The contact between the articulated slideway and the articulated movable ramp is ensured by holding fingers disposed on opposite sides of each surface of said ramp.
The articulated movable ramp is provided with several openings about its periphery which permit the replacement of an abutment for the targets. Said abutment is a recurved member such as a hook whose one part is fixed to the frame of the apparatus and whose other part can be disposed in one of the openings of the articulated movable ramp selected as a function of the size of the targets chosen.
This abutment in the form of a hook is disposed below the movable ramp, its end serving as an abutment per se passing through the selected opening of the articulated movable ramp.
The return of the hook has a height sufficient to be able to leave free the passage for the pivoting of the articulated movable ramp.
The fixed holding slideway is maintained by securements such as screws, rivets, axles, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are given by way of indicative but non-limiting examples. They will permit easy comprehension of the invention.
FIG. 1 shows the ejection arm and the control mechanism of the pivoting axle.
FIG. 2 shows a view from above of the movable and articulated launching ramp when the ejection arm is upstream of said ramp relative to the path of launching of the targets, the ramp being in reception position for a target.
FIG. 3 shows a view from above of the movable and articulated launching ramp when the ejection arm is above said ramp in a position just before ejection of the target.
FIG. 4 is a cross section on N--N of FIG. 2.
FIG. 5 is a cross section on M--M of FIG. 3.
FIG. 6 is a cross section at the level of the movable and articulated launching ramp and of the lower portion of the rotatable drum, said ramp being pivoted about its pivoting axis so as to accommodate a target as well as the movement of this target.
FIG. 7 is a view from above of the ramp according to FIG. 6.
FIG. 8 is a cross section through the movable and articulated launching ramp and through the lower portion of the rotatable drum, said ramp being in launching position of the target whose movement is presented.
FIG. 9 is a view from above of the ramp according to FIG. 8.
FIG. 10 is a view from above of the movable and articulated launching ramp in a position for receiving two targets as well as the movement of these targets.
FIG. 11 is a cross section on P--P of FIG. 10, of the movable and articulated launching ramp comprising two axles, one for pivoting, the other for swinging.
FIG. 12 is a partial cross-sectional view of the supply drum for targets, of the launching plate, of the movable articulated ramp of the holding abutment of the targets on said ramp.
FIG. 13 is a plan view showing the launching arm, the launching plate, the fixed guidance slideway and the articulated guidance slideway.
FIG. 14 is a longitudinal cross-sectional view of the launching plate and of the articulated movable ramp, in coplanar position, of the holding slideways and of the abutment.
FIG. 15 is a view as in FIG. 14, but in which the movable articulated ramp is inclined.
FIG. 16 is a side view of the holding slideways (fixed and articulated) showing their securement and articulation points.
FIG. 17 is a cross-sectional view on the axis C--C shown in FIG. 18.
FIG. 18 is a plan view of the holding slideways (fixed and articulated) showing their point of securement and of articulation.
FIG. 19 is a cross-sectional view on the axis A--A shown in FIG. 18.
FIG. 20 is a cross-sectional view on the axis B--B shown in FIG. 18.
FIG. 21 is a side view of the holding slideway which is articulated.
Finally, FIG. 22 is a view of the slideway according to FIG. 21 but from above.
DETAILED DESCRIPTION OF THE INVENTION
According to FIG. 1, an important element of the apparatus for launching movable discs or targets 2 is shown.
It comprises an ejection arm 7, which is secured to its axle of rotation 11.
A circular arrow shows moreover the movement of rotation which said arm 7 undergoes about its axle 11.
Situated below the arm 7 and of the axle 11 but still fixed thereto, a pivoting cam 13 permits giving rise to a pivoting movement, such as shown by the two arrows in opposite directions, on a roller 14 fixed to the movable and articulated launching ramp, which is not shown here.
FIG. 2 permits better understanding of the location of the element of FIG. 1 relative to the launching plate 6.
The launching plate 6 is formed of two launching ramps, one which is movable and articulated 8 and the other of which is fixed 9.
The roller 14 is fixed to the movable ramp 8 by its axle, but it is shown in phantom line because the pivoting cam 13 is disposed above the latter.
Also shown in broken line, the pivotal axis 10 of the movable and articulated launching ramp 8 is located in a medial position.
The functions of the different members will be more specifically developed by the cross sections of FIGS. 4 and 5.
In this figure, the ejection arm 7 is in cocked position and four elements are present to permit good operation of this launching apparatus.
There is a holding finger 15, a spring 16, a slideway 17 and the abutment 18.
This abutment 18 is adjustable, to several positions that it can occupy according to the different small holes which are located beside this abutment 18.
This is due to the fact that in practice, there exist principally two types of discs or clay pigeons: the French or European disc, which has a diameter of 110 mm, and the American disc, which has a diameter of 107.5 mm. This difference in diameter gives rise to problems in the use of the same launcher.
According to FIG. 3, the ejection arm 7 has undergone a rotation of about 90°, about its axle of rotation 11 and has come to occupy the position which is its own.
FIGS. 4 and 5 permit better understanding of what has been described above.
In FIG. 4, the roller 14 is in contact with the highest portion of the figures of the cam 13.
There is thus pivoting of the assembly of the movable launching ramp 8 about its axis 10 under the influence of spring 16.
The fixed launching ramp 9 is always parallel to the cam 13, which gives rise to an asymmetry of the launching plate 6, which is not uniformly flat.
FIG. 5 is very different.
As FIG. 3 shows, only the ejection arm 7 has been displaced and as a result all of the elements which are secured to said arm 7.
Such is the case with cam 13, which has swung, and of which the lowest part in the figures is now in contact with the roller 14, which permits the movable and articulated launching ramp 8 to pivot about its axis 10 under the force exerted by the spring 16, and thus to come into a position in prolongation of the fixed launching ramp 9.
The launching plate 6 is uniformly flat, while the ejection arm 7 is in position to launch a target.
The apparatus for launching targets is therefore characterized by the fact that the movable launching ramp 8 has, in its downstream portion relative to the direction of launching targets 2 and in its lower portion, a roller 14 which coacts with the cam 13 secured to the ejection arm 7, and in its upstream portion relative to the direction of launching targets 2, a spring 16; such that when the roller 14 is in contact with the portion of the cam 13 spaced farthest from the pivotal axis 10, the spring 16 brings said movable ramp 8 into pivoted position, whereas when the roller 14 is in contact with the portion of the cam 13 the nearest to pivotal axis 10, said cam 13 causes the movable ramp 8 to pivot about the pivoting axis 10, and brings it into launching position, which is to say that the upper surface of said movable ramp 8 is at the same level of height as the upper surface of the fixed launching ramp 9 which is located downstream of the movable ramp 8 relative to the direction of launching the targets.
FIG. 6 shows the use which is made of the inclination of the movable ramp 8 by the ensemble of the spring 16 and the cam 13, not shown here.
The launching plate 6 is therefore constituted by the fixed ramp 9 which is parallel to the lower plate 4 of the rotatable drum 1, but also by the movable ramp 8 whose downstream end comes into position at the height of and facing the recess 5 of the launching plate 4.
Said plate 4 supports columns 3 of movable targets 2 parallel to each other.
In this position, the next-to-last target 2 is maintained in the rotatable drum 1, while the last target 2, by gravity, falls on the downstream end of the movable ramp 8 from a very low height, without any risk of breaking.
Once the downstream portion of said movable ramp 8 is in its upper position, the target 2, still by gravity, slides into contact with the abutment 18, whose position has been adjusted as a function of the diameter of the target 2.
FIG. 7 shows the same phenomenon, from above, which is to say without the rotatable drum 1.
The target 2 slides on the movable ramp 8 up to the abutment 18.
So that this target 2 will be properly positioned, the slideway 17 orients the target 2 such that it does not leave the ramp 8 and wedges it with the help of abutment 18.
The movable and articulated launching ramp 8 has, in its upstream portion, different holes 21 which permit the securement of at least one abutment 18 adjustably in position.
FIG. 8 shows the phase following the one that has been described in the two preceding figures.
The movable launching ramp 8, under the influence of the displacement of the ejection arm 7 and of the cam 13 about their axle of rotation 11, is disposed parallel to the lower plate 4, namely at the level of the fixed ramp 9.
On the other hand, the target 2 is then displaced downstream of the movable ramp 8, so as to come into contact with the holding finger 15.
The launching plate 6 has a holding finger 15 for the targets 2 which is movable in rotation relative to its axis, and can return to its initial position by means of a spring.
According to FIG. 9, the target 2, just before being launched, is maintained in position on the launching plate 6, by the ejection arm 7 which can pass above the abutment 18, by the holding finger 15, and finally by the guide element 17, whose respective heights are less than the spacing which exists between the upper surface of the launching plate 6 and the path of the ejection arm.
The role of the holding finger 15 is to ensure good contact between the target 2 and the ejection arm 7 just before the launch itself.
This permits limiting breakage to a minimum.
In FIGS. 10 and 11, the apparatus for launching the targets 2 is usable for launchers comprising each two movable targets 2.
To arrive at this result, and according to FIG. 11, another axis, called swinging axis 12, permits, thanks to a camroller 19, swinging all of the movable ramp 8 toward the interior of the apparatus, which is to say in the direction of the axis of rotation I 1 of the ejection arm 7.
In other words, the operation of the pivoting axis 10 is always the same, except that before launching, this movement is effected twice.
Inserted between these two movements, the swinging movement permits the first target 2, received on the movable ramp 8, to be offset toward the axis of rotation 11 and thus not to hinder the arrival of the second target 2 beside the first target 2 already in place.
Then alone, the ejection arm 7 which has been disengaged from the cam 13, comes into contact with the two targets and causes them to slide to the holding finger 15.
So that all this may happen, it is preferable to use, instead of the abutment, an abutment element 20 which uses different points of securement of the adjustable abutment.
The abutment element has a shape such that it is impossible for the first target 2 which is subjected to lateral swinging to fall on the ground; thus, said abutment element 20 is of L shape.
The use of the abutment element 20, for launching a single target 2, is of course possible.
In the same way, to position two targets 2, one beside the other, the slideway 17 is adjustable as to arc and radius relative to the axle of rotation 11 of the ejection arm 7; this slideway 17 is installed laterally of the external side of the movable launching ramp 8.
Finally, to facilitate further the displacement of the targets 2 on the movable ramp 8, the adjustable slideway 17 is arcuate.
The target launching apparatus is of the type comprised of a rotatable drum 31 for automatic supply of targets 32, the movable targets 32 are disposed in columns maintained by vertical rollers between an upper plate and a lower plate 33, known means ensure the supply of targets 32 to the launching plate 34 by a movable launching ramp 35 articulated on an axis of articulation 49, said movable launching ramp 35 is provided laterally of the external side of an arcuate slideway 36 adjustable as to arc and as to radius relative to the axis of rotation of the ejection arm.
The guidance slideway is provided by two slideways, a fixed slideway 36 and an articulated slideway 37.
The fixed slideway 36 is parallel to the plane of the launching plate 34.
The articulated slideway 37 remains parallel to the plane of the movable launching ramp.
The articulated slideway 37 prolongs the fixed slideway 36 but it is articulated about a pivotal axis 38, its end in contact with the movable articulated launching ramp 35 ensures simultaneous movement with said ramp.
The contact of the articulated slideway 37 and of the articulated movable ramp 35 is ensured by holding fingers 39, 40 disposed on opposite sides of each surface of said ramp.
The articulated movable ramp 35 is provided with several openings 41, 42, 43 at its periphery which permit the replacement of an abutment 44 for the targets 32. Said abutment 44 is a recurved member such as a hook whose one portion 45 is secured at the level of the axis of articulation 49 of the movable ramp 35 and whose other portion 36 can be disposed in one of the openings of the articulated movable ramp 35, selected as a function of the size of the selected targets.
This abutment 44 in the form of a hook is disposed below the movable ramp 35, its end 46 serving as an abutment per se passes through the selected opening of the articulated movable ramp 35.
The return of the hook 46 has a height sufficient to be able to leave the passage free for the pivoting of the articulated movable ramp 35.
The fixed holding slideway is maintained by securements 47, 48 such as screws, rivets, axles, etc.
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Apparatus for launching targets for trap shooting whose speed and distance of projection are variable, of the type using a rotatable drum (1)into which are loaded movable targets (2). The movable targets (2) are superposed on each other in columns (3), maintained by tubes or vertical rollers, disposed between a recessed upper holding plate or having radial arms for the storage of movable targets and a lower recessed holding plate (4) for each column (3) of targets (2), or having radial arms between each column (3) of targets (2). The lower plate (4) is above and parallel to a fixed base plate which comprises a single recess (5) so as to permit the passage of movable targets (2) which are received on a launching plate (6) disposed before an ejection arm (7). One or several motors ensures the rotation of the drum (1) and the movement of the ejection arm (7). The launching plate (6)is comprised by a fixed launching ramp (9) and a movable launching ramp (8) articulated about a substantially transverse pivotal axis (10). The upper surfaces of the ramps (9, 8) are at the same height below and parallel to the path of the assembly of the ejection arm (7).
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BACKGROUND OF THE INVENTION
The present invention relates to an automatic transmission for an automotive vehicle of the front engine front drive type, and more particularly to an automatic transmission wherein torque from a main change speed gearing is delivered via an auxiliary change speed gearing and an output gear of the auxiliary change speed gearing.
Automatic transmissions are known which include an auxiliary change speed gearing in additional to a main change speed gearing to increase the number of speeds.
An object of the present invention is to improve an automatic transmission such that the setting of a gear ratio during underdrive of a planetary gear set of an auxiliary change speed gearing can be made with increased freedom.
SUMMARY OF THE INVENTION
According to the present invention, there are provided in an automatic transmission:
a main change speed gearing having an output shaft;
an auxiliary change speed gearing drivingly connected to said main change speed gearing;
said auxiliary change speed gearing having a frictional coupling device and a planetary gear set including a sun gear formed on a shaft that has one end coupled with a component of said frictional coupling device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an automatic transmission shown in FIG. 2;
FIG. 2 is a detailed section of the automatic transmission; and
FIG. 3 is a table of engagement or release of each of frictional coupling devices versus each of speeds.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2, an automatic transmission for an automative vehicle of the front engine front drive type is described. This automatic transmission provides four forward speeds and one reverse.
The automatic transmission includes a main change speed gearing 100 which provides three forward speeds and one revese and an auxiliary change speed gearing 200 which is shiftable to a direct drive or an underdrive. The arrangement is such that the auxiliary change speed gearing 200 has its axis of rotation laying in parallel with respect to an axis of rotation of the main change speed gearing 100.
The main change speed gearing 100 is known and thus explained briefly. As shown in FIG. 1, a main input shaft I M is subject to torque transmitted thereto from an engine output shaft E via a torque converter T/C. This main input shaft I M is arranged in line with a main output shaft O M . Arranged on or around both of the shafts I M and O M are a first planetary gear set G 1 , a second planetary gear set G 2 , a first clutch C 1 , a second clutch C 2 , a first brake B 1 , a second brake B 2 and a first one-way clutch OWC 1 .
The first planetary gear set G 1 includes a sun gear S 1 , a ring gear R 1 , and a pinion carrier PC 1 rotatably supporting a plurality of pinions P 1 , each being in mesh with both the sun and ring gears S 1 and R 1 . The second planetary gear set G 2 includes a sun gear S 2 , a ring gear R 2 , and a pinion carrier PC 2 rotatably supporting a plurality of pinions P 2 , each being in mesh with both the sun and ring gears S 2 and R 2 .
As is readily seen from FIG. 1, the sun gears S 1 and S 2 are connected to each other for unitary rotation and connectable via the first clutch C 1 to the main input shaft I M . The ring gear R 1 of the first planetary gear set G 1 is connectable via the second clutch C 2 to the main input shaft I M . The pinion carrier PC 1 of the first planetary gear set G 1 is connected to the ring gear R 2 of the second planetary gear set G 2 and also to the main output shaft O m for unitary rotation. The pinion carrier PC 2 of the second planetary gear set G 2 is prevented from rotating in a reverse direction opposite to a forward direction in which the main input shaft I M rotates.
The first brake of the band type is provided to anchor or brake the sun gears S 1 and S 2 . The second brake B 2 of the disk type is provided to anchor or brake the pinion carrier PC 2 of the second planetary gear set G 2 .
The main output shaft O M has a main output gear O GM splined thereto.
The auxiliary change speed gearing 200 includes an auxiliary input gear I GS in mesh with the main output gear O GM for rotation about an axis which lies in line with an axis of rotation of an auxiliary output shaft O S . The auxiliary output shaft O S has an auxiliary output integral gear O GS . Arranged between the auxiliary input gear I GS and auxiliary output shaft O S are a third planetary gear set G 3 and a third clutch C 3 . On the opposite side of the auxiliary input gear I GS to that side where the third planetary gear set G 3 is arranged, there are provided a third brake B 3 and a second one-way clutch OWC 2 .
The third planetary gear set G 3 includes a sun gear S 3 , a ring gear R 3 , and a pinion carrier PC 3 rotatably supporting pinions P 3 , each being in mesh with both the sun and ring gears S 3 and R 3 . The pinion carrier PC 3 is connected to the auxiliary output shaft O S for unitary rotation therewith. The ring gear R 3 is connected to the auxiliary input gear I GB for unitary rotation therewith. The sun gear S 3 is prevented from rotating in one direction by the second one-way clutch OWC 2 and brakeable by the third brake B 3 . The sun gear S 3 is connectable to the auxiliary output shaft O S and the pinion carrier PC 3 via a third clutch C 3 .
As will be seen from FIG. 3, the auxiliary change speed gearing 200 is conditioned in under drive position with the third brake B 3 applied and the third clutch C 3 disengaged to provide the first or second or third speed. Within the main change speed gearing 100, for the first speed, the first one-way clutch OWC 1 is operative to render the pinion carrier OWC 1 to serve as a reaction member with the second clutch C 2 engaged and with the first clutch C 1 disengaged and the first and second brakes B 1 and B 2 released. For an upshift from the first to second speed, the first brake B 1 is applied. For an upshift from the second to third speed, the first brake B 1 is released and the first clutch C 1 is engaged in timed relationship with the release of the first brake B 1 .
An upshift from the third to fourth speed is made by releasing the third brake B 3 and engaging the third clutch C 3 in timed relationship with the release of the third brake B 3 . In this case, the auxiliary change speed gearing 200 is conditioned in direct drive state, During the transient period from the third speed state to the fourth speed state, the second one-way clutch OWC 2 prevents rotation of the sun gear S 3 .
A downshift from the fourth to third speed is effected by releasing the third clutch C 3 and applying the third brake B 3 . Initiation of application of the third brake B 3 is delayed with respect to the release of the third clutch C 3 until the second one-way clutch OWC 2 is rendered operative.
Reverse is established with the first clutch C 1 engaged and the second and third brake B 2 and B 3 applied with the other clutches and brakes all disengaged and released.
FIG. 2 shows in detail the structure of the automatic transmission briefly explained in connection with FIG. 1.
Referring to FIG. 2, the reference numeral 300 designates a major casing in which a main change speed gearing 100 and an auxiliary change speed gearing 200 are arranged. Fixedly secured by bolts to the major casing 300 is a pump housing 302. A pump gear 304 is disposed within a space defined by the pump housing 302 and a pump cover 306 bolted to the pump housing 302. The pump gear 304 is driven by a pump impeller of a torque converter T/C. The pump impeller is driven by an engine.
With regard to the main change speed gearing 100 shown in FIG. 2, the reference numeral 102 designates a main input shaft that was denoted by the reference character I M in FIG. 1. The reference numeral 104 designates a main output shaft that was denoted by the reference character O M . The main output shaft 104 is splined to a main output gear 106 that was denoted by the reference character O GM .
The reference numerals 108 and 110 respectively designate a first planetary gear set that was denoted by the reference character G 1 in FIG. 1 and a second planetary gear set that was denoted by the reference character G 2 in FIG. 1. The first and second planetary gear sets 108 and 110 include sun gears 108S and 110S that were denoted by the reference characters S 1 and S 2 . These sun gears 108S and 110S are connected to the main input shaft 102 for unitary rotation therewith. The first planetary gear set 108 includes a ring gear 108R that was denoted by the reference character R 1 in FIG. 1. The ring gear 108R is connectable to the main input shaft 102 via a second clutch 114 that was denoted by the reference character C 2 . The first planetary gear set 108 includes a pinion carrier 108PC that was denoted by the reference character PC 1 . The pinion carrier 108PC 1 is connected to the main output shaft 104 by spline connection. The pinion carrier 108PC 1 rotatably supports a plurality of pinions 108P that were denoted by the reference numeral P 1 . A clutch casing 112A establishes connection between the sun gears 108S, 110S and the first clutch 112. Between the clutch casing 112A and the major casing 300 is arranged a first brake of the band type 113 that was denoted by the reference character B 1 . The band of the first brake 113 tighten a brake drum portion of the clutch casing 112A to hold stationary both of the sun gears 108S and 110S.
The second planetary gear set 110 includes a ring gear 110R that was denoted by the reference numeral R 2 . The ring gear 110R is connected to the main shaft 104 by spline connection. The second planetary gear set 110 includes a pinion carrer 110PC that was denoted by the reference character PC 2 . The pinion carrier PC 2 rotatably supports a plurality of pinions 110P that were denoted by the reference character P 2 . Arranged between the pinion carrier 110PC and the major casing 300 are a second brake 116 and a first one-way clutch 118 that were denoted by the reference characters B 2 and OWC 1 in FIG. 1.
The main output shaft 104 is rotatably supported by bearing 308 fixedly mounted to a portion adjacent an end portion of the major casing 300 and by bearing 312 fixedly mounted to a casing cover 310 bolted to the major casing 300. Disposed between both of the bearings 308 and 312 is the main output gear 106.
In the auxiliary change speed gearing 200, the reference numeral 202 designates an auxiliary input gear that was denoted by the reference character I GS in FIG. 1. The auxiliary input gear 202 which is in mesh with the main output gear 106 is hollowed and rotatably supported by an outer race of bearing 204 of the double ball type. The bearing 204 has an inner race supported by a boss portion of a bearing support 206 and fixed thereto by means of a nut 208 threadedly engaged with the inner peripheral wall of the boss portion. The bearing support 206 has an outer peripheral portion fixedly connected to the casing cover 310 by spline connection. The bearing support 206 has an outer peripheral portion defining a plate support 206a for a third brake described later.
The reference numeral 210 designates an auxiliary output shaft that was denoted by the reference character O S in FIG. 1. The auxiliary output shaft 210 has an integral auxiliary output gear 212 that was denoted by the reference character O GS . This auxiliary output gear 212 is in mesh with a ring gear 402 of a final drive 400.
The auxiliary output shaft 210 with the output gear 212 is rotatably supported by two axially spaced bearings 326 and 328 which are fixedly mounted to two spaced first and second walls 322 and 324 of the major casing 300, respectively. These walls 322 and 324 are provided for separating the final drive 400 from the change speed mechanism of the auxiliary change speed gearing 200 in fluid tight manner. The first wall 322 has a portion to which the pump housing 302 is fixed and it is formed with a recess 322A fixedly receiving an outer race of the bearing 326.
The second wall 324 is formed with a bore 324A fixedly receiving an outer race of the bearing 328. The second wall 324 has an integral partition wall 300 which merges continuously into the first wall 322. The separation in fluid tight manner is established except fluid communication through the bore 324A.
The bearing 328 which is press fit in the bore 324A is operative to prevent axial flow of oil through the bore 324A since the bearing 328 is of the so-called oil seal type.
The recess 322A, auxiliary output gear 212 and bore 324A have substantially the same diameter so as to make easy forming the bore 324A and recess 322A and assembling of associated components of the auxiliary output gear 212.
Designated by the reference numeral 214 is a bearing cap bolted to the second wall 324 to hold the bearing 328 within the bore 324A.
The auxiliary output shaft 210 is formed with an axial bearing bore 210A extending inwardly from the remotest end from that end portion thereof which has the auxiliary output gear 212. The axial bearing bore 201A rotatably receives via a needle bearing a reduced diameter leading end of a brake shaft 216. The brake shaft 216 is formed with a sun gear 218S that was denoted by the reference character S 3 in FIG. 1. This sun gear 218S is one of components of a third planetary gear set 218 that was denoted by the reference character G 3 in FIG. 1. The third planetary gear set 218 includes a ring gear 218R that was denoted by the reference character R 3 . The ring gear 218R is connected to the auxiliary input gear 202 for unitary rotation. The third planetary gear set 218 includes a pinion carrier 218PC that was denoted by the reference numeral PC 3 . The pinion carrier 218PC rotatably supports a plurality of pinions 218P that were denoted by the reference character P 3 . Via a clutch body 222A and a clutch drum 222B that is fixedly connected to the clutch body 222A, the pinion carrier 218PC is fixedly connected to the auxiliary output shaft 210 for unitary rotation. The clutch body 222A is splined to the auxiliary output shaft 210. The clutch body 222A and clutch drum 222B form parts of a third clutch 222 that was denoted by the reference character C 3 in FIG. 1.
Within the clutch drum 222B is a clutch hub splined to the sun gear 218S. The brake shaft 216 has fixed thereto a radial support plate 226 fixed to an outer race 224A of a second one-way clutch 224 that is denoted by the reference character OWC 2 in FIG. 1. An inner race 224B of the second one-way clutch 224 is splined to an integral inward projection 310A of the casing cover 310.
Arranged around the second one-way clutch 224 is a third brake 228 that is denoted by the reference character B 3 . The third brake 228 is of the frictional disk type including a set of interleaved plates consiting of a group of plates having their outer periphery splined to the casing cover 310 and another group of plates having their inner periphery splined to a sleeve extension of the support plate 226. The third brake 228 also includes a piston 228A biased by a return spring.
The final drive 400 is enclosed in fluid tight manner by a final drive casing 404.
The operation regarding the auxiliary change speed gearing 200 is explained again.
For the first to third forward speeds or reverse, the auxiliary change speed gearing 200 is conditioned in underdrive state owing to application of the third brake 228 (B 3 ) and disengagement of the third clutch 222 (C 3 ). Under this condition, the brake shaft 216 and thus the third sun gear 218S (S 3 ) is held stationary relative to the casing cover 310. Thus, the third planetary gear set 218 (G 3 ) provides a reduction drive in transmitting rotation from the auxiliary input gear 202 (I GS ) to the auxiliary output shaft 210 (O S ) via the ring gear 218R (R 3 ) and the pinion carrier 218PC (PC 3 ).
For the third planetary gear set 218, if the number of teeth of the sum gear 218S is expressed by Z S , the number of rotation per unit time of the sun gear 218S is expressed by N S , the number of teeth of the ring gear 218R is expressed by Z R , the number of rotation per unit time of the ring gear 218R is expressed by N R , and the number of rotation per unit time of the pinion carrier 218PC is expressed by N PC , the third planetary gear set 218 can be expressed by the following formula:
(1+a)N.sub.C =aN.sub.S +N.sub.R (1)
where:
a=Z S /Z R .
Considering the underdrive state, since the sun gear 218S is held stationary and thus N S =0, the formula (1) is converted to:
(1+a)N.sub.C =N.sub.R (2).
Thus, a gear ratio i given by the third planetary gear set 218 is expressed as:
i=N.sub.R /N.sub.C =1+a=Z.sub.S /Z.sub.R (3).
As will be appreciated from the formula (3), if the the ratio a becomes small, the gear ratio i becomes small. This means that if the number of teeth of the sun gear 218S (S 3 ) which is expressed by Z S decreases, the gear ratio i becomes small. In this manner, the setting freedom of the gear ratio has been increased.
For the fourth forward speed, the third brake 228 (B 3 ) is released and the third clutch 222 (C 3 ) is engaged. This caused the third planetary gear set 218 (G 3 ) to rotate as a unit, thus providing a direct drive state.
From the foregoing, it is now seen that the shaft 216 is held stationary for the first to third speeds and reverse and it is released to rotate as a unit with the other components of the third planetary gear set 218 for the fourth speed. Thus, the sun gear 218S with which the shaft 216 is formed is not subject to any stress from the shaft 216 which might cause irregular engagement with the pinions 218P resulting in making noise.
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An automatic transmission is of the type wherein power from a main change speed gearing is delivered to an input gear of an auxiliary change speed gearing. The input gear is connected to a ring gear of a planetary gear set of the auxiliary change speed gearing. The planetary gear set includes a pinion carrier connected to an output shaft with an output gear fro rotation therewith. The pinion carrier rotatably supports a plurality of pinions in mesh with the ring gear. A shaft is arranged in line with the output shaft and is formed with a sun gear in mesh with the plurality of pinions. This shaft is brakeable by a frictional coupling device, namely a brake. When this shaft with the sun gear is braked, the power is delivered to the output gear via the pinion carrier.
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BACKGROUND OF THE INVENTION
The invention relates to a speed control apparatus for a d.c. motor, and more particularly, to such apparatus which incorporates a switching control.
A conventional speed control apparatus for d.c. motor is illustrated in FIG. 1. Specifically, a d.c. motor 1 defines a branch of a bridge circuit, the remaining branches of which are defined by resistors 2, 3 and 4. The bridge circuit includes a pair of detecting terminals A, B, and a voltage detected thereacross may be compared against a reference voltage 7 by an error detector formed by a combination of a transistor 6 and a resistor 5. The error detector detects a difference therebetween, which may be used to control a feed transistor 8, thus controlling the power supplied to the motor to thereby control the speed thereof. In such an arrangement, the feed transistor 8 operates in its active region, and hence a voltage drop across the emitter and collector represents a Joule loss, causing a reduced efficiency.
SUMMARY OF THE INVENTION
It is an object of the invention to eliminate the described disadvantage of a conventional speed control apparatus, by providing a speed control apparatus for a d.c. motor having an improved efficiency. The efficiency is improved by reducing Joule losses in the feed control circuit, which is achieved by applying an output from an error detector, which detects the rotational speed of the motor, to a Schmidt trigger circuit, an output pulse of which is used to control the feed control circuit.
In accordance with the invention, the feed transistor which feeds power to the d.c. motor operates in a switching mode in order to control the speed of the motor. This reduces Joule losses and the power dissipation, thus improving the efficiency. A reduction in the amount of heat generated by the feed transistor increases the freedom in the circuit design. The use of the Schmidt trigger circuit to cause a switching operation of the feed transistor achieves a stable operation of the feed control circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram of an exemplary form of conventional speed control apparatus for d.c. motor;
FIG. 2 is a circuit diagram of a speed control apparatus for d.c. motor according to a first embodiment of the invention;
FIG. 3A is a schematic circuit diagram illustrating the operation of a feed control circuit used in the speed control apparatus of FIG. 2;
FIG. 3B shows an equivalent circuit of a d.c. motor;
FIG. 3C graphically shows the waveform of a current pasing through the motor;
FIG. 4 graphically shows the voltage-current characteristic of the base-emitter part of the transistor and the voltage-current characteristic of a diode, both used in an error detector used in the apparatus of FIG. 2;
FIG. 5 is a schematic circuit diagram illustrating the ripple elimination achieved with the apparatus of FIG. 2; and
FIG. 6 is a circuit diagram of a speed control apparatus according to a second embodiment of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 2, there is shown a circuit diagram of a speed control apparatus for d.c. motor according to a first embodiment of the invention. In FIG. 2, a bridge circuit is formed across positive and negative terminals 11, 12 of a d.c. source, by a d.c. motor 17 and resistors 18, 19 and 20. An error amplifier 39 is connected across a pair of detecting terminals A, B of the bridge circuit for detecting the rotational speed of the motor 17. An output from the amplifier 39 is fed to a Schmidt trigger circuit 40, the output of which is applied to a feed control circuit 41 which operates to control the power supplied to the motor.
The error amplifier 39 comprises an NPN transistor 21 having its emitter connected to the terminal A of the bridge circuit, a diode 22 having its cathode connected to the terminal B of the bridge circuit and having its anode connected to the base of the transistor 21, a constant current source 38 having its one end connected to the junction between the base of the transistor 21 and the anode of the diode 22, a resistor 25 connected to the collector of the transistor 21, a PNP transistor having its base connected to the collector of the transistor 21, a resistor 27 connected to the emitter of the transistor 28 and another resistor 29 connected to the collector of the transistor 28. The constant current source 38 comprises an N-channel field effect transistor 24 and a variable resistor 23 connected across the source and gate thereof.
The Schmidt trigger circuit 40 comprises a resistor 30 having its one end connected to the collector of the transistor 28 which represents the output of the error amplifier 39, an NPN transistor 32 having its base connected to the other end of the resistor 30, a resistor 31 connected to the collector of the transistor 32, a resistor 33 having its one end connected to the collector of the transistor 32, an NPN transistor 36 having its base connected to the other end of the resistor 33 and having its emitter connected to the emitter of the transistor 32, a resistor 35 having its one end connected to the collector of the transistor 36, a resistor 34 having its one end connected to the other end of the resistor 35 and its other end connected to the positive terminal 11 of the d.c. source, and a resistor 37 having its one end connected to the emitters of the transistors 32 and 36 and its other end connected to the negative terminal 12 of the d.c. source.
The feed control circuit 41 comprises a PNP feed transistor 14 having its emitter connected to the positive terminal 11 of the d.c. source and its base connected to the junction between the resistors 35 and 34 of the Schmidt trigger circuit 40 to receive an output thereof as an input, a coil 15 having one end connected to the collector of the transistor 14 and its other end connected to a feed terminal C of the bridge circuit, and a diode 13 having its cathode connected to the junction between the collector of the transistor 14 and the coil 15 and its anode connected to the other feed terminal which is connected to the negative terminal 12 of the d.c. source.
A capacitor 16 is connected in shunt with the bridge circuit and forms a low pass filter together with the coil 15. A capacitor 26 is connected between the feed terminal C of the bridge circuit and the collector of the transistor 28 in the error amplifier 39 for reducing any ripple component which may be contained in an input to the Schmidt trigger circuit 40 as a result of a sliding contact between a brush and a commutator of the d.c. motor.
The operation of the speed control apparatus will now be described. Representing the equivalent internal resistance of the d.c. motor 17 by R a , and the resistance of the resistors 18, 19 and 20 by R 18 , R 19 and R 20 , respectively, the bridge circuit which is fed with a voltage V 0 will produce a voltage V AB across the detecting terminals A, B as follows: ##EQU1## where E M represents the back electromotive force of the motor 17. If the bridge balance condition R a .R 20 =R 18 .R 19 is satisfied, this voltage can be rewritten as follows: ##EQU2## where Kv represents a constant relating to the back electromotive force of the motor and N the rotational speed thereof. Thus it will be seen that under balanced bridge conditions, the voltage V AB depends on the rotational speed alone, and is independent from the magnitude of the torque.
Consequently, the error amplifier 39 which receives the voltage V AB from the bridge circuit as an input produces an output potential at point E which varies depending on the rotational speed of the motor 17. Thus, when the rotational speed of the motor 17 increases, the potential at point D within the error amplifier 39 reduces while an output of the error amplifier 39 or the potential at the point E increases.
When the potential at the point E, which represents an input to the Schmidt trigger circuit 40, increases to a point where it exceeds a threshold voltage representing the upper limit of the trigger circuit 40, the output of trigger circuit 4d potential at point F) assumes a high level, thereby turning the transistor 14 off. Hence, the power supply to the motor 17 is interruped. When the power supply is interrupted, the rotational speed of the motor reduces, whereby the potential at the point D within the error amplifier 39 rises while the output therefrom or the potential at the point E reduces. When the potential at the point E reduces below a threshold voltage which represents the lower limit of the trigger circuit 40, an output thereof or the potential at the point F changes to its low level, whereby the transistor 14 is turned on, thus resuming the power supply to the motor 17. The motor 17 is driven by repeating the described operation.
If the load on the motor 17 increases, the rotaional speed does not rise immediately if the feed transistor 14 is turned on. On the other hand, the rotational speed reduces quickly if the feed transistor 14 is turned off. In this manner, the time interval during which the motor 17 is energized increases while the time interval during which the power supply to the motor is interrupted reduces. On the contrary, the reverse is true if the load is reduced. Because a constant speed control of the motor 17 is achieved through a switching control of the feed transistor, the Joule losses produced in this transistor are reduced, thus reducing the power dissipation.
The operation of the feed control circuit 41 will be described with reference to FIG. 3. FIG. 3A illustrates the current path through the d.c. motor 17 when the feed transistor 14 is turned on and off while FIG. 3B shows the equivalent circuit of the d.c. motor. When the feed transistor 14 is turned on, current I M flows from the positive terminal 11 of the source through a path including the feed transistor 14, coil 15, motor 17 and resistor 18 to the negative terminal 12 of the source, such path being shown in solid line arrows in FIG. 3A. When the transistor 14 is switched from its on to its off condition, electromagnetic energy stored in the coil 15 as well as the equivalent internal inductance La of the motor 17 maintains a current flow through a closed path, shown in broken line arrows in FIG. 3A, including the coil 15, motor 17, resistor 18 and diode 13. Thus, a current flow is maintained through the motor 17 even though the feed transistor 14 is repeatedly switched, resulting in a pulsating current waveform as shown in FIG. 3C, thus stabilizing the rotation of the motor 17. The combination of the coil 15 and the capacitor 16 forms a low pass filter, which maintains the potential at the terminal C of the bridge circuit at a level which is closer to a constant value. The capacitor 16 suppresses parasitic oscillations to provide a stabilized operation. The feed transistor can be operated with a variable switching frequency which is determined by the time constant of the current path including the motor 17 as mentioned above and the magnitude of hysteresis of the Schmidt trigger circuit 40.
The rotational speed N of the motor 17 is determined in accordance with the equation (2) as follows: ##EQU3## where V BE21 represents the voltage across the emitter and base of the transistor 21 and V D22 the forward voltage across the diode 22. Thus, the rotational speed N can be determined by the term (V BE21 -V D22 ), which can be established by changing the magnitude of current from the constant current source 38, by utilizing a difference in the current-voltage characteristic between the emitter and base of the transistor 21 and the diode 22 (specifically shown by curves (a) and (b) in FIG. 4). An adjustment of the variable resistor 23 allows a suitable choice of the magnitude of such current.
Referring to FIG. 5, the function of the capacitor 26 will be described. Ripple components which are produced due to a sliding contact between a brush and a commutator of the motor 17 are developed across the feed terminal C and the detecting terminal A of the bridge circuit. Because they are not a direct indication of the back electromotive force or the rotational speed of the motor, if they are allowed to be amplified by the amplifier 39 and applied to the Schmidt trigger circuit 40, a stable switching operation which depends solely on the rotational speed of the motor 17 is prevented. However, when the capacitor 26 is connected between the feed terminal C of the bridge circuit and the output terminal E of the amplifier 39, ripple components coupled through the capacitor 26 and having the same phase as those present at the point C are superimposed on ripple components coupled to the terminal E through the amplifier 39 and having the opposite phase to those present at the point C, thus producing a net reduction in the ripple components, which assures a stable switching operation.
FIG. 6 shows a second embodiment of the invention in which the bridge circuit comprising the motor 17 and resistors 18, 19 and 20 is slightly modified by changing the position where the motor 17 is connected, with the arrangement of an error amplifier 39A connected across the pair of detecting terminals of the bridge circuit partly modified. It is to be noted that parts corresponding to those shown in the first embodiment are designated by like numerals. The second embodiment operates in the similar manner as the first embodiment, and therefore will not be specifically described. Again, Joule loss in the feed transistor can be reduced, thus providing an efficient speed control apparatus.
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A speed control apparatus for a d.c. motor includes a bridge circuit which operates to detect a speed error signal. The speed error signal is applied to a Schmidt trigger circuit, an output of which is used to cause a switching operation of a power supply circuit for the motor in order to control the speed thereof. The apparatus minimizes power dissipation and improves efficiency.
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BACKGROUND OF THE INVENTION
[0001] Different applications in communications systems mostly operate with different data rates. But the underlying transmission channels, however, mostly offer, because they are embedded into certain transmission formats, only a fixed data transmission rate or a raw data transmission rate or only a discrete set of such data rates. Thus, it will be necessary, in general, to match the data rates to each other at the corresponding interface. This is described below using an example from the UMTS standardization.
[0002] At present, work is in progress on standardizing what is known as the UMTS (Universal Mobile Telecommunications System) mobile radio standard for third-generation mobile radio devices. In accordance with the known current state of UMTS standardization there is provision for subjecting the data to be transferred via a high frequency channel to channel coding, in which case convolutional codes are particularly used. The data to be transmitted is coded redundantly by channel coding which makes a more reliable retrieval of the transmitted data possible on the receiver side. The code used in each case for channel coding is characterized by its code rate r=k/n, where k is the number of data bits or message bits to be transmitted and n is the number of the bits present after encoding. As a rule, the smaller the code rate the more powerful the coding. A problem associated with coding, however, is that the data rate is reduced by a factor of r.
[0003] Rate matching is performed in the transmitter to adapt the data rate of the coded data stream to the relevant possible transmission rate with bits being either removed from the data stream in accordance with a specific pattern or duplicated in the data stream. The removal of bits is the called “puncturing” and the duplication is called “repetition”.
[0004] According to the current status of UMTS standardization, it is proposed for rate matching that an algorithm be used which performs puncturing with an almost regular puncturing pattern, with the bits to be punctured being distributed equidistantly over the coded data block to be punctured in each case.
[0005] In addition, it is known that for convolutional coding the bit error rate (BER) decreases at the edge of a correspondingly coded data block. It is also known that the bit error rate within a data block can be changed locally by regularly distributed puncturing. It is further known from WO 01/26273A1 and WO 01/39421 A1 that it is advantageous to puncture the individual data blocks of the data stream for adapting the data rate in accordance with a specific puncturing pattern, in which case the puncturing pattern is designed in such a way that it features a puncturing rate that increases constantly from a middle area of the individual data block to at least one end of the individual data block.
[0006] An object of the present invention is, thus, to specify a method for adapting the data rate of a data stream in a communications device as well as a corresponding communications device which guarantees a satisfactory bit error rate and can be used, in particular, in mobile radio systems with convolutional coding.
SUMMARY OF THE INVENTION
[0007] In this case, the methodology of convolutional codes will be used to find heuristic puncturing patterns after the use of which all bits of the punctured data block possess a bit error rate corresponding to their relevant importance.
[0008] Preferably, the puncturing pattern features a puncturing rate which increases from the middle area to both ends of the relevant data block. In this way, the bits at the start and the end of the data block to be punctured in each case are punctured more heavily where this is done, not with an evenly-distributed puncturing rate, but with any puncturing rate which essentially increases towards both ends of the data block; i.e., the gap between the punctured bits is on average ever shorter towards both ends of the data block. As will be shown below, the puncturing rate surprisingly does not have to increase in a strictly monotonous way towards the ends, or expressed in other terms, the puncturing gap does not have to decrease strictly monotonously. Instead, because of the specific characteristics of the convolutional codes used and, in particular, the generator polynomials used, it can be an advantage to use somewhat more irregular patterns.
[0009] This puncturing leads to an evenly-distributed error rate of the individual bits over the punctured data block and, in addition, results in a reduced overall error probability.
[0010] The present invention is particularly suitable for adapting the data rate of a convolutional coded data stream and, thus, preferably can be used in UMTS mobile radio systems, in which case this relates both to the area of the mobile radio transmitter and to the mobile radio receiver. The present invention, however is not restricted to this area of application but can be used wherever the data rate of data stream is to be adapted.
[0011] Additional features and advantages of the present invention are described in, and will be apparent from, the following Detailed Description of the Invention and the Figures.
BRIEF DESCRIPTION OF THE FIGURES
[0012] FIG. 1 shows a simplified block diagram of a mobile radio transmitter in accordance with the present invention.
[0013] FIG. 2 shows the bit error rate BER per bit for puncturing in accordance with an exemplary embodiment at HS-SCCH, Part 2, coding with R=⅓ with a ratio of the energy of the transmitted bits to the noise power density E3/N0=−2 dB. The HS-SCCH channel stands for the high-speed shared control channel via which specific configuration information is transferred and which can the subdivided into two subareas, known as Part 1 and Part 2. Part 1 is transferred first in this case and contains the information which the mobile station requires first in order to process the following data channel. Part 2 contains that information which the mobile station does not need until later. What this division into two parts achieves is to make the delay through the HS-SCCH as small as possible since only the first part has to be decoded before data can begin to be received.
[0014] FIG. 3 shows the bit error rate BER per bit for the rate matching proposed in UMTS (Specification 25.21. v5.0.0, chap. 4.2.7 “Rate Matching”) for HS-SCCH, Part 2, for a ratio of the energy of the transferred bits to the noise power density E3/N0=−2 dB.
[0015] FIG. 4 shows a comparison of the results which can be achieved with puncturing in accordance with the present invention (upper curve, crosses) or a conventional puncturing (lower curve, circles) as regards the resulting overall error probability, where the diagram shows the probability that at least one bit of a block has been transmitted incorrectly (known as the frame error rate).
[0016] FIG. 5 shows underlying schemes for convolutional codes in UMTS
[0017] FIG. 6 shows the bit error rate BER per bit for the rate matching proposed in UMTS (specification 25.21. v5.0.0, chap. 4.2.7 “Rate Matching”) for HS-SCCH, Part 1, for a ratio of the energy of the transferred bits to the noise power density E 3 /N 0 =−3 dB.
[0018] FIG. 7 shows how many input bits are involved for a puncturing of one output bit in the various output stages Output 1 , Output 2 and output 3 .
[0019] FIG. 8 shows which input bits (bit numbers) are affected by the puncturing.
[0020] FIG. 9 shows a table with the results of the puncturing depending on the number of punctured bits.
[0021] FIG. 10 shows the bit error rate BER per bit for a puncturing in accordance with an exemplary embodiment for HS-SCCH, Part 1, for a signal-to-noise ratio of the energy of the transferred bits for a noise power density of E 3 /N 0 =−3 dB.
[0022] FIG. 11 shows different exemplary embodiments for a puncturing of 8 bits (48 to 40 bits) for an encoding with a rate ⅓.
[0023] FIG. 12 shows different exemplary embodiments for a puncturing of 31 bits (puncturing from 111 to 80 bits), R=⅓.
[0024] FIG. 13 shows different exemplary embodiments for a repetition of 31 bits (repetition from 32 to 40 bits) R=½.
[0025] FIG. 14 shows different exemplary embodiments for a repetition of 6 bits (74 to 80 bits), R=⅓.
[0026] FIG. 15 shows different exemplary embodiments for a repetition of 4 bits (36 to 40 bits), R=½.
[0027] FIG. 16 shows different exemplary embodiments for a repetition of 14 bits (54 to 40 bits), R=⅓.
[0028] FIG. 17 shows further exemplary embodiments for a puncturing of 31 bits (puncturing from 111 to 80 bits), R=⅓. This figure also can be viewed as a continuation of FIG. 12 .
[0029] FIG. 18 shows an exemplary embodiment for a puncturing from 108 to 80 bits, R=⅓.
[0030] FIG. 19 shows exemplary embodiments for puncturing from 114 to 80 bits, R=⅓.
[0031] FIG. 20 shows exemplary embodiments for puncturing from 117 to 80 bits, R=⅓.
[0032] FIG. 21 shows exemplary embodiments for puncturing from 52 to 40 bits, R=½.
[0033] FIG. 22 shows exemplary embodiments for puncturing from 46 to 40 bits, R=½.
[0034] FIG. 23 shows exemplary embodiments for puncturing from 54 to 40 bits, R=⅓.
[0035] FIG. 24 shows exemplary embodiments for puncturing from 56 to 40 bits, R=½.
[0036] FIG. 25 shows exemplary embodiments for repetition from 36 to 40 bits, R=½.
[0037] FIG. 26 shows exemplary embodiments for puncturing from 48 to 40 bits.
[0038] FIG. 27 shows exemplary embodiments for puncturing from 11 to 40 bits.
[0039] FIG. 28 shows rate matching specifications from the 3 GPP Specification 25.211 v5.0.0, Chap. 4.2.7 Rate matching.
DETAILED DESCRIPTION OF THE INVENTION
[0040] In general, the rows in the table with all bold numbers refer to the relevant preferred exemplary embodiment, in which case however, the quality of the other exemplary embodiment does not necessarily differ in any major way from this highlighted exemplary embodiment. In FIGS. 26 and 27 , however, figures entered in bold indicate the bits punctured or repeated by the described construction principle of the rate matching formula in accordance with the present invention at the start or the end of the repetition pattern. These are defined such that, by contrast, the position of the bits not shown in bold type easily can be shifted by variation of the parameter or within the framework of the present invention (typically by one position).
[0041] FIG. 1 shows a schematic diagram of the structure of the mobile radio transmitter 1 in accordance with the present invention and from which data or communications information, especially voice information, will be transmitted via a high-frequency transmission channel to the receiver. In FIG. 1 the components involved in the coding of this information or data are shown, in particular. The information provided by a data source 2 , such as a microphone, is initially converted with a digital source coder 3 into a bit stream. The voice-coded data is subsequently coded with the aid of a channel coder, in which case the actual payload or message bits are coded redundantly which allows transmission errors to be detected and subsequently corrected. The channel coder 4 can be a convolutional coder. The code rate produced for channel coding r is an important variable to describe the codes used in each case for channel coding and is, as has already been mentioned, defined by the expression r k/n. In this expression, the k stands for the number of data bits and n for the total number of bits coded; i.e., the number of inserted redundant bits corresponds to the expression n−k. A code with the code rate r defined above is also referred to as an (n,k) code, in which case the performance of the code increases with a decreasing code rate r. For channel coding, so-called block codes or convolutional codes are normally used.
[0042] The following explanations are based on the assumption—that, as defined in the current state of UMTS—standardization, convolutional codes are used for channel coding. A major difference to block codes is that with convolutional codes individual data blocks are not coded consecutively but that a continuous processing is involved, in which case each current code word of an input sequence also depends on the previous input sequence. Independently of the code rate r=k/n convolutional codes are also characterized by what is known as the constraint length K. The constraint length specifies over how many clock pulses of k new input bits of the channel coder 4 a bit influences the code word output by the channel coder 5 .
[0043] For UMTS, the following convolutional codes are used, as shown in FIG. 5 . FIG. 5 is taken from specification 25.212, Chap. 4.2.3.1 “Convolutional coding.”
[0044] Before transmission of the channel-coded information to the receiver, the information can be routed to an interleaver 5 which reorders the bits to be transmitted in accordance with a specific scheme and thereby spreads them over time, in which case the errors which as a rule occur in bundles are distributed in order to obtain what is known as a memoryless transmission channel with a quasi-random error distribution. The information or data coded in this way is routed to a Modulator 7 which has the task of modulating the data onto a carrier signal and of transmitting in accordance with a prespecified multiple access method via a high-frequency transmission channel 3 to a receiver.
[0045] For transmission, the coded data stream is subdivided into data blocks, in which case the channel coder 4 is set to a known status at the beginning of a data block. At the end, each coded data block is terminated by what are known as tail bits so that the channel coder 4 is again in a known state. The result of this convolutional code and channel code 4 structure is that the bits at the start and end of a coded data block are better protected from transmission errors than those in the middle of the block. In this case, it is of no significance whether these tail bits all have the known value of 0 or whether they have another value. Random values also can be chosen for these tail bits, in which case both transmitter and receiver must know the values to be used.
[0046] The error probability of a bit differs depending on its position within the relevant data block. This effect is exploited, for example, in voice transmission in GSM mobile systems by placing the most important bits of the block at both ends where the error probability is at its lowest. With data transmissions, however, data packets are already rejected if just one single transmitted bit is in error which can, for example, be established in the receiver by a “Cyclic Redundancy Check” (CRC). Thus, it is not possible to refer to important or less important data in a data transmission, all bits being regarded as equally important. If errors occur in a control block, that is a data block which contains control information which contains information about how subsequent payload data is to be encoded and transferred, then correct detection of this payload data is then no longer possible even if just a single bit is received incorrectly, since the received data is then interpreted incorrectly.
[0047] To match the data rate of the coded data stream to the relevant transmission rate possible, the rate matching is performed before the modulator 7 . For the exemplary embodiment shown in FIG. 1 , rate matching is undertaken in the rate matching unit 6 b, in which case the puncturing unit 6 a first undertakes puncturing in accordance with a specific puncturing pattern in order to achieve a more equal error distribution over a data block. The execution sequence of the puncturing unit 6 a shown in FIG. 1 as well as of the interleaver are merely to be taken as examples. The interleaver also can be arranged after unit 6 b. Likewise the interleaver 5 also can be replaced by two interleavers before and after the rate matching unit 6 b etc.
[0048] The present invention further seeks to optimize puncturing patterns and match them to the polynomials used for the channel coder. There is also the task, depending on the convolution code used (including the polynomials used) and the block length, of selecting the quantity of bits to be punctured or repeated so that the decoding is undertaken as favorably as possible. As a rule, a large number of options are produced so it is at least very time and resource-consuming to develop a very good rate matching pattern purely through simulation. If, for example, one wishes to investigate all the options for puncturing of 48 bits to 40 bits this would be 48!/(8!*40)=377348994 different options which could not be investigated within a reasonable time.
[0049] This problem is particularly evident for short block lengths such as, for example, for the control information of the UMTS expansion HSDPA and, in particular, the HS-SCCH (high speed shared control) channel. This cannel transmits configuration information which specifies how the actual payload data sent over the specific data channel is coded and further details, for example, the spread codes used for transmission. By contrast to the data channel over which a large amount of data can be transmitted, this is a comparatively small amount of data. In UMTS convolution codes with the rate ½ or ⅓ are used for coding, The polynomials used are shown in FIG. 5 . Also referred to as polynomials are the exact design of the “tapping points” which delay stages are tapped for the individual output bit streams and logically combined by an exclusive OR operation.
[0050] The present invention is thus particularly applicable to what is known as the HS-SCCH (high speed shared control) channel.
[0051] The definition of the coding of the HS-SCCH is given in accordance with the current prior art in Specification 3GPP TS 25.1.212 V5.0.0 (2002-03) “Multiplexing and Channel Coding (FDD) (Release 5),” particularly in Chapter 4.6 “Coding for HS-SCCH.” This specification is abbreviated elsewhere in this Patent Application to 25.212. Subsection 4.6.6 “Rate Matching for HS-SCCH” defines that rate matching must be performed in accordance with the standard rate matching algorithm in Chapter 4.2.7 “Rate Matching” which essentially effects an equidistant (as possible) puncturing or repetition.
[0052] The block length of the two parts of the HS-SCCH amounts in the current version to 8 bits for the first part, or if the tail bits are included, 16 bits, 29 bits for the second part, or if the tail bits are included, 37 bits. Since the specification is still fluid, modifications to various parameters or other block lengths can be produced. Furthermore, the convolution codes with the rate ½ or ⅓ also come into the picture. The following rate matchings are particularly relevant:
[0053] a) 32 to 40 (with code rate R=½), or
[0054] b) 48 to 40 (with code rate R=⅓), or
[0055] c) 74 to 80 (with code rate R=½), or
[0056] d) 111 to 80 (with code rate R=⅓).
[0000] Method for Determining Puncturing and Repetition Patterns
[0057] In overview, it can be stated that for a rate matching, a puncturing and/or repetition or also a repetition alone is undertaken so that the overall bit error rate (BER) becomes minimal. To this end, let us first look at the situation shown in FIG. 3 . This records the bit error rate for the individual bits in a frame. The axis reflects the index or the relevant bit (frame index). One can clearly see that the first and last bits feature a lower bit error rate. This can be understood in conjunction with the scheme for con volution codes from FIG. 5 , for transmission bits from the various delay stages D of the decoder are linked together by the convolution code in each case. The first bits are, for example, then linked with the bits preceding them, at bits which do not actually exist. These “non-existent bits” are then set to a known value, typically zero. This is known to the receiver which on its side now decodes with these bits set to zero the first bits transmitted. Decoding is very secure here since one part of the bits is known with absolute certainty.
[0058] The same is true for the last bits. These are again followed by artificial bits, known as the tail bits, into which the delay elements D of the decoder are inserted; these tail bits being set, in turn, to a known value (usually zero).
[0059] In the middle area, bits are linked together for which the value is not known with certainty at the receiver. As such, on decoding there is a greater probability of an error occurring, which expresses itself in a higher bit error rate.
[0060] The envelope curve of the bit error rate in relation to the frame number is thus initially deformed upwards in a convex shape for equal repetition or puncturing. There are now various options for how the envelope curve changes when the puncturing (or repetition) is changed.
[0000] a) The Envelope Essentially Represents a Horizontal (or Approximates to One)
[0061] This refers to the bit error rate being essentially the same for all bits within a frame. This occurs, for example, when there is puncturing at the edges or repetition in the middle, or both, depending on the rate to be matched.
[0000] b) Envelope Curve has a Concave Shape
[0062] In this case, for example, puncturing has been so heavy at the edge that the bits in the middle area of the frame exhibit a lower bit error rate. This situation can be seen in FIG. 2 .
[0000] c) The Bit Error Rate is Irregularly Distributed in Relation to the Frame Number.
[0000] This case is not examined in any more detail here for the reasons given below.
[0063] The information given below relates to puncturing. Similar considerations can be applied to repetition or for a combination of puncturing and repetition.
[0064] There are now very many options for how individual bits can be punctured. If, for example, one wishes, as already stated previously, to investigate all the possible options for puncturing 48 bits to 40 bits, this would be 48!/(8!*40!) 377348994 different options, which cannot all be investigated within a reasonable time.
[0065] The aim, thus, is to eliminate non-viable options in advance. This is not done by random repetition and/or puncturing, which is why alternative c) will not be considered any further here.
[0066] An ordering principle is shown in FIG. 7 . For the first 9 input bits 1 - 9 as well as for the last 9 input bits n- 8 to n the puncturing level for the relevant output stage Output 0 , Output 1 , Output 2 is illustrated. The output stages themselves, as can be seen from FIG. 5 , are the relevant output function which is formed from all input bits preceding the input bit currently under consideration in time. Here, the output stages of FIG. 5 b are considered, that is the rate ⅓ convolutional encoder.
[0067] For puncturing with as little loss of information as possible, it makes sense to initially leave out bits (puncturing) which have little influence on other bits. The puncturing level thus specifies how many bits will be affected by puncturing of the bits concerned.
[0068] A typical methodology for leaving out or puncturing of bits is shown in FIG. 8 . In the first column, the first 9 input bits 1 - 9 are again specified, as well as the last 9 input bits n- 8 to n. In the following columns, the bit numbers of the information bits affected by puncturing, that is information bits or input bits for the relevant output stage output 0 , output 1 and output 2 are shown. The table fields are, as already in FIG. 7 , set against an increasingly darker background for an increasing number of information bits influenced. The bits belonging to the light table fields are thus candidates for puncturing.
[0069] FIG. 9 shows a table in which the most important variables for puncturing in the vicinity of the ends, that is puncturing of the first and last bits, are illustrated. n input bits (information bits) and k coded bits (bits at the output stage, output bits) are considered. In the first column, the number of punctured output bits (# punct bits) is specified. In the last column, the (cumulative) number of the bits affected by these bits at the input, in which case input bits which are affected a number of times, that is by the puncturing of a number of output bits, are also counted multiple times accordingly.
[0070] In the second column, Sequence specifies which output bit (bit number) has been punctured in this step. In this case, the puncturing takes place beginning with the least important bits in the first row through to the following bits in the following rows. The entire puncturing pattern for 7 bits to be punctured, for example, is thus produced from the bits specified in column 2 in rows 1 through 7 ; that is, bits 1 , k, 4 , k- 4 , k- 6 , 2 , k- 1 . This pattern thus includes the bits 1 , 2 4 , k- 6 k- 4 , k- 1 , k.
[0071] Above the first row is the indexing for the first information bits 1 - 9 as well as the last information bits k- 8 through k. For reasons of space this is written as just −8, etc., instead of k- 8 . The entries in the columns under the indexing of the information bits specify how greatly the relevant information is affected by the puncturing of the output bits which are specified in the 2nd column up to the relevant row and are thus punctured. This refers to how many of the punctured output bits were linked to this information bit. This is a measure of how greatly the information bit involved was weakened by puncturing.
[0072] In the last column (cumulative), finally, the sum of these effects is given. It is called the cumulative puncturing strength in this case.
[0073] The column average value gives the ratio V of the sum of the last column divided by the number of information bits involved. For example, for 6 punctured bits V=(2+1+1+1+1)/(1+1+1+1+1)=1.2. The average puncturing rate (av. puncturing rate) is the column “average value” divided by 18, the total number of exclusive OR operations occurring per information bit during encoding.
[0074] A procedure for puncturing any given number of bits includes preparing tables similar to the ones given above. The tables shown can be used for the rate ⅓ and the polynomials of the convolutional encoder considered. For other encoding rates and/or other polynomials the tables can be determined in a very similar way. With the aid of these tables a puncturing sequence is established in which first those output bits are punctured which have only a small effect on the cumulative puncturing strength. If there are a number of alternatives in these cases those bits which minimize the maximum of the puncturing strength of the individual bits are preferably punctured.
[0075] For a higher number of bits to be punctured and/or greater block lengths, as a rule the information from the tables must be combined with the idea of achieving as equal as possible a distribution over the entire block. It then makes sense to explicitly adopt additional bits in the middle part which are generated by the generator polynomials with the lowest powers; i.e., with the fewest logical combinations. At the same time it should be ensured that the overall distribution of the puncturing strengths in the middle area of the frame does not exhibit any obvious peaks.
[0076] The same applies to repeating, but with the reversed leading signs. As such, bits which were first punctured in accordance with the heuristic and even a repetition is first performed in the middle part, preferably by the polynomials of the most logical combinations. Afterwards, those bits are repeated at the edge which (for puncturing) have as great as possible an influence on the cumulative puncturing strength.
[0077] By contrast with methods in which the puncturing rate constantly increases up to the ends, this leads to a result which is not expected per se, since one would expect that the reliability of the coded bits constantly decreases towards the ends. A closer examination for the convolutional encoders used, however, shows that this assumption is surprisingly not true. The specific characteristics of the polynomials produce coded bits, particularly at the ends, which contribute less effectively to the coding. These bits, however, do not occur up to the end in constantly increasing volumes, but are somewhat irregularly distributed. By aligning the puncturing patterns specifically to these “weak” bits, that is by giving preference to puncturing these bits, one can improve the coding even further.
[0078] The present invention thus makes use of an heuristic method which allows:
the effect of the puncturing/repeating of a coded bit on the underlying information bits to be approximated via a newly-defined heuristic metric; specific bits to be selected explicitly and for each convolution code which are to be punctured or repeated; and the number of the rate matching patterns to be investigated to be greatly restricted.
[0082] After a number of promising rate matching patterns have been determined based on this method, they will be compared on the basis of the frame error rate and the bit error rate of each individual information bit (referred to hereafter as the bit error rate distribution). The rate matching pattern then can be iteratively further refined and optimized, based on the developed metric. The bit error rate distribution of the non-punctured/non-repeated blocks serves as start information.
[0083] The puncturing strength S i , per bit information bit i, will be defined as heuristic metric as the number of logical operations not transmitted by puncturing of one information bit with the relevant output bits of the encoder. S i is thus positive for puncturing. For repetition, S i,k =n−1 is defined for each logical operation transmitted n times.
[0084] S max is the maximum possible puncturing strength specified by the code-specific total number of existing logical operations.
[0085] A good rate matching pattern is searched for in accordance with the following quality criterion:
[0086] 1. select the cumulative puncturing strength to be close to the possible minimum;
[0087] 2. ensure that there is as even as possible a distribution of the bit error rate across all information bits.
[0088] For the selection of the bits to be punctured/repeated, tables will be set up based on the generator polynomials of the codes for the start and the end of the coded blocks which represent the cumulative puncturing strength per coded bit as well as the information bits concerned. This allows the coded bits to be divided into what are known as classes of the cumulative puncturing strength.
[0089] In accordance with the above quality criterion, these tables are now used to search for bits to be punctured/repeated in such a way that, initially, for those information bits which exhibit a lower bit error rate than other bits, the puncturing strength is increased and simultaneously the cumulative puncturing strength is kept low. Thus, the puncturing strength will be selected to be inversely proportional to the bit error rate of the information bit and, in addition, bits will be explicitly sought which contribute little to the cumulative puncturing strength.
[0090] This method then will be applied iteratively, based on the first pattern determined, so that, even after just a few simulations, a specifically optimized rate matching pattern can be found for the relevant convolution code.
[0091] FIGS. 11 and 12 show different options for puncturing patterns in accordance with the present invention, in which case the number of bits to be punctured (counting begins at one) is specified in each case. The tables are specified for different numbers of information bits to be transmitted and different numbers of bits to be transmitted after the rate matching.
[0092] FIG. 3 typically shows the graph of the bit error rate for the individual bits transmitted of a data block depending on their position or location in the data block for a conventional puncturing with a regular puncturing pattern.
[0093] FIG. 2 shows this graph for puncturing in accordance with the present invention with pattern and number 33 from FIG. 12 which has shown itself to be particularly suitable in simulations. It can be seen from FIG. 2 that by using the puncturing pattern in accordance with the present invention a more even curve of the bit error rate over the entire data block can be achieved. Since, in the middle area of the data block, puncturing is less frequent compared to the conventional method, a lower error probability can be obtained there. Actually, the error rate now rises slightly towards the ends which could appear unfavourable at first glance. The result of this is, however, that there are many “weak” bits at the edge, as already stated above, where puncturing can be performed very effectively.
[0094] FIG. 4 records the curve of the overall error rate over the ratio of the energy of the transmitted bits to the noise power density for the same cases. It can be seen from FIG. 4 that with the aid of the present invention (lower curve, circles), compared to the conventional method (upper curve, crosses), a frame error rate improved by around 0.2 dB can be achieved.
[0095] Similar improvements also can be achieved for other parameters. For example, FIG. 6 shows the graph of the bit error rate for the individually transmitted bits of a data block depending on their position in the data block for a conventional puncturing with a regular puncturing pattern for an encoding with a rate ⅓ and a puncturing of 8 bits (48 to 40 bits). This corresponds to a transmission of 8 input bits. FIG. 10 shows the distribution, if instead, the puncturing pattern No. 3 from FIG. 11 is used which also has proved particularly suitable in simulations. It can be seen that here a very evenly balanced distribution is produced. Here, too, an improvement is achieved of around 0.2 dB (but no curve is shown for this since it does not provide any further insights). FIG. 16 shows further preferred exemplary embodiments as part of the present invention with a puncturing of 14 of 54 bits in which case the patterns 3 and 4 produce the best results.
[0096] FIGS. 13, 14 and 15 show preferred repetition patterns which also are obtained using the rules shown in accordance with the present invention.
[0097] The present invention has been described on the basis of use in a mobile radio transmitter. The present invention also can, of course, be extended to mobile radio receivers where, for matching the data rate in the way described above, punctured or repeated signals must be processed in accordance with the puncturing or repetition pattern used in each case. In this case, in the relevant for bits punctured on the transmit side or repeated bits, additional bits are inserted into the received bit stream or two or more bits of the receive bit stream are gruped together. For insertion of additional bits, a flag is simultaneously set in the form of a soft decision to indicate that its information content is very uncertain. The processing of the receive signal can be undertaken in the relevant receiver in the same way in reverse order to FIG. 1 .
[0098] Further bit adaptation patterns determined using the inventive method explained above
[0099] The puncturing patterns specified previously predominantly concentrate on puncturing in the end areas and/or repetition in the middle area.
[0100] The further rate matching patterns now described were determined in the previously explained inventive method for different proposals for HS-SCCH coding in the standardization. The bits to be punctured or to be repeated are specified in each case. The bits are numbered consecutively from 1 through N. The preferred pattern is given first in each case. The further patterns, however, always exhibit similar favourable characteristics.
[0101] FIG. 17 , in which these further puncturing patterns are listed, thus represents an expansion of FIG. 12 . Accordingly puncturing patterns for various output bit rates are shown in FIGS. 18-24 and further repetition patterns in FIG. 25 .
[0102] Approximation of preferred rate matching patterns using components already specified in the UMTS
[0103] The patterns previously shown have the aim of proposing an optimum possible selection of bits to be punctured or to be repeated, in which case no other restrictions are imposed with regard to the pattern. In practical implementations, however, it can be of advantage to only consider those patterns which can be implemented with the least possible changes to existing rate matching circuits. A corresponding rate matching specification is described in document Specification 25.212 v5.0.0 Chap 4.2.7 it “Rate Matching” which already has been mentioned. The sections below will reflect the sense of the part of this specification which undertakes the actual puncturing or repetition and which is described in Chapter 4.2.7.5 “Rate matching pattern determination.”
[0104] Before rate matching, the bits are identified by x i1 , x i2 , x i3 , . . . x ix . In this case, i stands for the transport channel number, the sequence itself is defined in sections 4.2.7.4 of the Specification for the uplink and in 4.2.7.1 for the downlink. An uplink is taken to refer to a connection from a communications device to the base station, a downlink a communication from a base station to a communications device.
[0105] The rule for rate matching is reproduced in the section of the specification which runs when the condition is fulfilled that puncturing has to be performed.
First, an error value e is set to an initial value which lies between the original error value and the desired puncturing rate. In a loop with the index m of the bit currently considered as run parameter, up to the end of the sequence, that is up to index X i : the error value e his initially set to e minus , where eminus essentially represents the number of bits to be punctured; a check is then made as to whether the error value e<=0, In this case a check is made as to whether the bit with the index m is to be punctured, in which case a bit to be punctured is then set to a value of δ which is other than 0 or 1.
[0111] Where a repetition is to be undertaken, essentially the same procedure is performed, in which case a repeated bit is then set directly after the original bit.
[0112] For puncturing, the execution sequence then proceeds with the bits which have been set to the value δ being removed so that these bits are thus punctured.
[0113] The parameters Xi, e ini , e plus and e minus are selected so that the desired rate for matching can be achieved. Essentially, then, e plus =Xi, e minus =N p , where X i is the number of bits before rate matching and N p is the number of bits to be punctured or repeated. e ini can be chosen in the range between 1 and e plus , which produces a slight shift in the pattern, bits being used in specific cases (rate matching after a first interleaving), to shift the patterns in different frames suitably in relation to one other. The parameter i identifies different transport channels in the Specification. This parameter, is however, irrelevant in this case and is thus omitted. Options are shown below for how one can approximate preferred rate matching patterns for short block sizes with convolution codes using this existing rate matching algorithm. In this case, an attempt is made under the general conditions of this algorithm to preferably use bits at the end of the code block for puncturing and for repetition to, above all, use bits from the middle of the code block. A core aspect of this exemplary embodiment is not to limit the parameter e ini to the range of values from 1 to e plus , but instead to advantageously select it outside this range. Such a choice may appear contradictory at first glance since it no longer ensures that the desired number of bits are punctured or repeated. Through an advantageous matching of the values of e plus and e minus , however, it is possible to the still achieve the desired number.
[0114] Let
[0115] X i : Number of bits before rate matching
[0116] N p : Number of bits to be punctured/repeated (the index p in N p refers to the number are of bits to be punctured, N p also can, however, designate the number of bits to be repeated.
[0117] To fully specify the use of the rate matching algorithm and the rate matching pattern for the initial error value e ini , the error increment e plus and the error decrement e minus must be specified, since these parameters completely describe the rate matching pattern.
[0118] The paragraphs below illustrate the preferred rate matching patterns using the rate matching algorithm given in release 99 UTMS.
[0119] Subsequently, options are shown for how the preferred rate matching patterns already present in the standard rate matching algorithm (data rate matching algorithm) can be approximated for short block sizes with convolution codes. In this case, an attempt is made under the general condition of this algorithm for puncturing to preferably use bits at the ends of the code block and for repetition to, above all, use bits from the middle of the code block.
[0120] Puncturing
[0121] The parameters of the rate matching algorithm are selected so that the first N0 bits at the beginning of the code block are punctured, whereby the following equation must apply:
N 0 ·( e min us −e plus )< e ini ≦N 0 ·e min us −( N 0 −1)· e plus (1).
[0122] There is provision as a further criterion for the last bit of the block to be punctured as well, this being done in accordance with the following condition:
( N 0 −1)·( e minus −e plus )< e ini (2).
[0123] In this case, the value of the error variable e actually will be negative precisely for the last bit, whereby this bit is then punctured.
[0124] Both criteria are, for example, fulfilled by the following preferred selection of parameters:
e plus =X i −N 0 (3).
e min us =N p −N 0 (4).
e ini =N 0 ·e min us −( N 0 −1)· e plus (5).
[0125] Also included in these formulae is the special case in which no bit at the beginning of the code block is to be punctured (N 0 =0). Then, the following applies: e ini =X i , e plus =X i , e minus =N p .
[0126] The general implementations which select e ini in accordance with the formulae (1) to (4) produce frame matching patterns which differ from those in the preferred selection of parameters in accordance with (3) to (5) merely in that, from the (N 0 +1)th up to the (N p −1)th puncturing point, the index of the bits to be punctured can be decremented by one.
[0127] For the application example of puncturing of 48 bits to 40 bits, the table in FIG. 26 shows puncturing patterns in accordance with the preferred parameter selection up to N 0 =6. The puncturing points not printed in bold type can be decremented by one either partly or completely by variation of the e ini value in accordance with (1) and (2).
[0128] The table shown subsequently in FIG. 27 shows in the same manner the resulting pattern for a puncturing of 111 bits to 80 bits.
[0129] Although this does not allow the optimum puncturing patterns which already have been discussed above to be achieved, it is still possible to achieve a certain improvement of the transmission quality compared to the current status of the specification, in which case the changes to be made are comparatively small.
[0130] Repetition
[0131] The parameters of the rate matching algorithm are calculated in accordance with the present invention, so that a maximum gap between the last bit to be repeated and the block end is guaranteed, so that the following must apply:
e ini =1 +X i ·e min us −N p ·e plus (6).
[0132] Furthermore, the average gap between bits to be repeated R R can be prespecified. RR does not have to be a whole number but can be a positive rational number. The following then applies:
R R = e plus e minus . ( 7 )
[0133] As such, e plus and e minus can be freely selected under the general condition that their quotient produces precisely R R and, in total, N p bits are to be repeated.
[0134] If the first bit to be repeated, or to put it more precisely, the position of the first bit to be repeated (designated here as b 1 ) is to be prespecified, the following equation must apply in addition to (6):
e ini b 1 ≤ e minus < e ini b 1 - 1 , , ( 8 )
[0135] where e minus should be a whole number and b 1 ≦X i −N p +1.
[0136] A preferred parameter selection is produced for
e min us =N p · (9)
e plus =X i −b 1 +1 (10)
e ini =( b i −1)· N p +1 (11).
[0137] With this selection of parameters, the position of the first bit to be repeated is b 1 and, as required, N p bits are repeated.
[0138] Here, too, the repetition patterns produced are not optimal compared to the patterns already discussed above. Despite this, it is still possible to achieve a certain improvement in transmission quality the inventive method compared to the current state of the specification, in which case the changes to be made are again comparatively small. By selecting parameter b 1 well, it is possible to achieve repetition which does not begin right at the start. At the start, repetition is not actually needed since the bits at the start of the convolution decoder as shown above in any event exhibit a comparatively low error rate. It is, thus, far more beneficial when the bits to be repeated, as occurs with the inventive method, are concentrated further towards the middle.
[0139] Of course, a combination of the criteria given above is also possible for the selection of a puncturing pattern. For example, one can combine a pattern from two of the patterns presented here by using the start of one pattern at the start and the end of the second pattern at the end. Furthermore, it makes no difference if the bits are output in a changed sequence and at the same time the puncturing pattern is adapted accordingly. For example, the sequence of the polynomials in the convolution coder can be swapped over.
[0140] Although the present invention has been described with reference to specific embodiments, those of skill in the art will recognize that changes may be made thereto without departing from the spirit and scope of the present invention as set forth in the hereafter appended claims.
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A method is provided for adapting the data transfer rate of a data flow in a communication device according to which: the data flow can be subdivided into at least one data block containing transmission bits to be transmitted; the transmission bits are formed by a coding process from information-carrying input bits; transmission bits determined from a data block of the data flow are removed (punctured) in order to adapt the data transfer rate; a puncturing pattern stipulates which transmission bits are to be removed, and; the puncturing pattern is constructed in such a manner that transmission bits are preferably removed that, during the coding process, depend on few input bits. The present invention also relates to a corresponding communication device.
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FIELD OF THE INVENTION
This invention relates to heat radiating fins.
BACKGROUND OF THE INVENTION
Baseboard radiators were developed to take advantage of areas where space of considerable length was available. In general, the structure comprised a series of vertical plates (fins) which radiated heat arranged on a pipe which had a circulating fluid such as steam or hot water. Additionally, a front cover plate provided a hood to deflect the heat and a protective wall plate.
U.S. Pat. No. 1,776,080 discloses an early baseboard heater. The wall plate serves also as a mounting support.
U.S. Pat. No. 1,914,197 discloses a more sophisticated method of directing the air, by forming a curved channel. Production of this design is costly and bulky.
U.S. Pat. No. 3,091,289, incorporated herein by reference, presents alternative shaping to thin fin assemblies, presenting flat fins having trapezoidal and parallelogram shapes.
U.S. Pat. No. 3,367,132, shows a valance system, demonstrating that finded heating and cooling systems can be located in positions other than the floor.
U.S. Pat. No. 4,195,687, incorporated herein by reference, discloses a system which provides a bent fin that forms a wall plate and a front plate. A method for attaching the system to the wall is not disclosed.
SUMMARY OF THE INVENTION
A fin system, suitable for use with a solar collection system or with conventional systems is presented. The fin provides an easily accessible, flexible system of attachment to a wall or other support by means of a rear flange. Access to the flange is provided by a taper of the fin. The taper also improves the circulation of the heated air. In one version, a second flange substantially parallel to the rear flange is provided to add strength and eliminate the necessity of a front plate, element hanger, backplate, and/or a damper.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a fin during attachment.
FIG. 2 is a top view of a modification of the fin of FIG. 1.
FIG. 3 is a front view of the fin of FIG. 1.
FIG. 4 is a side view of a fin having a beak shaped top and bird tail like bottom.
FIG. 5 is a schematic view of a solar heating system using the fin of FIG. 4.
FIG. 6 shows a blank suitable for forming a fin.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIGS. 1 through 3 show a radiating fin having a modified trapezoidal shape. Radiating for purposes of this application shall mean radiating of coolness as well as warmth. The trapezoidal side web (58) has a back flange (18) which is placed against a wall (2). If desired, rubber grommets can be used to space the flange within 3 mm of the wall. The oblique upper (8) and lower (14) edges of the side web (58) provide access to a fastening device (4) such as a screw, nail, bolt or staple by a tool (6) such as a screw driver. A front flange (20) is shorter in length than the back flange (18), and has an optional front side flange (16) to provide smoother abutment between fins and to increase structural strength. The side web (58) has apertures (70) and (72) for a top (10) and bottom (12) pipes which carry a heated or cooled fluid. While the fins may be slipped on the pipes and depend on friction for contact, a collar (30) may be provided for better fit and contact. Alternatively, conduction between the pipe and the fin could be improved by attachment with a heat conductive cement.
When a number of the fins are placed side by side on a pipe, a back wall is formed by a plurality of back flanges (18) and a front wall is formed by a plurality of front flanges (20). Since each fin is provided with top and bottom apertures (22) and (24), attachment can be properly made at a variety of points, minimizing the problem of having structural attachment points such as studs match available holes of a baseboard or valance unit.
The shape of the fin also provides an efficient chimney effect, drawing cold air at the base (for heating) an spreading radiating it at the top. To further direct air at the emitting end of the fin, The rear fin could be extended at the top and the extension bent forward. For safety, it is suggested that the extension have side and front flanges. A blank for forming such a fin is shown in FIG. 6.
FIG. 4 shows a fin having a beak shaped upper side web (28) and a top flange (26). This design increases heating efficiency while maintaining the access to a fastener (4).
FIG. 6 shows a blank for a fin which can be cut from a sheet of metal. By valley folding along the dashed lines, section (60b) becomes a top front flange; section (64b) becomes a deflecting top; sections (62b), (66b) and (68b) become top side flanges; section (18b) becomes back flange (18); section (58b) becomes side web (58); section (20b) becomes front flange (20); and section (16b) becomes front side flange (16).
FIG. 5 shows a solar heating system using fins such as shown in FIG. 4. Lower pipe (12) and upper pipe (10) are connected at one end by pipe (32). Several fins are fitted over the pipes (10) and (12). The number of fins to form a length within the body of the radiator is dependent on the heat loss in a particular room or area. The fins can be formed by extrusion, or by stamping and then folding or roller forming. A vessel (34) having lower inlet (40) and upper outflow (42) pipes is connected to remaining ends of pipes (10) and (12) respectively. The vessel (34) has a heating element (44), limit control (36), circulating pump (38), a screw on/off top (82) for maintainence and filling with a heat transfer fluid, and electrodes (46). Terminals (54) of a photovoltaic solar collector (52) and terminals (50) of a storage battery (48) are connected by wires (56) to each other and the vessel electrodes (46). The storage battery (48) supplies energy during darkness, the collector (52) during day. Excess energy collected during the day is stored for later use by the battery (48). As heated fluid circulates through the pipes, heat is disbursed by two methods; radiation off front and top flanges, and convection through the chimney effect. Ideally, the vessel (34) is very compact so that it may reside next to the fins and behind a cover similar to the fins for continuity.
When a thermostat (80) indicates heat is called for, the pump (38) and heating element (44) are energized. The heating element (44), heats the fluid to a desired temperature, while the pump (38) circulates the fluid from the vessel (34) through the lower heating line (12), around through the top heating line (10) and back to the vessel (34) until the thermostat (80) is satisfied.
The limit control (36) is set to a predetermined temperature to prevent overheating of the fluid within the radiator. If, by chance, the temperature of the fluid reaches its limit, the limit control contacts open and the heating element (44) is automatically shut off. The pump (38) continues running until the thermostat and limit control are satisfied.
If desired, inlet (40) and outlet (42) pipes can be Teed into a backup system with the aid of check valves.
Pipes and fins are of rigid heat conductive material such as metal. Typically pipes are made from copper and fins from sheet or extruded aluminium or steel.
The fins disclosed herein may be attached to a unit prior to shipping, or could be attached at an installation site with minimal equipment in order to provide custom lengths.
While the fins disclosed have cross sections of right angled C shapes due to ease in forming, this should not be considered limiting. Other shapes such as Z, or a cross section similar to that disclosed in U.S. Pat. No. 4,195,687 are possible.
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A fin type radiating system is presented having an exposed rear flange for ease in installing, while improving efficiency. The resulting system is environmentally sound and durable.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation of U.S. patent application Ser. No. 10/682,093 filed Oct. 8, 2003, entitled Substrate and Collector Grid Structures for Integrated Series Connected Photovoltaic Arrays and Process of Manufacture of Such Arrays which is a Continuation-in-Part of U.S. patent application Ser. No. 10/186,546 filed Jul. 1, 2002, entitled Substrate and Collector Grid Structures for Integrated Series Connected Photovoltaic Arrays and Process of Manufacture of Such Arrays, now abandoned, which is a Continuation-in-Part of U.S. patent application Ser. No. 09/528,086, filed Mar. 17, 2000, entitled Substrate and Collector Grid Structures for Integrated Series Connected Photovoltaic Arrays and Process of Manufacture of Such Arrays, and now U.S. Pat. No. 6,414,235, which is a Continuation-in-Part of U.S. patent application Ser. No. 09/281,656, filed Mar. 30, 1999, entitled Substrate and Collector Grid Structures for Electrically Interconnecting Photovoltaic Arrays and Process of Manufacture of Such Arrays, and now U.S. Pat. No. 6,239,352. The entire contents of the above identified applications are incorporated herein by this reference.
BACKGROUND OF THE INVENTION
[0002] Photovoltaic cells have developed according to two distinct methods. The initial operational cells employed a matrix of single crystal silicon appropriately doped to produce a planar p-n junction. An intrinsic electric field established at the p-n junction produces a voltage by directing solar photon produced holes and free electrons in opposite directions. Despite good conversion efficiencies and long-term reliability, widespread energy collection using single-crystal silicon cells is thwarted by the exceptionally high cost of single crystal silicon material and interconnection processing.
[0003] A second approach to produce photovoltaic cells is by depositing thin photovoltaic semiconductor films on a supporting substrate. Material requirements are minimized and technologies can be proposed for mass production. The thin film structures can be designed according to doped homojunction technology such as that involving silicon films, or can employ heterojunction approaches such as those using CdTe or chalcopyrite materials. Despite significant improvements in individual cell conversion efficiencies for both single crystal and thin film approaches, photovoltaic energy collection has been generally restricted to applications having low power requirements. One factor impeding development of bulk power systems is the problem of economically collecting the energy from an extensive collection surface. Photovoltaic cells can be described as high current, low voltage devices. Typically individual cell voltage is less than one volt. The current component is a substantial characteristic of the power generated. Efficient energy collection from an expansive surface must minimize resistive losses associated with the high current characteristic. A way to minimize resistive losses is to reduce the size of individual cells and connect them in series. Thus, voltage is stepped through each cell while current and associated resistive losses are minimized.
[0004] It is readily recognized that making effective, durable series connections among multiple small cells can be laborious, difficult and expensive. In order to approach economical mass production of series connected arrays of individual cells, a number of factors must be considered in addition to the type of photovoltaic materials chosen. These include the substrate employed and the process envisioned. Since thin films can be deposited over expansive areas, thin film technologies offer additional opportunities for mass production of interconnected arrays compared to inherently small, discrete single crystal silicon cells. Thus a number of U.S. patents have issued proposing designs and processes to achieve series interconnections among the thin film photovoltaic cells. Many of these technologies comprise deposition of photovoltaic thin films on glass substrates followed by scribing to form smaller area individual cells. Multiple steps then follow to electrically connect the individual cells in series array. Examples of these proposed processes are presented in U.S. Pat. Nos. 4,443,651, 4,724,011, and 4,769,086 to Swartz, Turner et al. and Tanner et al. respectively. While expanding the opportunities for mass production of interconnected cell arrays compared with single crystal silicon approaches, glass substrates must inherently be processed on an individual batch basis.
[0005] More recently, developers have explored depositing wide area films using continuous roll-to-roll processing. This technology generally involves depositing thin films of photovoltaic material onto a continuously moving web. However, a challenge still remains regarding subdividing the expansive films A into individual cells followed by interconnecting into a series connected array. For example, U.S. Pat. No. 4,965,655 to Grimmer et. al. and U.S. Pat. No. 4,697,041 to Okamiwa teach processes requiring expensive laser scribing and interconnections achieved with laser heat staking. In addition, these two references teach a substrate of thin vacuum deposited metal on films of relatively expensive polymers. The electrical resistance of thin vacuum metallized layers significantly limits the active area of the individual interconnected cells.
[0006] It has become well known in the art that the efficiencies of certain promising thin film photovoltaic junctions can be substantially increased by high temperature treatments. These treatments involve temperatures at which even the most heat resistant plastics suffer rapid deterioration, thereby requiring either ceramic, glass, or metal substrates to support the thin film junctions. Use of a glass or ceramic substrates generally restricts one to batch processing and handling difficulty. Use of a metal foil as a substrate allows continuous roll-to-roll processing. However, despite the fact that use of a metal foil allows high temperature processing in roll-to-roll fashion, the subsequent interconnection of individual cells effectively in an interconnected array has proven difficult, in part because the metal foil substrate is electrically conducting.
[0007] U.S. Pat. No. 4,746,618 to Nath et al. teaches a design and process to achieve interconnected arrays using roll-to-roll processing of a metal web substrate such as stainless steel. The process includes multiple operations of cutting, selective deposition, and riveting. These operations add considerably to the final interconnected array cost.
[0008] U.S. Pat. No. 5,385,848 to Grimmer teaches roll-to-roll methods to achieve integrated series connections of adjacent thin film photovoltaic cells supported on an electrically conductive metal substrate. The process includes mechanical or chemical etch removal of a portion of the photovoltaic semiconductor and transparent top electrode to expose a portion of the electrically conductive metal substrate. The exposed metal serves as a contact area for interconnecting adjacent cells. These material removal techniques are troublesome for a number of reasons. First, many of the chemical elements involved in the best photovoltaic semiconductors are expensive and environmentally unfriendly. This removal subsequent to controlled deposition involves containment, dust and dirt collection and disposal, and possible cell contamination. This is not only wasteful but considerably adds to expense. Secondly, the removal processes are difficult to control dimensionally. Thus a significant amount of the valuable photovoltaic semiconductor is lost to the removal process. Ultimate module efficiencies are further compromised in that the spacing between adjacent cells grows, thereby reducing the effective active collector area for a given module area.
[0009] Thus there remains a need for an inexpensive manufacturing process which allows high heat treatment for thin film photovoltaic junctions while also offering unique means to achieve effective integrated series connections.
[0010] A further unsolved problem which has thwarted production of expansive surface photovoltaic modules is that of collecting the photogenerated current from the top, light incident surface. Transparent conductive oxide (TCO) layers have been employed as a top surface electrode. However, these TCO layers are relatively resistive compared to pure metals. This fact forces individual cell widths to be reduced in order to prevent unacceptable resistive power losses. As cell widths decrease, the width of the area between individual cells (interconnect area) should also decrease so that the relative portion of inactive surface of the interconnect area does not become excessive. Typical cell widths of one centimeter are often taught in the art. These small cell widths demand very fine interconnect area widths, which dictate delicate and sensitive techniques to be used to electrically connect the top TCO surface of one cell to the bottom electrode of an adjacent series connected cell. Furthermore, achieving good stable ohmic contact to the TCO cell surface has proven difficult, especially when one employs those sensitive techniques available when using the TCO only as the top collector electrode. The problem of collecting photovoltaic generated current from the top light impinging surface of a photovoltaic cell has been addressed in a number of ways, none entirely successful.
[0011] In a somewhat removed segment of technology, a number of electrically conductive fillers have been used to produce electrically conductive polymeric materials. This technology generally involves mixing of the conductive filler into the polymer resin prior to fabrication of the material into its final shape. Conductive fillers typically consist of high aspect ratio particles such as metal fibers, metal flakes, or highly structured carbon blacks, with the choice based on a number of cost/performance considerations. Electrically conductive resins have been used as bulk thermoplastic compositions, or formulated into paints. Their development has been spurred in large part by electromagnetic radiation shielding and static discharge requirements for plastic components used in the electronics industry. Other known applications include resistive heating fibers and battery components.
[0012] In yet another separate technological segment, electroplating on plastic substrates has been employed to achieve decorative effects on items such as knobs, cosmetic closures, faucets, and automotive trim. ABS (acrylonitrile-butadiene-styrene) plastic dominates as the substrate of choice for most applications because of a blend of mechanical and process properties and ability to be uniformly etched. The overall plating process comprises many steps. First, the plastic substrate is chemically etched to microscopically roughen the surface. This is followed by depositing an initial metal layer by chemical reduction (typically referred to as “electroless plating”). This initial metal layer is normally copper or nickel of thickness typically one-half micrometer. The object is then electroplated with metals such as bright nickel and chromium to achieve the desired thickness and decorative effects. The process is very sensitive to processing variables used to fabricate the plastic substrate, limiting applications to carefully molded parts and designs. In addition, the many steps employing harsh chemicals make the process intrinsically costly and environmentally difficult. Finally, the sensitivity of ABS plastic to liquid hydrocarbons has prevented certain applications. The conventional technology for electroplating on plastic (etching, chemical reduction, electroplating) has been extensively documented and discussed in the public and commercial literature. See, for example, Saubestre, Transactions of the Institute of Metal Finishing, 1969, Vol. 47, or Arcilesi et al., Products Finishing, March 1984.
[0013] Many attempts have been made to simplify the process of electroplating on plastic substrates. Some involve special chemical techniques to produce an electrically conductive film on the surface. Typical examples of this approach are taught by U.S. Pat. No. 3,523,875 to Minklei, U.S. Pat. No. 3,682,786 to Brown et. al., and U.S. Pat. No. 3,619,382 to Lupinski. The electrically conductive film produced was then electroplated. None of these attempts at simplification have achieved any recognizable commercial application.
[0014] A number of proposals have been made to make the plastic itself conductive enough to allow it to be electroplated directly thereby avoiding the “electroless plating” process. Efforts to advance systems contemplating metal electrodeposition directly onto the surface of an electrically conductive polymer have encountered a number of obstacles. The first is the combination of fabrication difficulty and material property deterioration brought about by the heavy filler loadings often required. A second is the high cost of many conductive fillers employed such as silver flake.
[0015] Another major obstacle involved in the electroplating of electrically conductive polymers is a consideration of adhesion between the electrodeposited metal and polymeric substrate (metal/polymer adhesion). In some cases such as electroforming, where the electrodeposited metal is eventually removed from the substrate, metal/polymer adhesion may actually be detrimental. However, in most cases sufficient adhesion is required to prevent metal/polymer separation during extended environmental and use cycles.
[0016] A number of methods to enhance adhesion have been employed. For example, etching of the surface prior to plating can be considered. Etching can be achieved by immersion in vigorous solutions such as chromic/sulfuric acid. Alternatively, or in addition, an etchable species can be incorporated into the conductive polymeric compound. The etchable species at exposed surfaces is removed by immersion in an etchant prior to electroplating. Oxidizing surface treatments can also be considered to improve metal/plastic adhesion. These include processes such as flame or plasma treatments or immersion in oxidizing acids.
[0017] In the case of conductive polymers containing finely divided metal, one can propose achieving direct metal-to-metal adhesion between electrodeposit and filler. However, here the metal particles are generally encapsulated by the resin binder, often resulting in a resin rich “skin”. To overcome this effect, one could propose methods to remove the “skin”, exposing active metal filler to bond to subsequently electrodeposited metal.
[0018] Another approach to impart adhesion between conductive resin substrates and electrodeposits is incorporation of an “adhesion promoter” at the surface of the electrically conductive resin substrate. This approach was taught by Chien et al. in U.S. Pat. No. 4,278,510 where maleic anhydride modified propylene polymers were taught as an adhesion promoter. Luch, in U.S. Pat. No. 3,865,699 taught that certain sulfur bearing chemicals could function to improve adhesion of initially electrodeposited Group VIII metals.
[0019] An additional major obstacle confronting development of electrically conductive polymeric resin compositions capable of being directly electroplated is the initial “bridge” of electrodeposit on the surface of the electrically conductive resin. In electrodeposition, the substrate to be plated is normally made cathodic through a pressure contact to a metal rack tip, itself under cathodic potential. However, if the contact resistance is excessive or the substrate is insufficiently conductive, the electrodeposit current favors the rack tip to the point where the electrodeposit will not bridge to the substrate.
[0020] Moreover, a further problem is encountered even if specialized racking successfully achieves electrodeposit bridging to the substrate. Many of the electrically conductive polymeric resins have resistivities far higher than those of typical metal substrates. The polymeric substrate can be relatively limited in the amount of electrodeposition current which it alone can convey. Thus, the conductive polymeric substrate does not cover almost instantly with electrodeposit as is typical with metallic substrates. Except for the most heavily loaded and highly conductive polymer substrates, a large portion of the electrodeposition current must pass back through the previously electrodeposited metal growing laterally over the surface of the conductive plastic substrate. In a fashion similar to the bridging problem discussed above, the electrodeposition current favors the electrodeposited metal and the lateral growth can be extremely slow and erratic. This restricts the size and “growth length” of the substrate conductive pattern, increases plating costs, and can also result in large non-uniformities in electrodeposit integrity and thickness over the pattern.
[0021] This lateral growth is dependent on the ability of the substrate to convey current. Thus, the thickness and resistivity of the conductive polymeric substrate can be defining factors in the ability to achieve satisfactory electrodeposit coverage rates. When dealing with selectively electroplated patterns long thin metal traces are often desired, deposited on a relatively thin electrically conductive polymer substrate. These factors of course work against achieving the desired result.
[0022] This coverage rate problem likely can be characterized by a continuum, being dependent on many factors such as the nature of the initially electrodeposited metal, electroplating bath chemistry, the nature of the polymeric binder and the resistivity of the electrically conductive polymeric substrate. As a “rule of thumb”, the instant inventor estimates that coverage rate problems would demand attention if the resistivity of the conductive polymeric substrate rose above about 0.001 ohm-cm.
[0023] Beset with the problems of achieving adhesion and satisfactory electrodeposit coverage rates, investigators have attempted to produce directly electroplateable polymers by heavily loading polymers with relatively small metal containing fillers. Such heavy loadings are sufficient to reduce both microscopic and macroscopic resistivity to a level where the coverage rate phenomenon may be manageable. However, attempts to make an acceptable directly electroplateable resin using the relatively small metal containing fillers alone encounter a number of barriers. First, the fine metal containing fillers are relatively expensive. The loadings required to achieve the particle-to-particle proximity to achieve acceptable conductivity increases the cost of the polymer/filler blend dramatically. The metal containing fillers are accompanied by further problems. They tend to cause deterioration of the mechanical properties and processing characteristics of many resins. This significantly limits options in resin selection. All polymer processing is best achieved by formulating resins with processing characteristics specifically tailored to the specific process (injection molding, extrusion, blow molding etc.). A required heavy loading of metal filler severely restricts ability to manipulate processing properties in this way. A further problem is that metal fillers can be abrasive to processing machinery and may require specialized screws, barrels, and the like. Finally, despite being electrically conductive, a simple metal-filled polymer still offers no mechanism to produce adhesion of an electrodeposit since the metal particles are generally encapsulated by the resin binder, often resulting in a non-conductive resin-rich “skin”. For the above reasons, fine metal particle containing plastics have not been widely used as substrates for directly electroplateable articles. Rather, they have found applications in production of conductive adhesives, pastes, and paints.
[0024] The least expensive (and least conductive) of the readily available conductive fillers for plastics are carbon blacks. Attempts have been made to produce electrically conductive polymers based on carbon black loading intended to be subsequently electroplated. Examples of this approach are the teachings of U.S. Pat. Nos. 4,038,042, 3,865,699, and 4,278,510 to Adelman, Luch, and Chien et al. respectively.
[0025] Adelman taught incorporation of conductive carbon black into a polymeric matrix to achieve electrical conductivity required for electroplating. The substrate was pre-etched in chromic/sulfuric acid to achieve adhesion of the subsequently electroplated metal. A fundamental problem remaining unresolved by the Adelman teaching is the relatively high resistivity of carbon loaded polymers. The lowest “microscopic resistivity” generally achievable with carbon black loaded polymers is about 1 ohm-cm. This is about five to six orders of magnitude higher than typical electrodeposited metals such as copper or nickel. Thus, the electrodeposit bridging and coverage rate problems described above remained unresolved by the Adelman teachings.
[0026] Luch in U.S. Pat. No. 3,865,699 and Chien et al. in U.S. Pat. No. 4,278,510 also chose carbon black as an electrically conductive filler for polymeric compounds to be electroplated. However, these inventors further taught incorporation of an electrodeposit coverage or deposition rate accelerator to overcome the galvanic bridging and lateral electrodeposit growth rate problems described above. In the embodiments, examples and teachings of U.S. Pat. Nos. 3,865,699 and 4,278,510, it was shown that certain sulfur bearing materials, including elemental sulfur, can function as electrodeposit coverage or growth rate accelerators to overcome those problems associated with electrically conductive polymeric substrates having relatively high resistivity. In addition to elemental sulfur, sulfur in the form of sulfur donors such as sulfur chloride, 2-mercapto-benzothiazole, N-cyclohexyle-2-benzothiaozole sulfonomide, dibutyl xanthogen disulfide, and tetramethyl thiuram disulfide or combinations of these and sulfur were identified. Those skilled in the art will recognize that these sulfur donors are the materials which have been used or have been proposed for use as vulcanizing agents or accelerators. Since the polymer-based compositions taught by Luch and Chien et al. could be electroplated directly they could be accurately defined as directly electroplateable resins (DER). These resins can be generally described as electrically conductive polymers with the inclusion of a growth rate accelerator.
[0027] Specifically for the present invention, specification, and claims, directly electroplateable resins, (DER), are characterized by the following features.
[0028] (a) having a polymer or resin matrix or binder;
[0029] (b) presence of conductive fillers in the polymer matrix in amounts sufficient to provide an electrical volume resistivity of the polymer/conductive filler mix, which is sufficiently low to allow direct electrodeposition. Typically, a resistivity less than 1000 ohm-cm., e.g., 100 ohm-cm., 10 ohm-cm., 1 ohm-cm. 0.1 ohm-cm., 0.01 ohm-cm., 0.001 ohm-cm., suffices;
[0030] (c) presence of an electrodeposit coverage rate accelerator;
[0031] (d) presence of the polymer, conductive filler and electrodeposit coverage rate accelerator in the directly electroplateable composition in cooperative amounts required to achieve direct coverage of the composition with an electrodeposited metal or metal-based alloy. It has been found that Group VIII metals or Group VIII metal-based alloys are particularly suitable as the initial electrodeposit on the DER surface.
[0032] It is understood the electrical conductivity required to allow for direct electrodeposition can also be achieved thru the use of an inherently conductive polymer. In this instance it may not be necessary to add electrical fillers to the polymer.
[0033] In his patents, Luch specifically identified unsaturated elastomers such as natural rubber, polychloroprene, butyl rubber, chlorinated butyl rubber, polybutadiene rubber, acrylonitrile-butadiene rubber, styrene-butadiene rubber etc. as suitable for the matrix polymer of a directly electroplateable resin. Other polymers identified by Luch as useful included polyvinyls, polyolefins, polystyrenes, polyamides, polyesters and polyurethanes.
[0034] When used alone, the minimum workable level of carbon black required to achieve “microscopic” electrical resistivities of less than 1000 ohm-cm. for a polymer/carbon black mix appears to be about 8 weight percent based on the combined weight of polymer plus carbon black. The “microscopic” material resistivity generally is not reduced below about 1 ohm-cm. by using conductive carbon black alone. This is several orders of magnitude larger than typical metal resistivities. Other well known, finely divided highly conductive fillers (such as metal flake) can be considered in DER applications requiring lower “microscopic” resistivity. In these cases the more highly conductive fillers can be used to augment or even replace the conductive carbon black.
[0035] The “bulk, macroscopic” resistivity of conductive carbon black filled polymers can be further reduced by augmenting the carbon black filler with additional highly conductive, high aspect ratio fillers such as metal containing fibers. This can be an important consideration in the success of certain applications. Furthermore, one should realize that incorporation of non-conductive fillers may increase the “bulk, macroscopic” resistivity of conductive polymers loaded with finely divided conductive fillers without significantly altering the “microscopic resistivity” of the conductive polymer “matrix” encapsulating the non-conductive filler particles.
[0036] It is important to recognize a number of important characteristics of directly electroplateable resins (DERs) which facilitate the current invention. First, regarding electrodeposit coverage rate accelerators, both Luch and Chien et al. in the above discussed U.S. patents demonstrated that sulfur and other sulfur bearing materials such as sulfur donors and accelerators served this purpose when using an initial Group VIII “strike” layer. One might expect that other elements of Group 6A nonmetals, such as oxygen, selenium and tellurium, could function in a way similar to sulfur. In addition, other combinations of electrodeposited metals and nonmetal coverage rate accelerators may be identified. It is important to recognize that such an electrodeposit coverage accelerator is extremely important in order to achieve direct electrodeposition in a practical way onto polymeric substrates having relatively high resistivity compared to metals (i.e. 0.001 ohm-cm. or above) or very thin electrically conductive polymeric substrates having restricted current carrying ability.
[0037] A second important characteristic of directly electroplateable resins is that electrodeposit coverage speed depends not only on the presence of an electrodeposit coverage rate accelerator but also on the “microscopic resistivity” and less so on the “macroscopic resistivity” of the DER formulation. Thus, large additional loadings of functional non-conductive fillers can be tolerated in DER formulations without undue sacrifice in electrodeposit coverage or adhesion. These additional non-conductive loadings do not greatly affect the “microscopic resistivity” associated with the polymer/conductive filler/electrodeposit coverage accelerator “matrix” since the non-conductive filler is essentially encapsulated by “matrix” material. Conventional “electroless” plating technology does not permit this compositional flexibility.
[0038] A third important characteristic of DER technology is its ability to employ polymer resins generally chosen in recognition of the fabrication process envisioned and the intended end use requirements. For example, should an extrusion blow molding fabrication be desired, resins having the required high melt strength can be employed. Should the part be injection molded and have thin wall cross-sections, a typical situation encountered in selective design of conductive trace patterns, a high flow resin can be chosen. Should a coating, ink, paint, or paste be envisioned, a soluble resin such as an elastomer can be considered. All polymer fabrication processes require specific resin processing characteristics for success. The ability to “custom formulate” DER's to comply with these changing processing and end use requirements while still allowing facile, quality electroplating is a significant factor in the electroplating teachings of the current invention. Conventional “electroless” plating technology does not permit great flexibility to “custom formulate”.
[0039] Due to multiple performance problems associated with their intended end use, none of the attempts identified above to directly electroplate electrically conductive polymers or plastics has ever achieved any recognizable commercial success. Nevertheless, the current inventor has persisted in personal efforts to overcome certain performance deficiencies associated with the initial DER technology. Along with these efforts has come a recognition of unique and eminently suitable applications employing the DER technology. Some examples of these unique applications for electroplated articles include solar cell electrical current collection grids, electrical circuits, electrical traces, circuit boards, antennas, capacitors, induction heaters, connectors, switches, resistors, inductors, batteries, fuel cells, coils, signal lines, power lines, radiation reflectors, coolers, diodes, transistors, piezoelectric elements, photovoltaic cells, emi shields, biosensors and sensors. One readily recognizes that the demand for such functional applications for electroplated articles is relatively recent and has been particularly explosive during the past decade.
[0040] While not precisely definable, electrically insulating materials may generally be characterized as having electrical resistivities greater than 10,000 ohm-cm. Also, electrically conductive materials may generally be characterized as having electrical resistivities less than 0.001 ohm-cm. Also electrically resistive or semi-conductive materials may generally be characterized as having electrical resistivities in the range of 0.001 ohm-cm to 10,000 ohm-cm. The characterization “electrically conductive polymer” covers a very wide range of intrinsic resistivities depending on the filler, the filler loading and the methods of manufacture of the filler/polymer blend. Resistivities for electrically conductive polymers may be as low as 0.00001 ohm-cm. for very heavily filled silver inks, yet may be as high as 10,000 ohm-cm or even more for lightly filled carbon black materials or other “anti-static” materials. “Electrically conductive polymer” has become a broad industry term to characterize all such materials. Thus, the term “electrically conductive polymer” as used in the art and in this specification and claims extends to materials of a very wide range of resitivities from about 0.00001 ohm-cm. to about 10,000 ohm-cm and higher.
[0041] In order to eliminate ambiguity in terminology, for the present invention the following definitions are supplied:
[0042] “Metal-based” refers to a material or structure having at least one metallic property and comprising one or more components at least one of which is a metal or metal-containing alloy.
[0043] “Alloy” refers to a substance composed of two or more intimately mixed materials.
[0044] “Group VIII metal-based” refers to a substance containing by weight 50% to 100% metal from Group VIII of the Periodic Table of Elements.
OBJECTS OF THE INVENTION
[0045] An object of the invention is to eliminate the deficiencies in the prior art methods of producing expansive area, series interconnected photovoltaic arrays. A further object of the present invention is to provide improved substrates to achieve series interconnections among expansive thin film cells.
[0046] A further object of the invention is to permit inexpensive production of high efficiency, heat treated thin film photovoltaic cells while simultaneously permitting the use of polymer based substrate materials and associated processing to effectively interconnect those cells.
[0047] A further object of the present invention is to provide improved processes whereby expansive area, series interconnected photovoltaic arrays can be economically mass produced.
[0048] A further object of the invention is to provide improved processes and structures for supplying current collector grids.
[0049] Other objects and advantages will become apparent in light of the following description taken in conjunction with the drawings and embodiments.
SUMMARY OF THE INVENTION
[0050] The current invention provides a solution to the stated need by producing the active photovoltaic film and interconnecting substrate separately and subsequently combining them to produce the desired expansive series interconnected array. The invention contemplates deposition of thin film photovoltaic junctions on metal foil substrates which can be heat treated following deposition in a continuous fashion without deterioration of the metal support structure. In a separate operation, an interconnection substrate structure is produced in a continuous roll-to-roll fashion.
[0051] The metal foil supported photovoltaic junction is then laminated to the interconnecting substrate structure and conductive connections are deposited to complete the array. In this way the interconnection substrate structure can be uniquely formulated from polymer-based materials since it does not have to endure high temperature exposure. Furthermore, the photovoltaic junction and its metal foil support can be produced in bulk without the need to use the expensive and intricate material removal operations currently taught in the art to achieve series interconnections.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] The various factors and details of the structures and manufacturing methods of the present invention are hereinafter more fully set forth with reference to the accompanying drawings wherein:
[0053] FIG. 1 is a top plan view of a thin film photovoltaic cell including its support foil.
[0054] FIG. 2 is a sectional view taken substantially along the line 2 - 2 of FIG. 1 .
[0055] FIG. 3 is an expanded sectional view showing a form of the structure of layer 11 of FIG. 2 .
[0056] FIG. 4 illustrates a process for producing the structure shown in FIGS. 1-3 .
[0057] FIG. 5 is a sectional view illustrating the problems associated with making series connections among thin film photovoltaic cells shown in FIGS. 1-3 .
[0058] FIG. 6 is a top plan view of a substrate structure for achieving series interconnections of thin film photovoltaic cells.
[0059] FIG. 7 is a sectional view taken substantially along the line 7 - 7 of FIG. 6 .
[0060] FIG. 8 is a sectional view similar to FIG. 7 showing an alternate embodiment of a substrate structure for achieving series interconnections of thin film photovoltaic cells.
[0061] FIG. 9 is a top plan view of an alternate embodiment of a substrate structure for achieving series interconnections of thin film photovoltaic cells.
[0062] FIG. 10 is a sectional view similar to FIGS. 7 and 8 taken substantially along line 10 - 10 of FIG. 9 .
[0063] FIG. 11 is a top plan view of another embodiment of a substrate structure for achieving series interconnections of thin film photovoltaic cells.
[0064] FIG. 12 is a sectional view taken substantially along the line 12 - 12 of FIG. 11 .
[0065] FIGS. 13A and 13B schematically depict a process for laminating the foil supported thin film photovoltaic structure of FIGS. 1 through 3 to an interconnecting substrate structure. FIG. 13A is a side view of the process. FIG. 13B is a sectional view taken substantially along line 13 B- 13 B of FIG. 13A .
[0066] FIGS. 14A , 14 B, and 14 C are views of the structures resulting from the laminating process of FIG. 13 and using the substrate structure of FIGS. 7 , 8 , and 10 respectively.
[0067] FIGS. 15A , 15 B, and 15 C are sectional views taken substantially along the lines 15 a - 15 a , 15 b - 15 b , and 15 c - 15 c of FIGS. 14A , 14 B, and 14 C respectively.
[0068] FIG. 16 is a top plan view of the structure resulting from the laminating process of FIG. 13 and using the substrate structure of FIGS. 11 and 12 .
[0069] FIG. 17 is a sectional view taken substantially along the line 17 - 17 of FIG. 16 .
[0070] FIG. 18 is a top plan view of the structures of FIGS. 14A and 15A but following an additional step in manufacture of the interconnected cells.
[0071] FIG. 19 is a sectional view taken substantially along the line 19 - 19 of FIG. 18 .
[0072] FIG. 20 is a top plan view of a completed interconnected array.
[0073] FIG. 21 is a sectional view taken substantially along line 21 - 21 of FIG. 20 .
[0074] FIG. 22 is a sectional view similar to FIG. 15A but showing an alternate method of accomplishing the mechanical and electrical joining of the lamination process of FIG. 13 .
[0075] FIG. 23 is a sectional view similar to FIG. 15A but showing an alternate embodiment of the laminated structure.
[0076] FIG. 24 is a sectional view of an alternate embodiment.
[0077] FIG. 25 is a sectional view of the embodiment of FIG. 24 after a further processing step.
[0078] FIG. 26 is a sectional view of another embodiment of a laminated intermediate article in the manufacture of series interconnected arrays.
[0079] FIG. 27 is a top plan view of a starting material for another embodiment of substrate structure.
[0080] FIG. 28 is a greatly magnified plan view of the material of FIG. 27 .
[0081] FIG. 29 is a sectional view taken substantially along line 29 - 29 of FIG. 28 .
[0082] FIG. 30 is a sectional view taken substantially along line 30 - 30 of FIG. 28 .
[0083] FIG. 31 is a simplified sectional view representing the structure depicted in FIGS. 29 and 30 .
[0084] FIG. 32 is a view similar to FIG. 27 but defining three distinct area portions of the structure produced by a process step.
[0085] FIG. 33 is a greatly magnified plan view of that portion of FIG. 32 defined by “W 2 ”.
[0086] FIG. 34 is a greatly magnified sectional view of a portion of the structure of FIG. 33 taken substantially from the perspective of line 34 - 34 of FIG. 33 .
[0087] FIG. 35 is a sectional view similar to FIG. 34 showing the structure following an optional additional process step.
[0088] FIG. 36 is a simplified plan view of the structure of FIG. 32 useful in illustrating the process and structure of the embodiment.
[0089] FIG. 37A is a simplified sectional view taken substantially along line 37 - 37 of FIG. 36 , useful in illustrating the process and structure of the embodiment.
[0090] FIG. 37B is a simplified sectional view similar to FIG. 37A incorporating an optional additional process step.
[0091] FIG. 38 is a schematic depiction of a process for joining the foil supported thin film photovoltaic structure of FIGS. 1 through 3 to the substrate structure of FIG. 32 or 36 .
[0092] FIG. 39 illustrates one form of the process depicted in FIG. 38 .
[0093] FIG. 40 is a view of the process of FIG. 39 taken substantially along line 40 - 40 of FIG. 39 .
[0094] FIG. 41 is a plan view of the structure resulting from the process of FIG. 38 .
[0095] FIG. 42A is an embodiment of the structure of FIG. 41 taken substantially along line 42 - 42 of FIG. 41 .
[0096] FIGS. 42B and 42C are views similar to 42 A showing alternate embodiments of the structure depicted in FIG. 41 .
[0097] FIG. 43 is an enlarged view of the portion of FIG. 42A shown within circle
[0098] FIG. 44 is a plan view of the structure of FIG. 43 after an additional processing step.
[0099] FIG. 44A is a sectional view taken substantially along the line 44 A- 44 A of FIG. 44 .
[0100] FIG. 45 is a view similar to FIG. 44 after a further processing step.
[0101] FIG. 46 is a top plan view of another embodiment of the novel substrate structures useful in the manufacture of series interconnected photovoltaic arrays.
[0102] FIG. 47 is a sectional view taken substantially along line 47 - 47 of FIG. 46 .
[0103] FIG. 48 is a view similar to FIG. 47 following an additional processing step.
[0104] FIG. 49 is a sectional view similar to FIG. 43 illustrating an alternate processing sequence.
[0105] FIG. 50 is a top plan view of a starting component of an additional embodiment of the invention.
[0106] FIG. 51 is a sectional view taken along line 51 - 51 of FIG. 50 .
[0107] FIG. 52 is a simplified representation of the sectional view of FIG. 51 .
[0108] FIG. 53 is a top plan view of the embodiment of FIGS. 50 through 52 following an additional processing step.
[0109] FIG. 54 is a sectional view taken along the line 54 - 54 of FIG. 53 .
[0110] FIG. 55 is a sectional view taken along the line 55 - 55 of FIG. 53 .
[0111] FIG. 56 is a top plan view of embodiment of FIGS. 53 through 55 after an additional processing step.
[0112] FIG. 57 is a sectional view taken along line 57 - 57 of FIG. 56 .
[0113] FIG. 58 is a sectional view taken along line 58 - 58 of FIG. 56 .
[0114] FIG. 59 is a sectional view taken along line 59 - 59 of FIG. 56 .
[0115] FIG. 60 is a simplified representation of a process used in the manufacture of an embodiment of the invention.
[0116] FIG. 61 is a sectional view taken along the line 61 - 61 of FIG. 60 using the structures of FIGS. 19 and 59 .
[0117] FIG. 62 is a sectional view showing a lamination resulting from the process of FIG. 60 .
[0118] FIG. 63 is an enlarged sectional view of the portion of FIG. 62 within Circle “A” of FIG. 62 .
[0119] FIG. 64 is a simplified sectional view of a starting substrate component for an additional embodiment of the invention.
[0120] FIG. 65 is a sectional view of the FIG. 64 components following additional processing steps.
[0121] FIG. 66 is a sectional view of the structure resulting from combining the structures shown in FIGS. 56 and 65 using the process illustrated in FIG. 60 .
[0122] FIG. 67 is a top plan view of a starting component for an additional embodiment of the invention.
[0123] FIG. 68 is a sectional view taken along line 68 - 68 of FIG. 67 .
[0124] FIG. 69 is a top plan view after an additional processing step employing the structure of FIGS. 67 and 68 .
[0125] FIG. 70 is a simplified sectional view taken along line 70 - 70 of FIG. 69 .
[0126] FIG. 71 is a top plan view, similar to FIG. 69 , of an alternate embodiment.
[0127] FIG. 72 is a sectional view of the structure of FIG. 70 after an additional processing step.
[0128] FIG. 73 is a sectional view of a portion of the FIG. 72 structure after an additional processing step.
[0129] FIG. 74 is a sectional view similar to FIG. 13B just prior to the process illustrated in FIG. 13A , employing the structures shown in the sectional view in FIGS. 7 and 73 .
[0130] FIG. 75 is a sectional view showing the structure resulting from application of the process of FIG. 13A to the structural arrangement shown in FIG. 74 .
[0131] FIG. 76 is a sectional view of the spacial positioning of the structure shown in FIG. 75 and an additional component of the embodiment just prior to a process employed to combine them.
[0132] FIG. 77 is a plan view taken along the line 77 - 77 of FIG. 76 .
[0133] FIG. 78 is an alternate embodiment of the FIG. 77 structure.
[0134] FIG. 79 is yet another alternate embodiment of the FIG. 77 structure.
[0135] FIG. 80 is a sectional view showing one possible example of the structural makeup of a portion the components illustrated in FIGS. 77 through 79 .
[0136] FIG. 81 is a sectional view of the structure resulting from the process envisioned in FIG. 76 .
[0137] FIG. 82 is an illustration of a lamination process used to produce an additional embodiment of the series interconnected photovoltaic cells of the disclosure.
[0138] FIG. 83 embodies the results of the lamination process of FIG. 82 .
DESCRIPTION OF PREFERRED EMBODIMENTS
[0139] Reference will now be made in detail to the preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. In the drawings, like reference numerals designate identical or corresponding parts throughout several views and an additional letter designation is characteristic of a particular embodiment.
[0140] Referring to FIGS. 1 and 2 , a thin film photovoltaic cell is generally indicated by numeral 10 . Cell 10 has a light-incident top surface 59 and a bottom surface 66 . Structure 10 has a width X- 10 and length Y- 10 . Width X- 10 defines a first photovoltaic cell terminal edge 45 and second photovoltaic cell terminal edge 46 . It is contemplated that length Y- 10 is considerably greater than width X- 10 and length Y- 10 can generally be described as “continuous” or being able to be processed in a roll-to-roll fashion. FIG. 2 shows that cell 10 comprises a thin film semiconductor structure 11 supported by metal-based foil 12 . Foil 12 has first surface 65 , second surface 66 , and thickness “Z”. Metal-based foil 12 may be of uniform composition or may comprise a laminate of two or more metal-based layers. For example, foil 12 may comprise a base layer of inexpensive and processable metal 13 with an additional metal-based layer 14 disposed between base layer 13 and semiconductor structure 11 . The additional metal-based layer may be chosen to ensure good ohmic contact between the top surface 65 of support 12 and photovoltaic semiconductor structure 11 . Bottom surface 66 of foil support 12 may comprise a material 75 chosen to achieve good electrical and mechanical joining characteristics to the substrate as will be shown. The thickness Z of support layer 12 is generally contemplated to be between 0.001 cm. and 0.025 cm. This thickness would provide adequate handling strength while still allowing flexibility for roll-to-roll processing.
[0141] Semiconductor structure 11 can be any of the thin film structures known in the art. In its simplest form, a photovoltaic cell combines an n-type semiconductor with a p-type semiconductor to from an n-p junction. Most often an optically transparent window electrode such as a thin film of zinc or tin oxide is employed to minimize resistive losses involved in current collection. FIG. 3 illustrates an example of a typical photovoltaic cell structure in section. In FIGS. 2 and 3 and other figures, an arrow labeled “hv” is used to indicate the light incident side of the structure. In FIG. 3 , 15 represents a thin film of a p-type semiconductor, 16 a thin film of n-type semiconductor and 17 the resulting photovoltaic junction. Window electrode 18 completes the typical photovoltaic structure. The exact nature of the photovoltaic semiconductor structure 11 does not form the subject matter of the present invention.
[0142] FIG. 4 refers to the method of manufacture of the foil supported photovoltaic structures generally illustrated in FIGS. 1 through 3 . The metal-based support foil 12 is moved in the direction of its length Y through a deposition process, generally indicated as 19 . Process 19 accomplishes deposition of the active photovoltaic structure onto support foil 12 . Support foil 12 is unwound from supply roll 20 a , passed through deposition process 19 and rewound onto takeup roll 20 b . Process 19 can comprise any of the processes well-known in the art for depositing thin film photovoltaic structures. These processes include electroplating, vacuum sputtering, and chemical deposition. Process 19 may also include treatments, such as heat treatments, intended to enhance photovoltaic cell performance.
[0143] Referring now to FIG. 5 , there are illustrated cells 10 as shown in FIG. 2 . The cells have been positioned to achieve spacial positioning on the support substrate 21 . Support structure 21 is by necessity non-conductive at least in that distance indicated by numeral 70 separating the adjacent cells 10 . This insulating space prevents short circuiting from metal foil electrode 12 of one cell to foil electrode 12 of an adjacent cell. In order to achieve series connection, electrical communication must be made from the top surface of window electrode 18 to the foil electrode 12 of an adjacent cell. This communication is shown in the FIG. 5 as a metal wire 41 . Metal wire 41 is clearly impractical for inexpensive continuous production and is shown for illustration purposes only. The direction of the net current flow for the arrangement shown in FIG. 5 is indicated by the double pointed arrow “I”.
[0144] It should be noted that foil electrode 12 is relatively thin, on the order of 0.001 cm to 0.025 cm. Therefore connecting to its edge as indicated in FIG. 5 would be impractical. Referring now to FIGS. 6 and 7 , one embodiment of the interconnection substrate structures of the current invention is generally indicated by 22 . Unit of substrate 22 comprises electrically conductive sheet region 23 and electrically insulating joining portion region 25 . Electrically conductive sheet region 23 has a top surface 26 , bottom surface 28 , width X- 23 , length Y- 23 and thickness Z- 23 . Width X- 23 defines a first terminal edge 29 and a second terminal edge 30 of conductive sheet 23 . Top surface 26 of conductive sheet 23 can be thought of as having top collector surface 47 and top contact surface 48 separated by imaginary insulating boundary 49 . The purpose for these definitions will become clear in the following.
[0145] Electrically conductive sheet 23 includes an electrically conductive polymer. Typically, electrically conductive polymers exhibit bulk resistivity values of less than 1000 ohm-cm. Resistivities less than 11000 ohm-cm can be readily achieved by compounding well-known conductive fillers into a polymer matrix binder.
[0146] The substrate unit 22 may be fabricated in a number of different ways. Electrically conductive sheet 23 can comprise an extruded film of electrically conductive polymer joined to a strip of compatible insulating polymer 25 at or near terminal edge 29 as illustrated in FIG. 7 . Alternatively, the conductive sheet may comprise a strip of electrically conductive polymer 23 a laminated to an insulating support structure 31 as illustrated in section in FIG. 8 . In FIG. 8 , electrically insulating joining portions 25 a are simply those portions of insulating support structure 31 not overlaid by sheets 23 a.
[0147] It is contemplated that electrically conductive sheets 23 may comprise materials in addition to the electrically conductive polymer. For example, a metal may be electrodeposited to the electrically conductive polymer for increased conductivity. In this regard, the use of a directly electroplateable resin (DER) may be particularly advantageous.
[0148] A further embodiment of fabrication of interconnection substrate unit 22 is illustrated in FIGS. 9 and 10 . In FIG. 9 , electrically conductive sheet 23 b comprises electrically conductive polymer impregnated into a fabric or web 32 . A number of known techniques can be used to achieve such impregnation. Insulating joining portion 25 b in FIG. 9 is simply an un-impregnated extension of the web 32 . Fabric or web 32 can be selected from a number of woven or non-woven fabrics, including non-polymeric materials such as fiberglass.
[0149] Referring now to FIG. 11 , an alternate embodiment for the substrate structures of the present invention is illustrated. In the FIG. 11 , a support web or film 33 extends among and supports multiple individual cell units, generally designated by repeat dimension 34 . Electrically conductive sheets 35 are analogous to sheet 23 of FIGS. 6 through 10 . At the stage of overall manufacture illustrated in FIG. 11 , electrically conductive sheets 35 need not comprise an electrically conductive polymer as do sheets 23 of FIGS. 6 through 10 . However, as will be shown, electrically conducting means, typically in the form of an electrically conductive polymer containing adhesive, must eventually be utilized to join photovoltaic laminate 10 to the top surface 50 of electrically conductive sheets 35 . In addition, the electrically conducting sheets 35 must be attached to the support carrier 33 with integrity required to maintain positioning and dimensional control. This is normally accomplished with an adhesive, indicated by layer 36 of FIG. 12 .
[0150] Conductive sheets 35 are shown in FIGS. 11 and 12 as having length Y- 35 , width X- 35 and thickness Z- 35 . It is contemplated that length Y- 35 is considerably greater than width X- 35 and length Y- 35 can generally be described as “continuous” or being able to be processed in roll-to-roll fashion. Width X- 35 defines a first terminal edge 53 and second terminal edge 54 of sheet 35 .
[0151] It is important to note that the thickness of the conductive sheets 35 , Z- 35 must be sufficient to allow for continuous lamination to the support web 33 . Typically when using metal based foils for sheets 35 , thickness between 0.001 cm and 0.025 cm would be chosen.
[0152] As with the substrate structures of FIGS. 6 through 10 , it is helpful to characterize top surface 50 of conductive sheets 35 as having a top collector surface 51 and a top contact surface 52 separated by an imaginary barrier 49 . Conductive sheet 35 also is characterized as having a bottom surface 80 .
[0153] Referring now to FIGS. 13A and 13B , a process is shown for laminating the metal-based foil supported thin film photovoltaic structure of FIGS. 1 through 3 to the substrate structures taught in FIGS. 6 through 12 . In FIGS. 13A and 13B , photovoltaic cell structures as illustrated in FIGS. 1 through 3 are indicated by numeral 10 . Substrate structures as taught in the FIGS. 6 through 12 are indicated by the numeral 22 . Numeral 42 indicates a film of electrically conductive adhesive intended to join electrically conductive metal-based foil 12 of FIGS. 1 through 3 to electrically conductive sheet 23 of FIGS. 6 through 10 or electrically conductive sheets 35 of FIGS. 11 and 12 . It will be appreciated by those skilled in the art that the adhesive strip 42 shown in FIGS. 13A and 13B is one of but a number of appropriate metal joining techniques which would maintain required ohmic communication. For example, it is contemplated that methods such as doctor blading a conductive resin prior to lamination, spot welding, soldering, joining with low melt temperature metals or alloys, or crimped mechanical contacts would serve as equivalent methods to accomplish the ohmic joining illustrated as achieved in FIGS. 13 a and 13 b with a strip of conductive adhesive. These equivalent methods can be generically referred to as conductive joining means. In FIG. 13B , the process of FIG. 13A is illustrated using the substrate structure of FIGS. 6 and 7 .
[0154] Referring now to FIGS. 14 and 15 , there is shown the result of the lamination process of FIG. 13 using the substrate structure of FIGS. 6 through 10 . In these and most subsequent figures, cells 10 are shown as a single layer for simplicity, but it is understood that in these figures cells 10 would have a structure similar to that shown in detail in FIG. 2 . FIGS. 14A and 15A correspond to the substrate structures of FIGS. 6 and 7 . FIGS. 14B and 15B correspond to the substrate structure of FIG. 8 . FIGS. 14C and 15C correspond to the substrate structures of FIGS. 9 and 10 .
[0155] In the FIGS. 15A , 15 B and 15 C, electrically conductive adhesive layer 42 is shown as extending completely and contacting the entirety of the second surface 66 of metal-based foil supported photovoltaic cells 10 . This complete surface coverage is not a requirement however, in that foil 12 is highly conductive and able to distribute current over the expansive width X- 10 with minimal resistance losses. For example, the structure of FIG. 22 shows an embodiment wherein electrical communication is achieved between conductive sheet 23 of FIGS. 6 and 7 and second surface 66 of foil 12 through a narrow bead of conductive joining means 61 . An additional bead of adhesive shown in FIG. 22 by 44 , may be used to ensure spacial positioning and dimensional support for this form of structure. Adhesive 44 need not be electrically conductive.
[0156] In the FIGS. 15A , 15 B and 15 C, the conductive sheets 23 , 23 a and 23 b are shown to be slightly greater in width X- 23 than the width of foil X- 10 . As is shown in FIG. 23 , this is not a requirement for satisfactory completion of the series connected arrays. FIG. 23 is a sectional view of a form of the substrate structures of FIGS. 6 and 7 laminated by the process of FIG. 13 to the photovoltaic structures of FIGS. 1-3 . In FIG. 23 , width X- 10 is greater than width X- 23 . Electrical communication is achieved through conductive joining means 42 and additional joining means 44 to achieve dimensional stability may be employed. The only requirement of the current invention is that first conductive sheet terminal edge 29 be offset from first photovoltaic cell terminal edge 45 to expose a portion of top surface 26 of conductive sheet 23 .
[0157] In FIG. 23 , insulating joining portion 25 is shown as extending continuously from second terminal edge 30 of one conductive sheet 23 to the first terminal edge 29 of an adjacent conductive sheet. As shown in FIG. 26 , this is not necessary. In FIG. 26 , metal foil supported photovoltaic cell 10 is attached to a first conductive sheet 23 through electrically conductive joining means 42 and also to insulating joining portion 25 of an adjacent substrate structure through adhesive 44 . Thus, the substrate structure 22 can be discrete. In the embodiment of FIG. 26 , the foil based photovoltaic structure 10 is of sufficient strength to maintain proper spacial relationships and positioning among cells.
[0158] Referring now to FIGS. 16 and 17 , there is shown an alternate structure resulting from the laminating process of FIG. 13 as applied to the photovoltaic cells of FIGS. 1-3 and the substrate structure of FIGS. 11 and 12 . In a fashion similar to that of FIGS. 15 , 22 , and 23 , the first terminal edge 53 of conductive sheets 35 supported by insulating substrate 33 are slightly offset from the first terminal edge 45 of photovoltaic cells 10 . This offset exposes a portion of top surface 50 of conductive sheet 35 . Electrical and mechanical joining of sheets 35 with second surface 66 of metal-based foil 12 is shown in FIG. 17 as being achieved with conductive adhesive 42 as in previous embodiments. However, it is contemplated as in previous embodiments that this electrical and mechanical joining can be accomplished by alternate means such as soldering, joining with compatible low melting point alloys, spot welding, or mechanical crimping.
[0159] In FIG. 17 , support web or film 33 is shown as extending continuously among many cells. However, it should be clear that support film 33 can be discontinuous. Support film 33 need only be attached to a portion of a first sheet 35 and a portion of a second sheet 35 of an adjacent cell. This arrangement would suffice to achieve the desired spacial positioning among cells and leave exposed a portion of back surface 80 of electrically conductive sheet 35 .
[0160] Comparing the sectional views of FIGS. 15 , 22 , 23 and 17 , one observes many similarities. The most important common structural similarity is that the first terminal edges 29 of conductive sheets 23 be offset slightly from first terminal edge 45 of photovoltaic cells 10 ( FIGS. 15 , 22 , 23 ). Similarly, first terminal edges 53 of conductive sheets 35 are slightly offset from first terminal edges 45 of photovoltaic cells 10 ( FIG. 17 ). As will be shown, the resulting exposed top surface portions are used as contact surfaces for the final interconnected array.
[0161] It should also be observed that the structures equivalent to those shown in FIGS. 16 and 17 can also be achieved by first joining photovoltaic cells 10 and conductive sheets 35 with suitable electrically conductive joining means 42 to give the structure shown in FIG. 24 and laminating these strips to an insulating support web 33 . An example of such an equivalent structure is shown in FIG. 25 , wherein the laminates of FIG. 24 have been adhered to insulating web 33 in defined repeat positions with adhesive means 57 and 44 . As mentioned above and as shown in FIGS. 24 and 25 , conductive sheets 35 do not have to contact the whole of the bottom surface 66 of photovoltaic cell 10 . In addition, support web 33 need not be continuous among all the cells. The support web 33 need only extend from the adhesive means 57 of one cell to the adhesive attachment 44 of an adjacent cell. This arrangement would leave a portion of the bottom surface 66 of foil 12 , and perhaps a portion of the bottom surface 80 of conductive sheet 35 exposed.
[0162] Referring now to FIGS. 18 and 19 , insulating beads 56 and 60 of insulating material having been applied to the first and second terminal edges 45 and 46 respectively of photovoltaic cells 10 . While these beads 56 and 60 are shown as applied to the structure of FIG. 15 a , it is understood that appropriate beads of insulating material are also envisioned as a subsequent manufacturing step for the structures of FIGS. 15 b , 15 c , 17 , 22 , 23 , 25 , and 26 . The purpose of the insulating beads is to protect the edge of the photovoltaic cells from environmental and electrical deterioration. In addition, as will be shown the insulating bead allows for electrical interconnections to be made among adjacent cells without electrical shorting.
[0163] It is noted that the application of insulating material 56 to first terminal edge 45 of photovoltaic cells 10 effectively divides the top surfaces 26 and 50 of conductive sheets 23 and 35 respectively into two regions. The first region (region 48 of surface 26 or region 52 of surface 50 ) can be considered as a contact region for series interconnects among adjacent cells. The second region (region 47 of surface 26 or region 51 of surface 50 ) can be considered as the contact region for interconnecting the substrate to the second surface 66 of photovoltaic cells 10 .
[0164] Referring now to FIGS. 20 and 21 , there is shown the method of forming the final interconnected array. Grid fingers 58 of a highly electrically conductive material are deposited to achieve electrical communication between the top surface 59 of the photovoltaic cell 10 and the remaining exposed contact regions 48 or 52 of an adjacent cell. It is contemplated that these fingers can be deposited by any of a number of processes to deposit metal containing or metal-based foils or films, including masked vacuum deposition, printing of conductive inks, electrodeposition or combinations thereof. In the embodiments of FIGS. 20 and 21 , the net current flow among cells will be understood by those skilled in the art to be in the direction of the double pointed arrow labeled “I” in the figures.
[0165] Referring now to FIG. 27 , the starting material for yet another embodiment is illustrated in plan view. Web, mesh or fabric strip 90 is characterized by having a width “W” and a length “L”. It is contemplated that length “L” is considerably greater than width “W” and length “L” can generally be described as “continuous” or being able to be processed in a roll-to-roll fashion. FIG. 28 , a greatly magnified plan view of a portion of the structure of FIG. 27 , shows the fabric 90 comprising fibrils 92 interwoven to form a sturdy structure. Holes 94 are present among the interwoven fibrils. It is understood that the fibrils need not be actually interwoven as shown. Equivalent structures comprising fibrils and holes, such as polymeric non-woven fabric or adhesively bonded fibril mats, can be employed.
[0166] FIGS. 29 and 30 are sectional views of the embodiment of FIG. 28 taken substantially along line 29 - 29 and line 30 - 30 of FIG. 28 respectively.
[0167] FIG. 31 is a greatly simplified sectional representation of the structure depicted in FIGS. 29 and 30 . This simplified representation of FIG. 31 is useful in the illustration of subsequent embodiments.
[0168] Referring now to FIG. 32 , there is shown the material shown in FIG. 27 following an additional processing step. The material of width “W” is now generally designated as 104 to indicate this additional process step. Width “W” has been further defined as comprising three minor widths “W 1 ”, “W 2 ”, and “W 3 ”. Each of these widths “W 1 ”, “W 2 ”, and “W 3 ” is understood to extend along length “L” as indicated.
[0169] FIG. 33 is a greatly magnified plan view of the portion of FIG. 32 structure identified as minor width “W 2 ”. In contrast to the plan view shown in FIG. 28 , the structure of FIG. 33 appears continuous in the two-dimensional plan view. This continuity results from coating the fibrils with an electrically conductive coating. The structure of the coated fibrils is best shown in the sectional view of FIG. 34 , which is a view taken substantially along line 34 - 34 of FIG. 33 . In FIG. 34 , fibrils 92 in the region “W 2 ” have been coated with electrically conductive coating 96 . It is anticipated that coating 96 and the deposition process for applying coating 96 can be chosen from any number of suitable techniques. Included in such techniques are painting, dipping, or printing of conductive inks, laminating, and masked chemical or vapor deposition of metals or other conductive materials. In the case of a temperature resistant fabric such as fiberglass, deposition of a low melting point metal such as solder could be employed. A particularly advantageous coating 96 to prepare the structure of FIG. 34 is directly electroplateable resin (DER) applied as a ink, paint solution or paste. The DER is inexpensive, and readily formulated and applied from solution form.
[0170] A method to form an equivalent structure to that shown in FIG. 34 would be to manufacture portion “W 2 ” from a woven or non-woven web of solid DER fibrils.
[0171] The important feature of the structure of FIG. 34 is that through-hole electrical communication extends from the top surface 98 to the bottom surface 100 in the region defined by “W 2 ” of FIG. 34 . This situation is readily achieved by using the coated fabric or solid DER web approaches of the present embodiments.
[0172] FIG. 35 is a sectional view similar to FIG. 34 following an additional optional process step. In FIG. 35 , the electrical conductivity and mechanical and environmental integrity of the structure is further enhanced by applying an additional highly conductive coating 102 overlaying coating 96 . This subsequent coating 102 can be conveniently applied by metal electrodeposition. The structure of FIG. 35 gives highly conductive communication, equivalent to a metal screen, from top surface 98 to bottom surface 100 in region “W 2 ” by virtue of the through-hole electrodeposition.
[0173] Referring now to FIG. 36 , there is shown a simplified plan view of the 104 structure intended to facilitate teaching of the processing steps envisioned to accomplish manufacture of the series connected photovoltaic arrays using the substrate structure 104 . In FIG. 36 , the regions “W 1 ” and “W 3 ” have structure shown in detail in FIGS. 28-30 . In FIG. 36 , region “W 2 ” has structure shown in detail in FIGS. 33 and 34 and optionally FIG. 35 .
[0174] Referring now to FIG. 37 a , there is shown a simplified sectional view of the 104 structure employing the “W 2 ” structure depicted in FIG. 34 . FIG. 37 b shows a similar view of the 104 structure employing the “W 2 ” structure depicted in FIG. 35 . These simplifications will help illustration of the processing steps and the structures resulting from these processing steps.
[0175] Referring now to FIG. 38 there is shown a schematic depiction of a process for joining the foil supported thin film photovoltaic structure of FIGS. 1 through 3 with the substrate strips 104 . Photovoltaic cells 10 are continuously fed to the process in spaced relationship to substrate strips 104 . The process accomplishes attaching one edge portion of cells 10 to a portion “W 3 ” of one substrate strip 104 and an opposite edge portion of cells 10 to a portion “W 1 ” of a second substrate strip 104 .
[0176] FIGS. 39 and 40 illustrate the process of FIG. 38 in more detail. In FIG. 39 , spacially positioned substrate strips 104 are continuously fed to the joining process 110 from roll 106 . Spacially positioned photovoltaic cells 10 are continuously fed to the process 110 from roll 108 . The resultant combined structure is designated by the numeral 112 .
[0177] FIG. 40 illustrates the process of FIG. 39 from the perspective of line 40 - 40 of FIG. 39 .
[0178] FIG. 41 is a plan view of the combined structure resulting from joining process 110 .
[0179] FIG. 42A is a simplified sectional view taken substantially along line 42 - 42 of FIG. 41 of the product from process 110 when structure 104 shown in FIG. 37A is employed. Adhesive bead 114 is used to attach a first edge portion 118 of photovoltaic cell structure 10 to portion “W 3 ” of a substrate strip and adhesive bead 116 attaches the second edge portion 120 of cell 10 to portion “W 1 ” of another substrate strip. Insulating beads 56 and 60 protect the first and second terminal edges of photovoltaic cells 10 .
[0180] FIG. 42B is a structure similar to 42 A but shows that the substrate structure need not be discrete strips but can be joined. This is equivalent to stating the portion “W 1 ” of one strip is joined to portion “W 3 ” of another strip. Maintenance of spacial positioning and mechanical integrity are promoted by the structure depicted in FIG. 42B .
[0181] FIG. 42C is a view similar to FIG. 42A but employing the substrate structure 104 shown in FIG. 37B .
[0182] FIG. 43 is an enlarged view of the structural portion within circle “A” of FIG. 42A .
[0183] FIG. 44A is a view similar to FIG. 43 but following an additional manufacturing step in preparation of the series connected array. In FIG. 44A an electrically conductive coating 122 extends from the top surface 59 of photovoltaic cell 10 A over insulating bead 60 and to electrically conductive region “W 2 ”. Coating 122 can comprise a number of electrically conductive media, such as conductive inks or conductive adhesives. Appropriate conductive inks or adhesives can be applied by silk screening, masked printing, or simple extrusion of molten conductive thermoplastic. Alternate forms of applying coating 122 are chemical or vacuum deposition of conductive materials in conjunction with appropriate masking techniques.
[0184] As indicated in FIG. 44A , conductive coating 122 extends outward across the surfaces of cells 10 A, 10 B in the form of grid fingers. These grid fingers obviously do not cover the entire top surface 59 of cell 10 , but are positioned in spaced relationship on the surface. This arrangement is best shown by the plan view of FIG. 44 .
[0185] FIG. 44A also shows an electrically conductive coating 124 extending from the second lower surface 66 of cell 10 B and to electrically conductive region “W 2 ”. Coating 124 need not be the same composition nor applied by the same process as coating 122 .
[0186] FIG. 44A shows that electrical communication is established between the top surface 59 of photovoltaic cell 10 A and the bottom surface 66 of adjacent photovoltaic cell 10 B. However, coatings 122 and 124 may not supply sufficient conductivity, either because coating resistivities are high relative to pure metals or coating thicknesses are small, as would be the case with vacuum or chemical deposited metal coatings. The conductivity of the grid fingers can be further enhanced to minimize resistive power losses by depositing additional metal or metal-based material onto fingers 122 . In a preferred embodiment, this additional metal or metal-based material is applied by electrodeposition. This is accomplished by first employing masking techniques to cover those areas of top surface 59 not covered by grid coating 122 with a protective insulating coating. The insulating coating prevents electrodeposition on those areas and also protects the surface from the possible deleterious effects of the electroplating solution. Masking techniques well known in the art are envisioned, and can be as simple a registered pad printing of an insulative organic coating. The plan views of FIG. 44 indicates the location of the insulative masking coating 150 . The structure depicted in FIGS. 44 and 44A may be continuously passed through one or more metal electrodeposition baths to result in the structure depicted in the sectional view of FIG. 45 . In FIG. 45 , the electrodeposited material 126 extends from the top surface 59 of cell 10 A to the bottom surface 66 of adjacent cell 10 B by virtue of the holes in region “W 2 ”. As with other embodiments, the direction of net current flow is shown by the double pointed arrow labeled “I” in FIG. 45 . Those skilled in the art will recognize that a similar combination of conductive coating 122 and electrodeposit 126 may be used to produce the grid fingers 58 depicted in FIGS. 20 and 21 . In the embodiments depicted in FIGS. 20 , 21 and FIG. 45 , the fact that the bottom surfaces 66 ( FIG. 45) and 28 ( FIG. 21 ) are conductive and exposed facilitate the continuous electrodeposition step by allowing cathodic contacting to these bottom surfaces, exposing the opposite top surfaces to the electroplating baths.
[0187] In a preferred embodiment of the grid structure taught above in conjunction with FIGS. 20 , 21 and FIG. 45 conductive grid coating 122 comprises a DER. “DERS” are inexpensive, can be formulated to achieve good adhesion and ohmic contact to top surface 59 comprising the transparent conductive oxide (TCO), and achieves good ohmic contact and adhesion to the electrodeposit 126 . In essence, the DER functions as a “conductive adhesive” joining the TCO and the electrodeposit 126 . Those skilled in the art will recognize that electrodeposit 126 , while illustrated as a single layer, may comprise multiple layers.
[0188] FIG. 49 is a sectional view similar to FIG. 43 of an alternative intermediate article resulting from feeding the material of FIGS. 27 through 31 to the process of FIGS. 38 through 40 rather than the joining strips 104 of FIGS. 36 and 37 . Here the conductive coating 96 defining region “W 2 ” of FIGS. 36 and 37 has not been applied. However, applying the conductive coating 96 to the FIG. 49 structure at the time of applying conductive coatings 122 and 124 (see discussion of FIG. 44A ), results in converting the FIG. 49 structure into one equivalent to that shown in FIG. 44A .
[0189] FIG. 46 shows yet another embodiment of the current disclosure. The plan view of 46 illustrates a polymer based sheet 130 of width “W” subdivided into three areas “W 1 ”, “W 2 ”, and “W 3 ” in fashion similar to that of FIG. 32 . Polymer based sheet 130 can be conveniently formed by coextrusion of materials 132 , 134 , and 136 , corresponding to regions “W 1 ”, “W 2 ”, and “W 3 ” respectively. Materials 132 , 134 , and 136 can be all based on the same polymer or different polymers can be chosen. It is important however that proper joining integrity be established at mating interfaces 138 and 140 .
[0190] The material 134 chosen for region “W 2 ” is an electrically conductive polymer. A particularly advantageous resin is a DER.
[0191] FIG. 47 is a sectional view taken substantially along line 47 - 47 of FIG. 46 . As shown in FIGS. 46 and 47 , region “W 2 ” is caused to have holes 142 along its length. In the simplest conceptual case, these holes are simply punched in the region “W 2 ”. Another approach would be to formulate the region “W 2 ” of FIGS. 46 and 47 from a fabric (non-woven or woven) of electrically conductive polymer.
[0192] FIG. 48 shows the structure of FIG. 47 following an additional processing step of depositing metal 144 through holes 142 to establish high electrical conductivity from top surface 146 to bottom surface 148 . Preferably this metal deposition is by electroplating although chemical and vapor deposition techniques could be used.
[0193] In many respects the structures shown in FIGS. 47 and 48 resemble the structures depicted in FIGS. 37 a and 37 b respectively. Thus the use of the structures of FIGS. 47 and 48 in the process of FIGS. 38 through 40 would give results similar to those previously taught as one skilled in the art will recognize.
[0194] It is important to recognize that the unique design and process taught by the present invention is accomplished in a fully additive fashion. No wasteful and costly material removal steps are needed to achieve the integrated series connected arrays taught. This is a significant advantage over the prior art.
[0195] Despite the relative simplicity envisioned for production of the current collector grid/interconnect structures using the combination “conductive coating plus electrodeposition” approach taught above in conjunction with FIGS. 20 , 21 and FIGS. 44 , 44 A and 45 , it can be contemplated that separate production of the grid/interconnect array followed by subsequent application to a geometrically registered arrangement of photovoltaic cells may be employed to advantage. This concept would avoid the masking and possible exposure of the photovoltaic cells to the wet electrochemistry involved in the approaches taught above in conjunction with FIGS. 20 , 21 and 44 , 44 A and 45 . Thus, a further embodiment of the grid structure, design and fabrication process is taught below in conjunction with FIGS. 50 through 66 .
[0196] FIG. 50 is a plan view of a polymeric film or glass substrate 160 . Substrate 160 has width X- 160 and length Y- 160 . In one embodiment, taught in detail below, Y- 160 is much greater than width X- 160 , whereby film 160 can generally be described as “continuous” in length and able to be processed in length Y- 160 in a continuous roll-to-roll fashion. FIG. 51 is a sectional view taken substantially from the view 51 - 51 of FIG. 50 . Thickness dimension Z- 160 is small in comparison to dimensions Y- 160 , X- 160 and thus substrate 160 has a sheetlike structure. As shown in FIG. 51 , substrate 160 may be a laminate of multiple layers 162 , 164 , 166 etc. or may comprise a single layer of material. The multiple layers 162 , 164 , 166 etc. may comprise inorganic or organic components such as thermoplastics or silicon containing glass-like layers. The various layers are intended to supply functional attributes such as environmental barrier protection or adhesive characteristics. Such functional layering is well-known and widely practiced in the plastic packaging art. Sheetlike substrate 160 has first surface 190 and second surface 192 .
[0197] FIG. 52 depicts the structure 160 (possibly laminate) as a single layer for purposes of presentation simplicity. Substrate 160 will be represented as this single layer in the subsequent embodiments.
[0198] FIG. 53 is a plan view of the structure following an additional manufacturing step, and FIG. 54 is a sectional view taken along line 54 - 54 of FIG. 53 .
[0199] FIG. 55 is a sectional view taken along line 55 - 55 of FIG. 53 . In FIGS. 53 through 55 , it is seen that a pattern of “fingers”, designated 170 , extends from “buss” structures, designated 171 . Both “fingers” 170 and “busses” 171 are deposited on and supported by substrate 160 . While shown as a single layer, “fingers” 170 and “busses” 171 may comprise multiple layers. “Fingers” 170 and “busses” 171 may comprise electrically conductive material, or may comprise non-conductive-material which would assist accomplishing a subsequent deposition of conductive material. For example, “fingers” 170 or “busses” 171 could comprise a seeded polymer which would catalyze chemical deposition of a metal in a subsequent step. A second example would be materials selected to promote adhesion of a subsequently applied conductive material. “Fingers” 170 and “busses” 171 may differ in actual composition.
[0200] FIGS. 56 , 57 and 58 correspond to the views of FIGS. 53 , 54 and 55 following an additional processing step. FIG. 59 is a sectional view taken substantially along line 59 - 59 of FIG. 56 . FIGS. 56 through 59 show additional conductive material deposited onto the “fingers” and “busses” of FIGS. 53 through 55 . This additional conductive material is designated by layers 173 , 175 . While shown as multiple layers 173 , 175 , it is understood that this conductive material could be a single layer. As best shown in FIG. 58 , “fingers” 170 have top free surface 185 and “busses” 171 have top free surface 187 . In a preferred embodiment, additional layers 173 , 175 etc. are deposited by electrodeposition, taking advantage of the deposition speed, low cost and selectivity of the electrodeposition process. Alternatively, these additional metal-based layers may be deposited by selective chemical deposition or registered masked vapor deposition. Metal-filled conductive resins may also be used to form these additional layers 173 , 175 .
[0201] FIGS. 60 through 63 illustrate a process 177 by which the interconnection component of FIGS. 56 through 59 is combined with the structure illustrated in FIG. 19 to accomplish series interconnections among geometrically spaced cells. In FIG. 60 roll 179 represents a “continuous” feed roll of the grid/buss structure on the sheetlike substrate as depicted in FIGS. 56 through 59 . Roll 181 represents a “continuous” feed roll of the sheetlike geometrical arrangement of cells depicted in FIG. 19 . As indicated in FIGS. 60 through 63 , process 177 laminates these two sheetlike structures together in a spacial arrangement wherein the grid “fingers” project laterally across the top surface 59 of cells 10 and the “finger/buss” structure extends to the top contact surface 48 of an adjacent cell. As with prior embodiments, the double pointed arrow labeled “i” indicates the direction of net current flow in the embodiments of FIGS. 62 and 63 .
[0202] The actual interconnection between adjacent cells is depicted in greatly magnified form in FIG. 63 , magnifying the encircled region “A” of FIG. 62 . In the embodiments of FIGS. 62 and 63 , “buss” structure ( 171 , 173 , 175 ) is shown to extend in the “continuous” Y direction of the laminated structure (direction normal to the paper). It will be appreciated by those skilled in the art that the only electrical requirement to achieve proper interconnection of the cells is that the grid “fingers” extend to the contact surface 48 of an adjacent cell. However, in those cases where the grid fingers comprise an electrodeposit, inclusion of the “busses” provides a convenient way to pass electrical current by providing a continuous path from the rectified current source to the individual grid “fingers”. This facilitates the initial electrodeposition of layers 173 , 175 etc. onto the originally deposited materials 170 , 171 . Those skilled in the art will recognize that if the grid “fingers” comprise material deposited by selective chemical, masked vapor deposition or printing, the grid “fingers” could constitute individual islands and the “buss” structure could be eliminated.
[0203] Those skilled in the art will recognize that contact between the top surface 59 of the cell and the mating surface 185 of the grid finger will be achieved by ensuring good adhesion between first surface 190 of sheet 160 and the top surface 59 of the cell in those regions where surface 190 is not covered by the grid. However, electrical contact between grid “fingers” 170 and cell surface 59 can be further enhanced by selectively printing a conductive adhesive onto “fingers” 170 prior to the lamination process taught in conjunction with FIGS. 60 and 61 . In this way surface 185 is formed by a conductive adhesive resulting in secure adhesive and electrical joining of grid “fingers” 170 to top surface 59 following the lamination process.
[0204] Alternatively, one may employ a low melting point metal-based material as a constituent of the material forming surface 185 . In this case the low melting point metal-based material is caused to melt during the process 177 of FIG. 60 thereby increasing the contact area between the mating surfaces 185 and 59 . In a preferred embodiment indium or indium containing alloys are chosen as the low melting point contact material at surface 185 . Indium melts at a low temperature, considerably below possible lamination temperatures. In addition, Indium is known to bond to glass and ceramic materials when melted in contact with them. Given sufficient lamination pressures, only a very thin layer of Indium would be required to take advantage of this bonding ability.
[0205] Bonding to the contact surface 48 of conductive sheet 23 can be accomplished by any number of the electrical joining techniques mentioned above. These include electrically conductive adhesives, solder, and melting of suitable metals or metal-base alloys during the heat and pressure exposure of the process 177 of FIG. 60 . As with the discussion above concerning contact of the “fingers”, selecting low melting point metal-based materials as constituents forming surface 187 could aid in achieving good ohmic contact and adhesive bonding of “busses” 171 to the contact surface 48 of sheet 23 .
[0206] FIGS. 64 through 66 show the result of the FIG. 60 process using a substrate structure similar to that illustrated in FIG. 37B , except that the portion “W- 3 ” shown in FIG. 37B is omitted. FIG. 65 shows photovoltaic cells 10 spacially arranged using the substrate structure of FIG. 64 . Conductive joining means 202 connect cells 10 to portions of top surface 200 of conductive regions W- 2 . Insulating beads 56 , 60 protect the edges of cells 10 . Adhesive 204 attaches cell 10 to the non-conductive region W- 1 of the substrate. The structure depicted in FIG. 65 is similar in electrical and spacial respects to the structure depicted in FIG. 19 . Substituting the structure of FIG. 65 for the FIG. 19 structure shown in the prior embodiments of FIGS. 60 through 63 results in the structure shown in the sectional view of FIG. 66 . In this case the through-holes associated with the FIG. 64 substrate structures may assist in the lamination process by permitting a reduced pressure on the bottom side 206 of the sheetlike structures ( FIG. 65 ) thereby promoting removal of air from between the sheetlike structures of FIGS. 56 through 59 and the sheetlike structure of FIG. 65 just prior to lamination.
[0207] The sectional views of FIGS. 63 and 66 embody application of the invention to the substrate structures taught in FIGS. 7 and 64 respectively. It is understood that similar results would be achieved using the other substrate structures taught in the disclosure, such as those embodied in FIGS. 8 through 12 , 24 and 25 , 26 , 27 through 37 B, 46 through 48 , and 49 .
[0208] The sectional view of FIGS. 63 and 66 show film 160 remaining as part of the structure following the process 177 of FIG. 60 . In some cases in may be advantageous to employ film 160 in a manner wherein it is removed after attachment of the “fingers” and “busses” to the respective surfaces of the cells and substrate. In this application, the film 160 would serve as surrogate support and spacial positioning means during formation, placement and bonding of the “finger/buss” structure. In this case a suitable “release” material would be positioned between surface 190 of film 160 and “fingers/busses” 170 / 171 .
[0209] A further embodiment of a front face current collector structure is taught in conjunction with FIGS. 67 through 81 . FIG. 67 is a top plan view of a metal foil/semiconductor photovoltaic structure similar to the laminated structure depicted in FIGS. 1 and 2 . However, the structure of FIG. 67 , generally referred to as 300 , also includes narrow strips of insulating material 302 extending in the length direction Y- 300 . Strips 302 are usually positioned at repeat distances R in the width direction X- 300 of structure 300 . As will be seen below, dimension R approximates the width X- 10 of the eventual individual cells.
[0210] FIG. 68 is a sectional view taken substantially along line 68 - 68 of FIG. 67 . FIG. 68 shows a laminate comprising separate layers 75 , 13 , 14 , 11 , and 18 as previously described for the structure of FIG. 2 . Insulating strips 302 are shown positioned on top surface 59 of structure 300 . However, it is understood that strips 302 could be positioned on top surface 303 of semiconductor material 11 . In this latter case, window electrode 18 could be deposited over the entire surface (including strips 302 ) or selectively onto the surface areas between strips 302 . For simplicity, the embodiments of FIGS. 67 through 78 will show strips 302 disposed on top surface 59 of window electrode 18 . The purpose of the insulating strips 302 is to prevent shorting between top and bottom electrode material during subsequent slitting into individual cells, as will become clear below.
[0211] In the embodiment shown, length Y- 300 is much greater than width X- 300 and length Y- 300 can generally be described as “continuous” or being able to be processed in roll-to-roll fashion. In contrast to width X- 10 of the individual cell structure of FIGS. 1 and 2 , X- 300 of FIGS. 67 and 68 is envisioned to be of magnitude equivalent to the cumulative widths of multiple cell structures. Strips 302 are typically 0.002 inch to 0.050 inch wide (dimension “T”, FIG. 67 ). Strips 302 can be applied to the surface 59 by any number of methods such as thermoplastic extrusion, roll printing or photo masking.
[0212] In order to promote simplicity of presentation, layers 75 , 13 , 14 , 11 and 18 of structure 300 will be depicted as a single layer 370 in subsequent embodiments.
[0213] FIG. 69 is a top plan view of the FIG. 67 structure following an additional processing step and FIG. 70 is a sectional view taken substantially along line 70 - 70 of FIG. 69 . Electrically conductive material has been deposited in conductive strips 304 onto the top surface of the structure 300 . Strips 304 extend in the width direction X- 300 and traverse a plurality of repeat distances “R”. Dimension “N” of strips 304 is normally made as small as possible, typically 0.002 inch to 0.100 inch. Dimension “C”, the repeat distance between strips 304 depends to some extent on dimension “N” but is typically 0.05 inch to 1.0 inch.
[0214] Strips 304 can comprise electrically conductive resins or adhesives applied by printing or thermoplastic extrusion. Alternatively, strips 304 can comprise metal-based materials applied by selective deposition. It is, of course, advantageous to select materials and techniques which promote adhesive and ohmic contact to the top surface 59 of window electrode 18 . As will be appreciated by those skilled in the art in light of the following teachings, electrically conductive resins, and DER's in particular, are very suitable as materials for conductive strips 304 .
[0215] In the embodiment of FIG. 69 , those areas of the top surface of structure 300 not covered with conductive strips 304 have been coated with a thin coating of electrically insulating material 305 .
[0216] FIG. 71 is a plan view of an alternate embodiment. In FIG. 71 , 300 A designates a structure similar to the structure 300 of FIGS. 67 , 68 but strips 302 are not shown. They have either been excluded or are invisible in the plan view of FIG. 71 , having been deposited on the surface of semiconductor material 11 (and thus overcoated with window electrode 18 ) or covered by insulating layer 305 A. 304 A designates strips or islands of electrically conductive material which have dimension “Q” slightly less than repeat distance “R”. Those skilled in the art will recognize, in light of the teachings that follow below, that the structure embodied in FIG. 71 would be conceptually equivalent to the structure of FIG. 69 .
[0217] FIG. 72 is a sectional view similar to FIG. 70 after an additional processing step. In FIG. 72 , additional highly electrically conductive material 306 has been deposited overlaying conductive material 304 . Material 306 has exposed top surface 352 . In a preferred embodiment, highly electrically conductive material 306 is electrodeposited. Electrodeposition permits relatively rapid deposition rates and permits facile deposition of very conductive materials such as copper and silver. In this regard, it is highly advantageous to employ a DER for the conductive material 304 . It can be appreciated that material strips 304 / 306 extend in the “X” direction a distance equivalent to multiple widths “R”. This concept therefore allows for deposition of the individual cell grid fingers in an essentially continuous, “bulk” fashion.
[0218] FIG. 73 is a sectional view of a portion of the FIG. 72 structure after an additional processing step comprising slitting the FIG. 72 structure along the insulating strips 302 at repeat distances “R” to give individual units 308 comprising laminate portions of structures 370 , 302 , 304 , 306 of the prior embodiments. Units 308 have width “R” which, as will be seen, approximates the eventual photovoltaic cell width. During this slitting process, insulating beads 302 prevent smearing of the top conductive material to the bottom electrode material 12 which would result in electrical shorting.
[0219] FIG. 74 is a view similar to FIG. 13B showing the FIG. 73 structures just prior to a laminating process similar to FIG. 13A . Individual structures 308 are positioned in spacial relationship with electrically conductive adhesive 42 and conductive sheets 23 . As in prior embodiments, sheets 23 are separated by insulating joining portions 25 . Conductive sheets 23 can be considered to have a top contact surface region 48 and top collector surface area 47 .
[0220] FIG. 75 is a sectional view of the structure after the lamination depicted in FIG. 74 plus an additional step of applying insulating beads 56 , 60 to the terminal edges of the individual units 308 . As shown in FIG. 75 , at least a portion of top contact surface 48 remains exposed following this lamination. In addition, the lamination is characterized by repeat dimension 34 , which is slightly greater than dimension “R”.
[0221] FIG. 76 is a sectional view prior to a further laminating step in the production of the overall array. FIG. 76 shows introduction of an additional sheetlike interconnection component 309 comprising material strips 316 mounted on sheet 310 having top surface 312 and bottom surface 314 . Sheet 310 , shown as a single layer for simplicity, may comprise a laminate of multiple layers of materials to supply adhesive and barrier properties to the sheet.
[0222] Mounted in spaced arrangement on the bottom surface 314 of sheet 310 are strips 316 of material having an exposed surface 340 which is electrically conductive. Strips 316 are also shown in FIG. 76 to comprise layer 320 which adhesively bonds conductive layer 318 to sheet 310 . Layer 320 need not necessarily be electrically conductive and may be omitted if adhesion between conductive material 318 and sheet 310 is sufficient. Layer 18 may comprise, for example, an electrically conductive adhesive.
[0223] FIG. 77 , a plan view taken substantially along line 77 - 77 of FIG. 76 , indicates the linear nature of strips 316 extending in the direction Y- 309 . Strips 316 have a width dimension “B” sufficient to span the distance between conductive strips 306 of one unit 308 to the contact surface 48 of sheet 23 corresponding to an adjacent unit. Typical magnitudes for dimension “B” are from 0.020 inch to 0.125 inch depending on registration accuracy during the multiple lamination processes envisioned.
[0224] FIGS. 78 and 79 present alternatives to the FIG. 77 component. In FIG. 78 , tab extensions 322 of width “E” reach out in the “X” direction from the strips 316 A. Tabs 322 are positioned at repeat distances “C” in the “Y” direction corresponding to the repeat dimension “C” of the conductive strips 304 / 306 . Proper positional registration during the lamination process envisioned in FIG. 76 allows tabs 322 to overlap and contact strips 306 , permitting increased contact area between strips 306 and tabs 322 and also a possible reduction in width “D” of strips 316 a ( FIG. 78 ) in comparison to dimension “B” ( FIG. 77 ).
[0225] FIG. 79 shows an alternate embodiment wherein strips 316 and 316 A of FIGS. 77 and 78 respectively have been replaced by individual islands 316 B. Thus, material forming conductive surface 340 need not be continuous in the “Y” direction. Islands 316 B can comprise, for example, an electrically conductive adhesive. Dimension “E” ( FIG. 79 ) is similar to dimension “N” ( FIG. 69 ). Dimension “D”, ( FIG. 79 ) is sufficient to span the distance between conductive strips 306 of one unit 308 to the contact surface 48 of sheet 23 corresponding to an adjacent unit.
[0226] Since the linear distance between strips 306 of one unit 308 and surface 48 corresponding to an adjacent unit is small, the structures 316 , 316 a and 322 , and 316 b of FIGS. 77 , 78 , and 79 respectively do not necessarily comprise materials exhibiting electrical conductivities characteristic of pure metals and alloys. However, as will be discussed below, proper selection of metal-based materials to form surface 340 of these structures can be used to advantage in achieving excellent ohmic and adhesive contacts to grid material 306 and contact surfaces 48 of conductive sheets 23 .
[0227] Accordingly, an example of a laminated structure envisioned for conductive layer 318 is shown in the sectional view of FIG. 80 . A layer of electroplateable resin 324 is attached to adhesive layer 320 (layer 320 not shown in FIG. 80 ). This is followed by layers 326 , 328 of electrodeposited metal for mechanical and electrical robustness. Finally a layer of low melting point metal or alloy 330 is deposited to produce free surface 340 . Those skilled in the art will recognize that DER's would be a highly attractive choice for resin layer 324 . Alternatively, a material, not necessarily conductive, which would allow selective deposition of metal by chemical techniques could be chosen for layer 324 .
[0228] Using the structure embodied in FIG. 80 for the layer 318 , the material 330 with surface 340 is caused to melt during the lamination process depicted in FIG. 76 , resulting in a “solder” bond between material forming contact surface 48 of sheet 23 and material 330 with surface 340 . A similar “solder” bond is formed between material forming top surface 352 of strip 306 and material 330 having surface 340 .
[0229] One will note that the retention of sheets 310 of FIGS. 76 through 78 is not an absolute requirement for achieving the electrical interconnections among cells, but does facilitate handling and maintenance of spacial positioning during formation of the conductive interconnect structures and the subsequent laminating process envisioned in FIG. 76 . In this regard, sheet 310 could be a surrogate support which is removed subsequent to or during lamination. This removal could be achieved, for example, by having layer 320 melt during the lamination process to release sheet 310 from structure 316 , etc.
[0230] One also should recognize that the electrical interconnections between grid material 306 of units 308 and contact surface 48 corresponding to an adjacent cell could be made by using individual “dollops” of conductive material spanning the gap between surface 48 and each individual grid finger of an adjacent cell.
[0231] FIG. 81 is a greatly exploded view of a completed interconnection achieved according to the teachings embodied in FIGS. 67 through 80 . FIG. 81 shows first cell 360 and a portion of adjacent cell 362 . Interconnect region 364 is positioned between cells 360 and 362 . It is seen that robust, highly efficient top surface current collection and cell interconnections are achieved with inexpensive, controllable and repetitive manufacturing techniques. Sensitive, fine processing involving material removal techniques and adversely affecting yields are avoided. The double pointed arrow “i” in FIG. 81 indicates the direction of net current flow among the interconnected cells.
[0232] While the grid/interconnect structure taught in conjunction with FIGS. 67 through 81 employed the substrate structure depicted in FIGS. 6 and 7 , it is understood that similar results would be achieved with the other substrate embodiments revealed in conjunction with the teachings corresponding to FIGS. 8 through 66 .
[0233] Since the layer 370 exhibits reasonable “through conductivity”, it is contemplated that the required electrodeposition current could be achieved by contacting the exposed back metallic surface 66 of metal-based foil 12 . However, it is understood that should this electrodeposition current have a deleterious effect on the cell itself, electrodeposition could still be accomplished by masking surface 66 and including a “buss” structure of conductive material extending in the “Y- 300 ” direction of the structure shown in FIG. 69 .
[0234] A further embodiment of the series connected photovoltaic arrays of the instant disclosure is taught in conjunction with FIGS. 82 and 83 . FIG. 82 is a depiction similar to FIG. 74 illustrating a laminating process resulting in a series interconnected array of multiple photovoltaic cells. FIG. 82 shows multiple cells 308 (as described in conjunction with FIG. 73 ) whose bottom conductive metal-based surface 66 slightly overlaps top, light-incident surface 352 of the grid fingers of an adjacent cell. Conductive adhesive strips 42 are positioned in this area of overlap. Adhesive strips 44 augment positioning and handling reliability by firmly attaching the cells to support web 400 . Should the conductive adhesive bonding imparted by adhesive strips 42 be of sufficient strength and integrity, support web 400 can be considered optional. In addition, conductive adhesive strips 42 are but one of several ways to achieve the electrical joining required, as has been previously disclosed.
[0235] FIG. 83 embodies the result of the laminating process of FIG. 82 . The individual cells 308 are electrically connected in series through a “shingling” arrangement, wherein the bottom conductive surface 66 of a first cell is electrically and adhesively joined to a light incident top surface 352 of the current collector grid fingers of an adjacent cell. Insulating strips 60 protect terminal edges of individual cells from electrical shorting. The double pointed arrow “I” indicates the direction of net current flow among cells of the FIG. 83 embodiment.
[0236] The simplified series interconnections among multiple photovoltaic cells taught in the present disclosure are made possible in large measure by the ability to selectively electrodeposit highly conductive metal-based materials to manufacture both supporting interconnect substrates and current collector grid structures. This selectivity is readily and inexpensively achieved by employing directly electroplateable resins (DERs) as defined herein.
[0237] Although the present invention has been described in conjunction with preferred embodiments, it is to be understood that modifications, alternatives and equivalents may be included without departing from the spirit and scope of the inventions, as those skilled in the art will readily understand. Such modifications, alternatives and equivalents are considered to be within the purview and scope of the invention and appended claims.
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The invention teaches novel structure and methods for producing electrical current collectors and electrical interconnection structure. Such articles find particular use in facile production of modular arrays of photovoltaic cells. The current collector and interconnecting structures may be initially produced separately from the photovoltaic cells thereby allowing the use of unique materials and manufacture. Subsequent combination of the structures with photovoltaic cells allows facile and efficient completion of modular arrays. Methods for combining the collector and interconnection structures with cells and final interconnecting into modular arrays are taught.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to substrate surface cleaning and, more particularly, to a method and apparatus for improving semiconductor substrate cleaning following fabrication processes.
2. Description of the Related Art
As is well known to those skilled in the art, the fabrication of semiconductor devices involves numerous processing operations. These operations include, for example, impurity implants, gate oxide generation, inter-metal oxide depositions, metallization depositions, photolithography patterning, etching operations, chemical mechanical polishing (CMP), etc. Typically, these operations generate contaminants such as particles, residue, or absorbed components (e.g., chemicals), which are adhered to the wafer surface and/or wafer topography features. It is well established that contaminants should be removed as the presence of such contaminants has detrimental effects on the performance of the integrated circuit devices. To achieve this task, wafer surfaces and topography features are cleaned so as to dislodge and remove contaminants.
Common cleaning operations may involve brush scrubbing of the wafer surfaces wherein the wafer surfaces are cleaned purely by applying mechanical energy. Another widely use cleaning operation involves megasonic cleaning of the wafer surfaces in order to dislodge any adhered contaminants.
The brush scrubbing operation is usually performed by either a double-sided horizontal wafer scrubber or horizontal wafer scrubber designed to clean top and bottom surfaces of a wafer. Top and bottom surfaces of the wafer are brushed by a pair of brushes, each mounted on a corresponding brush core. Each of the brush cores includes a respective shaft, each connected to a fluid inlet. The outer surfaces of the brushes are typically covered with a plurality of nodules. The wafer is engaged by a pair of rollers while the top and bottom surfaces of the wafer are scrubbed by the brushes. The wafer is cleaned as the brushes come in contact with top and bottom surfaces of the wafer, thus removing the contaminants.
FIG. 1A shows a simplified, partial, exploded, cross sectional view of an exemplary prior art brush scrubbing operation. A brush 12 having a plurality of nodules 14 is shown to be applied to the wafer surface 8 ′ so as to clean planer surface as well as the topography features 8 a – 8 d defined on the wafer surface 8 ′. As can be seen, a plurality of contaminants 10 a – 10 f is adhered to the planer surface of the wafer surface 8 ′ or in deep topography features 8 a – 8 d . For instance, contaminants 10 a , 10 b , 10 d , and 10 e are adhered to the planer surface of the wafer surface 8 ′ while contaminant 10 c is adhered inside the feature 8 b , and contaminant 10 f is adhered inside the feature 8 d.
Normally, wafer surface 8 ′ is brush scrubbed using chemicals so as to remove any contaminants adhered to the wafer surface 8 ′. The wafer surface 8 ′ is then rinsed by flushing the wafer surface 8 ′ with DI water, thus disposing the contaminant 10 a – 10 e . At this point, the cleaned wafer is removed from the brush scrubber, allowing the next wafer to be placed in the brush scrubber. In this fashion, each wafer is scrubbed and rinsed in the prior art brush box.
Unfortunately, brush scrubbing operations can generally only dislodge contaminants defined on planer surfaces, i.e., 10 a , 10 b , 10 d , and 10 e . This occurs as the brush materials 12 may not penetrate through very high aspect ratio features 8 a – 8 d (e.g., trenches and vias, etc.) so as to clean contaminants 10 c and 10 f defined deep within the features. As a result, brush scrubbing operations may exhibit a rather poor cleaning capacity when cleaning surface topography features such as trenches or vias open to the wafer surface 8 ′. For instance, at the conclusion of the brush scrubbing operation, contaminants defined on the planer surface of the wafer surface (i.e., 10 a , 10 b , 10 d , and 10 e ) have been removed while, in some cases, contaminants 10 c and 10 f may still remain adhered to the wafer surface 8 ′. In some circumstance, this limitation associated with brush scrubbing operations becomes more noticeable as the feature sizes get smaller (e.g., smaller than 0.2 microns). As can be appreciated, smaller feature sizes may prevent penetration of the brush material into the topography features, thus limiting or blocking access to the contaminants lodged therein.
Another commonly used cleaning operation is cleaning of wafer surface 8 ′ using a megasonic cleaner shown in the simplified, partial, exploded, cross sectional view of FIG. 1B , in accordance with the prior art. As shown, a megasonic transducer is fabricated using a plurality of crystals 32 of piezoelectric material bonded to a resonator 30 . The crystals 32 are powered, thus causing the resonator 30 to vibrate. The vibration of the high frequency acoustic energy transducer creates sonic pressure waves in the liquid medium or the meniscus present. In this manner, contaminants 10 a – 10 f are expected to be removed by cavitation and sonic agitation generated in the high frequency acoustic energy cleaner.
Megasonic cleaning has proven to be more than reliable in cleaning and dislodging contaminants defined deep into the topography features 8 a – 8 d defined on the wafer surface 8 ′. However, megasonic cleaning may achieve an inadequate cleaning of the planer surfaces. By way of example, contaminant 10 c lodged deep into the feature 8 b and contaminant 10 f lodged into the feature 8 d are easily dislodged and removed by megasonic cleaning. Contaminants 10 a , 10 b , 10 d , and 10 e , nevertheless may still remain on the wafer surface 8 ′ subsequent to the megasonic cleaning. Furthermore, as shown, megasonic cleaning may not be capable of dislodging contaminants pressed onto the wafer surface 8 ′, such as contaminant 10 d.
In an attempt to compensate the limitations associated with either brush scrubbing or megasonic cleaning operations, typical wafer cleaning processes of the prior art involve performing cleaning operations in multiple stand alone modules in a given order. For instance, as shown in FIG. 1C , the prior art cleaning operation starts by brush scrubbing wafer surfaces in a stand alone brush box 2 for a specific period of time subsequent to which the cleaned wafer is removed from the brush box 2 and transferred into the stand alone megasonic cleaner 4 . At this point, the wafer surfaces are cleaned in the stand alone megasonic cleaner 4 for a particular time after which the cleaned wafer is transferred to a spin, rinse, and dry (SRD) module 6 . Next, the wafer is spin-rinsed and dried. In this fashion, each wafer is scrubbed, megasonically cleaned, and spin-rinsed in accordance with the prior art.
As can be appreciated, each wafer has to be brush scrubbed, megasonically cleaned, and spin rinsed, separately and for a corresponding period of time, in three different stand alone modules, thus making the cleaning process of the prior art an extended and lengthy process. Prolonging the cleaning period even more is the transition time necessary for removing and transferring of wafers between the stand alone modules. In this manner, the cleaning cycle for each wafer is significantly and unnecessarily increased. As can be appreciated, this reduces the overall wafer throughput.
In view of the foregoing, a need therefore exists in the art for a method and apparatus capable of producing a substantially clean patterned and/or unpatterned semiconductor substrate, while maximizing cleaning efficiency and minimizing semiconductor substrate cleaning cycle.
SUMMARY OF THE INVENTION
Broadly speaking, the present invention fills this need by providing a system for cleaning semiconductor substrates by concurrently using a combination of high frequency acoustic energy cleaning and brush scrubbing in a stand alone cleaning module or clustered with other modules. It should be appreciated that the present invention can be implemented in numerous ways, including as a process, an apparatus, a system, a device, or a method. Several inventive embodiments of the present invention are described below.
In one embodiment, a substrate cleaning apparatus is provided. The apparatus includes a transducer capable of resonating at a high frequency and a brush material attached to a surface of the transducer. The brush material includes at least one passage extending to the surface of the transducer and is configured to be applied to a surface of a substrate. When the transducer resonates at the high frequency, the transducer is capable of imparting acoustic energy to the surface of the substrate at a location of the at least one passage.
In another embodiment, a substrate cleaner is provided. The substrate cleaner includes a transducer that includes a first side and a second side, a brush, a housing, and an arm. The brush is disposed on the first side of the transducer and is configured to include a plurality of openings. The plurality of openings is configured to facilitate transmission of high frequency acoustic energy imparted by the transducer to a surface of a substrate at a respective location of each opening of the plurality of openings. The housing is configured to cover the brush and the transducer and an arm coupled to a backside of the housing. The arm is configured to controllably apply the brush disposed on the transducer onto the surface of the substrate.
In yet another embodiment, a brush scrubbing-high frequency acoustic energy (AE) cleaning system is provided. The system includes a brush core having a first end, a second end, and an outer surface, a shaft, a fluid inlet, a transducer, and a brush. The brush core includes a plurality of orifices extending from a center of the brush core to the outer surface of the brush core. The shaft is connected to the first end of the brush core. The fluid inlet is configured to deliver a fluid medium to the brush core through the shaft. The transducer is disposed on an outer surface of the brush core and is capable of resonating at a high frequency. The brush includes a plurality of openings and is configured to cover the transducer. When the transducer resonates at the high frequency, high energy acoustic energy is imparted from the transducer to a surface of a substrate at respective locations of each of the plurality of openings.
In still another embodiment, another brush scrubbing-high frequency acoustic energy (AE) cleaning system is provided. The system includes a brush core having a first end, a second end, and an outer surface, a shaft, a transducer, and a brush. The shaft is connected to the first end of the brush core. The transducer is disposed on an outer surface of the brush core and is capable of resonating at a high frequency. The brush includes a plurality of openings and is configured to cover the transducer. When the transducer resonates at the high frequency, high energy acoustic energy is imparted from the transducer to a surface of a substrate at respective locations of each of the plurality of openings.
In still another embodiment, a method for making a brush scrubbing-high frequency acoustic energy cleaning assembly is provided. The method includes making a plurality of orifices in a brush core. The method also includes disposing a plurality of transducers on an outer surface of the brush core such that a subset of the plurality of orifices in the brush core is exposed to a brush. The plurality of transducers is capable of resonating at a high frequency. Also included is making a plurality of openings in the brush and placing the brush over the plurality of transducers such that the plurality of transducers is exposed to a subset of the plurality of openings in the brush. When the transducer resonates at the high frequency, high energy acoustic energy is imparted from the plurality of transducer to a surface of a substrate at respective locations of each of the plurality of openings.
In yet another embodiment, a method for making a brush scrubbing-high frequency acoustic energy cleaning assembly is provided. The method includes disposing a plurality of transducers on an outer surface of a brush core and making a plurality of openings in a brush. The method further includes covering the brush over the plurality of transducers such that the plurality of transducers is exposed to a subset of the plurality of the openings in the brush core.
In still another embodiment, a method for making a brush scrubbing-high frequency acoustic energy (AE) cleaning assembly is provided. The method includes making an opening in a brush. The opening extends through the brush. The method also includes disposing the brush over a transducer capable of resonating at a high frequency. When the transducer resonates at the high frequency, high energy acoustic energy is imparted from the transducer to a surface of a substrate at a location of the opening.
The advantages of the present invention are numerous. Most notably, the embodiments of the present invention concurrently utilize brush scrubbing and high frequency acoustic energy cleaning, thus achieving a substantially improved cleaning operation. Another advantage of the present invention is that performing of brush scrubbing-AE cleaning in a single cleaning module enhances the substrate cleaning efficiency. Another advantage of the embodiments of the present invention is that by concurrently performing brush scrubbing and AE cleaning, the cleaning cycle per wafer is substantially reduced, ultimately leading to an increase in wafer throughput. Still another advantage of the present invention is that single semiconductor wafers can be cleaned substantially eliminating the possibility of recontamination of the wafer by contaminants set free during the cleaning of other semiconductor wafers. Yet another advantage of the present invention is that in the cleaning module of the present invention the cleaning operation can easily be switched between contact cleaning (brush scrubbing), non-contact cleaning (AE cleaning), or contact-noncontact cleaning, depending on the application requirements. Yet another advantage is that the embodiments of the present invention can be implemented in a multi-station cleaning module designed to clean a plurality of substrates in individual combination cleaning modules.
Other aspects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, and like reference numerals designate like structural elements.
FIG. 1A shows a simplified, partial, exploded, cross sectional view of an exemplary prior art brush scrubbing operation.
FIG. 1B shows a simplified cross sectional view of an exemplary prior art megasonic cleaning.
FIG. 1C shows a simplified schematic diagram illustrating cleaning modules implemented in a prior art cleaning operation.
FIG. 2A is a simplified cross sectional view of an exemplary cleaning module, in accordance with one embodiment of the present invention.
FIG. 2B is a simplified, exploded, cross sectional view of an exemplary flat brush scrubbing-AE cleaning assembly, in accordance with one embodiment of the present invention.
FIG. 2C is a simplified cross sectional view illustrating cleaning of the wafer top surface by an exemplary brush scrubbing-AE cleaning assembly, in accordance with another embodiment of the present invention.
FIG. 2D is an exploded, simplified, cross sectional view of a portion of the flat brush of the brush scrubbing-AE cleaning assembly, in accordance with one embodiment of the present invention.
FIG. 3A is a simplified bottom view of an exemplary circular-shaped flat brush scrubbing-AE cleaning assembly, in accordance with another embodiment of the invention.
FIG. 3B is a simplified bottom view of an exemplary quarter-arc flat brush scrubbing-AE cleaning assembly, in accordance with yet another embodiment of the invention.
FIG. 3C is a simplified bottom view of an exemplary eight-arc flat brush scrubbing-AE cleaning assembly, in accordance with still another embodiment of the invention.
FIG. 4 is a simplified top view of an exemplary flat brush scrubbing-AE cleaning assembly cleaning a wafer top surface, in accordance with still another embodiment of the invention.
FIG. 5A is a simplified three-dimensional view of a pair of exemplary roller-type brush scrubbing-AE cleaning assemblies, in accordance with one embodiment of the invention.
FIG. 5B is a simplified cross sectional view or the roller-type brush scrubbing-AE cleaning assembly being applied to the top surface of the wafer, in accordance with still another embodiment of the invention.
FIG. 5C is a simplified cross sectional view of an exemplary roller-type brush scrubbing-AE cleaning assembly, in accordance with still another embodiment of the invention.
FIG. 5D is a simplified, exploded, cross sectional view of yet another exemplary roller-type brush scrubbing-AE cleaning assembly, in accordance with still another embodiment of the invention.
FIG. 5E is a simplified top view of an unrolled exemplary roller-type brush, in accordance with one embodiment of the present invention.
FIG. 6 is a simplified three-dimensional view of a pair of exemplary roller-type brush scrubbing-AE cleaning assemblies, in accordance with still another embodiment of the present invention.
FIG. 7 is a simplified cross sectional view of an exemplary multi-station cleaning module including a plurality of single-wafer combination cleaning assemblies, in accordance with yet another embodiment of the present invention.
FIG. 8 is a flowchart diagram of method operations performed in making a brush scrubbing-AE cleaning assembly, in accordance with still another embodiment of the present invention.
FIG. 9 is a flowchart diagram of method operations performed in making a roller-type brush scrubbing-AE cleaning assembly, in accordance with yet another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Several exemplary embodiments of the invention will now be described in detail with reference to the accompanying drawings. FIGS. 1A , 1 B, and 1 C are discussed above in the “Background of the Invention” section.
The embodiments of the present invention provide an apparatus and a method for cleaning a semiconductor substrate by concurrently using a combination of high frequency acoustic energy cleaning and brush scrubbing in a stand alone cleaning module. In one embodiment, a brush scrubbing-high frequency acoustic energy cleaning assembly capable of substantially removing contaminants lodged on wafer planer surfaces or deep wafer topography features. In one embodiment, a flat brush scrubbing-acoustic energy (AE) cleaning assembly is provided. The flat brush scrubbing-AE cleaning assembly includes a housing, a transducer having a crystal bonded to a resonator, and an arm configured to move the housing and thus the flat brush scrubbing-AE cleaning assembly. A flat brush having a plurality of openings functioning as AE passageways are defined in the brush. In another embodiment, a roller-type brush scrubbing-AE cleaning assembly is provided. The roller-type brush scrubbing-AE cleaning assembly includes a plurality of transducers defined on the outer surface of a brush core. In such an embodiment, each pair of adjacent transducers can be separated by a portion of the brush material. In one embodiment, fluid medium is introduced onto the wafer surfaces through the brush. In another embodiment, fluid medium is dripped onto the wafer surface through a nozzle.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be understood, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known process operations have not been described in detail in order not to unnecessarily obscure the present invention.
FIG. 2A is a simplified cross sectional view of an exemplary cleaning module 100 , in accordance with one embodiment of the present invention. A chamber 111 of the cleaning module 100 is shown to include a flat (i.e., pancake) brush scrubbing-AE assembly 120 , an arm 118 , a nozzle 126 , and a wafer 108 engaged by a pair of rollers 124 a and 124 b . The flat brush scrubbing-AE assembly 120 is connected to an arm control module 116 by an arm 118 . The arm 118 is configured to move in a movement direction 122 , thus causing the flat brush scrubbing-AE cleaning assembly 120 to scan the wafer top surface in the movement direction 122 during the brush scrubbing-AE cleaning operation. In this manner, in one embodiment, maximized wafer coverage and averaging of cleaning efficiency can be achieved by scanning the flat brush scrubbing-AE cleaning assembly 120 from the center of the wafer 108 to the edge of the wafer 108 . Fluid medium 127 is introduced onto the wafer surface through the nozzle 126 .
As can be appreciated, in one embodiment, the flat brush scrubbing-AE cleaning assembly may be configured to symmetrically clean the wafer backside. In such an implementation, the chamber 111 further includes a second brush scrubbing-AE assembly 120 ′ connected to a second arm control module 116 ′ using an arm 118 ′. The wafer backside 108 b is cleaned as the second brush scrubbing-AE assembly 120 ′ scans the wafer backside in the movement direction 122 . A fluid medium 127 ′ is introduced into the cleaning interface using a second nozzle 126 ′.
As can be seen, the wafer 108 is engaged by the rollers 124 a and 124 b during the cleaning operation. The rollers 124 a and 124 b are respectively placed in the chamber 111 using corresponding spindles 128 a and 128 b of a chuck. In one example, the rollers 124 a and 124 b are configured to rotate, thus causing the wafer 108 to rotate during the cleaning operation. In another embodiment, the cleaning module 100 may include a third roller (not shown in FIG. 2A ). In such example, the third roller is configured to rotate while the rollers 124 a and 124 b are designed to remain stationary. The rotation of the third roller is configured to cause the wafer 108 to rotate during the cleaning operation. In one example, the cleaning efficiency is averaged by rotating the wafer 108 and/or the brush scrubbing-AE cleaning assembly 120 and 120 ′.
Reference is made to a simplified, exploded, cross sectional view of an exemplary flat brush scrubbing-AE cleaning assembly 120 shown in FIG. 2B , in accordance with one embodiment of the present invention. As shown, a transducer 133 includes a crystal 132 bonded to a resonator 130 defined in a housing 134 . In one example, the crystal 132 is a piezoelectric crystal. The crystal is shown to be defined on a backside of the resonator 130 , facing away from the wafer 108 to be cleaned.
A brush 112 is shown to be placed on the face of the resonator 130 . In one example, as shown in the embodiment of FIG. 2B , the brush 112 covers the sidewalls of the resonator 130 and portions of the resonator 130 sidewalls. A plurality of openings 112 a – 112 f defined in the brush 112 is configured to function as AE passageways and facilitate the transmission of acoustic energy onto the wafer surface.
FIG. 2C is a simplified cross sectional view illustrating cleaning of the wafer top surface 108 a by an exemplary brush scrubbing-AE cleaning assembly 120 , in accordance with one embodiment of the present invention. The brush 112 is shown to be applied onto the wafer top surface 108 a while the crystal 132 is powered by the electrical connection module 138 . In this manner, the electrical connection is used to apply power to the transducers. As shown, the plurality of openings 112 a – 112 f faces the wafer top surface 108 a during the brush scrubbing-AE cleaning operation.
In the embodiment shown in FIG. 2C , the flat brush scrubbing-AE cleaning assembly 120 scans the top surface 108 a of the wafer 108 in the movement direction 122 while rotating in a rotation direction 119 . In this manner, the brush scrubbing-assembly 120 can be implemented to clean almost the entire wafer top surface 108 a . In one embodiment, a diameter of the transducer 133 can be smaller than the diameter of the wafer 108 . In another embodiment, the diameter of the transducer 133 can be substantially equivalent to the diameter of the wafer 108 or be slightly larger than the diameter of the wafer 108 .
The fluid medium 127 is shown to be introduced onto the wafer top surface 108 a through nozzles 126 a and 126 b creating a layer of meniscus 136 on the wafer top surface 108 a . In this manner, the brush 112 is saturated with fluid medium 127 as the fluid medium 127 is applied to the wafer top surface 108 a . In one preferred embodiment, the fluid medium 127 and thus the meniscus 136 propagate into the openings 112 – 112 f . In this manner, the fluid medium 127 defined in the exemplary openings 112 a – 112 f is implemented to transmit high frequency acoustic energy imparted by the resonator to the wafer top surface 108 during the cleaning operation.
One having ordinary skill in the art must appreciate that any suitable number of nozzles can be implemented to introduce the fluid medium 127 onto the wafer surfaces. Furthermore, in one example, the mechanical energy created to clean the wafer surfaces is created by the linear velocity of the brush scrubbing-cleaning assembly and the wafer. For instance, linear velocity can be created by rotating brush scrubbing-cleaning assembly, rotating brush scrubbing-cleaning assembly and scanning the wafer surface using the brush scrubbing-cleaning assembly, or rotating the wafer. For instance, as the wafer 108 rotates, the fluid medium introduced onto the wafer surface is spread on the wafer surface due to the centrifugal force, thus causing the fluid medium to be substantially evenly distributed on the wafer surface. In one embodiment, the wafer is configured to rotate approximately about 1 and 200 RPMs, and a more preferred range of approximately about 5 and 50 RPMs and most preferably approximately about 5 RPMs during the cleaning operation. In another embodiment, the brush scrubbing-cleaning assembly can be configured to linearly move back and forth on the wafer surface while the wafer 108 rotates.
In one exemplary embodiment, the vibration of the high frequency acoustic energy transducer 133 creates sonic pressure waves in the fluid medium 127 defined in the openings 112 a – 112 f as well as the meniscus 136 . As the transducer 133 scans across the wafer 108 using the fluid medium 127 , the contaminants are removed by cavitation and sonic agitation generated by the high frequency acoustic energy.
FIG. 2D is an exploded, simplified, cross sectional view of a portion of the flat brush of the brush scrubbing-AE cleaning assembly 120 , in accordance with one embodiment of the present invention. As can be seen, fluid medium 127 substantially fills the opening 112 c . In one embodiment, the brush 112 is saturated with the fluid medium 127 as the fluid medium 127 is continuously introduced onto the wafer top surface 108 a and the cleaning interface. In this manner, once the brush 112 is applied onto the wafer top surface 108 with pressure, excess fluid medium 127 is squeezed out of the brush 112 in a direction 138 and into the opening 112 c , substantially filling the opening 112 c . As a result, the wafer top surface 108 a is concurrently cleaned by both mechanical action as well as high frequency acoustic energy imparted by the resonator. For instance, the portions of the brush 112 surrounding the opening 112 c are applied to the wafer top surface 108 a , cleaning the wafer top surface 108 a as shown the mechanical energy 139 a . In comparison, the portion of the wafer top surface 108 a defined beneath the opening 112 c is cleaned using the high frequency acoustic energy 139 b . Of course, as the brush scrubbing-AE cleaning assembly 120 rotates and scans the wafer top surface 108 a , each section of the wafer top surface 108 a is most likely exposed to both, the high frequency acoustic energy as well as mechanical action. In this manner, limitations associated with separately performing brush scrubbing and AE cleaning in different brush scrubbing modules and AE cleaning modules are eliminated.
In one embodiment, sonic agitation subjects the fluid medium 127 to acoustic energy waves. In one example, the acoustic energy waves are configured to occur at frequencies between approximately about 0.4 Megahertz (MHz) and about 1.5 MHz, inclusive. In one implementation, the sonic agitation can have a frequency of between approximately about 400 kHz to about 2 MHz. By way of example, in typical implementations, the megasonic energy ranges typically between approximately about 700 kHz to about 1 MHz. For instance, lower frequencies can be used for cleaning applications in the ultrasonic range, which are used mainly for part cleaning. However, preferably, the higher frequencies are used to clean wafers and semiconductor substrates, substantially reducing the possibility of damage to the substrates, which is known to occur at the lower frequencies.
In one embodiment, the top and bottom transducers 133 and 133 ′ are configured to create acoustic pressure waves through sonic energy with frequencies approximately about 1 Megahertz. In this manner, the brush scrubbing and AE cleaning are performed simultaneously and in concert, each augmenting the cleaning power of the other.
In one example, high frequency acoustic energy originating from the top or bottom transducers 133 and 133 ′ is respectively transmitted through top and bottom resonators 130 and 130 ′. Thereafter, the top and bottom resonators 130 and 130 ′ propagate the acoustic energy to the top and bottom surfaces 108 a and 108 b of the wafer 108 .
It must be appreciated that the performance of the transducer is determined by the material properties of the piezoelectric crystals as well as the bonding method of the crystal 132 to the resonator 130 . The piezoelectric crystal 132 can be made of any appropriate piezoelectric material (e.g., piezoelectric ceramic, lead zirconium tintanate, piezoelectric quartz, gallium phosphate, etc.). In a like manner, the resonators 130 can be made of any appropriate material (e.g., ceramic, silicon carbide, stainless steel, aluminum, quartz, etc.). In one preferred embodiment, the resonator 130 is constructed from a material that is compatible with the cleaning chemistries (i.e., fluid medium) used. In another embodiment, the resonator 130 can be protected from the fluid medium a coating.
One having ordinary skill in the art must further appreciate that a thickness of the crystal 132 depends on the design of the crystal, mechanical strength of the crystal material, and type of crystal material. In one example, the thickness of the crystal 132 is configured to range between approximately about 1 mm and approximately about 6 millimeter, and a more preferred range of approximately about 2 mm and approximately about 4 mm and most preferably between approximately about 1 mm to approximately about 2 millimeters. In one embodiment, wherein the crystals are ceramic type crystals, the thickness of the crystals 132 is configured to range between approximately about 1 to about 4 millimeters.
FIGS. 3A through 3C are simplified bottom views of exemplary flat brush scrubbing-AE cleaning assemblies, in accordance with several embodiments of the present invention. The flat brush scrubbing-AE cleaning assembly of FIG. 3A has a circular-shaped brush, wherein the brush 112 includes a plurality of openings such as 112 a – 112 c . In one embodiment, a size of the circular shaped brush 112 can be substantially equivalent to the size of the semiconductor substrate while in another embodiment, the size of the circular shaped brush 112 can be different than the size of the semiconductor substrate.
In one embodiment, the openings are configured to occupy a substantial portion of the brush so as to allow undisturbed transfer of high frequency acoustic energy. In one embodiment, the openings occupy between approximately about 10 and approximately about 80, and a more preferred range of approximately about 20 and approximately about 70 and most preferably approximately about 50% of the brush surface.
The brush 112 ′ of FIG. 3B is shown to have the shape of a quarter-arc length of a circle 113 while the embodiment 112 ″ shown in FIG. 3C has the shape of an eight-arc length of a circle 113 , wherein a radius R of the circle 113 is equivalent to a radius of the wafer 108 . As can be appreciated, in one preferred embodiment, the brush 112 ′ of the flat brush scrubbing-AE cleaning assembly 120 of FIG. 3B is designed such that the brush scrubbing-AE cleaning assembly 112 ′ covers, at least partially, a center C′ of the assembly 112 ′. In a like manner, brush 112 ″ of the brush scrubbing-AE cleaning assembly 120 of FIG. 3C is designed such that the brush 112 ″ covers, at least partially, a center C″ of the assembly 112 ″. In this manner, the centers C′ and C″ are substantially cleaned despite the brushes 112 ′ and 112 ″ having smaller sizes than the wafer 108 . As can be appreciated, the brushed 112 ′ and 112 ″ are shown to include the plurality of exemplary openings 112 ′ a–c and 112 ″ a – 112 c ″, respectively. One of ordinary skill in the art must appreciate that the brushes 112 ′ and 112 ″ can be configured to remain stationary, to rotate, or to rotate and scan while cleaning the wafer top surface 108 . Furthermore, one having ordinary skill in the art must appreciate that the brush-transducers of the present invention can be configured to have any appropriate shape.
FIG. 4 is a simplified top view of an exemplary flat brush scrubbing-AE cleaning assembly 120 cleaning a wafer top surface 108 , in accordance with another embodiment of the present invention. As shown, the wafer 108 is engaged with three rollers 124 a – 124 c , each rotating in a respective rotation direction 125 a , 125 b , and 125 c . The rotation of the driving roller 124 a is designed to cause the wafer 108 to rotate in the rotation direction 125 . The flat brush scrubbing-AE assembly 120 is shown to clean the wafer top surface 108 a as the assembly 120 moves over the wafer top surface 108 a . In one embodiment, the assembly 120 can scan over the wafer top surface 108 a in a linear direction 122 a while in a different embodiment, the assembly is configured to move in a radial direction 122 b . The assembly 120 of the present invention can be implemented to clean substantially the entire wafer top surface 108 a , even the edge of the wafer 108 being engaged by the rollers 124 a – 124 c . In this manner, the brush scrubbing-cleaning assembly can thus be moved onto the wafer surfaces horizontally through the spaces defined between adjacent rollers.
In one exemplary embodiment, the wafer surface is cleaned by changing the liner velocity of the brush scrubbing-cleaning assembly, as the brush scrubbing-cleaning assembly is cleaning the center of the surface versus the edge of the wafer. For instance, the liner velocity of the brush scrubbing-cleaning assembly can be configured to be reduced as the brush scrubbing-cleaning assembly moves from the center of the wafer to the edge of the wafer. In one embodiment, the arm control defines the applied pressure, velocity, and trajectory. For instance, in one embodiment, the brush 212 can have a thickness between approximately about 0.25 and 0.5 inch. In such embodiment, the compression of the brush 212 can be between approximately about 0.5 mm and approximately about 14 mm, and a more preferred range of approximately about 1 mm and approximately about 10 mm and most preferably approximately about 2 and approximately about 3 mm.
FIG. 5A is a simplified three-dimensional view of a pair of exemplary roller-type brush scrubbing-AE cleaning assemblies 200 a and 200 b , in accordance with one embodiment of the present invention. As shown, the top roller-type brush scrubbing-AE cleaning assembly 200 a includes a top brush 212 mounted on a top brush core 240 that includes a top shaft 215 connected to a top fluid inlet 246 . As shown, the surface of top brush 212 is covered by a plurality of openings such as 212 a – 212 d . The top brush 212 is shown to be rotating in a rotation direction 222 as the rollers 224 a – 224 c rotate, thus causing the wafer 108 to rotate in the direction 125 .
In one example, the wafer 108 can be engaged by two engaging rollers 224 a and 224 b and a driving roller 224 c . As can be seen, during the brush scrubbing-AE cleaning operation, the wafer 108 is held horizontally by the engaging rollers 224 a and 224 b and the driving roller 224 b and top brush 212 . In such an embodiment, the wafer 108 is rotated in the wafer rotation direction 125 by the driving roller 224 c.
In accordance with one implementation, the backside of the wafer 108 can be cleaned using a bottom roller-type brush scrubbing-AE cleaning assembly 200 b . Similar to the top roller-type assembly 200 a , the bottom roller-type brush scrubbing-AE cleaning assembly 200 b includes a bottom brush 212 ′ mounted on a bottom brush core 240 ′ that includes a bottom shaft 215 ′ connected to a bottom fluid inlet 246 ′. The surface of the bottom brush 212 ′ is shown to be covered by a plurality of openings such as 212 ′ a – 212 ′ d . The bottom brush 212 ′ is shown to be rotating in a rotation direction 222 ′ as the wafer is rotated in the direction 125 .
As can be seen, top and bottom brushes 212 and 212 ′ are configured to rotate around an axis of rotation in respective rotation directions 222 and 222 ′. In this manner, top and bottom surfaces of the wafer 108 are cleaned as top and bottom brushes 212 and 212 ′ come into contact with top and bottom surfaces 108 a and 108 b , applying equal but opposite forces to the wafer top and bottom surfaces 108 a and 108 b , respectively. Additional information with respect to the mechanism of the roller-type brush scrubbing-AE cleaning assemblies 200 a and 200 b are provided below with respect to FIGS. 5B–5D .
In one embodiment, top and bottom brushes 212 and 212 ′ are polyvinyl alcohol (PVA) brushes (i.e., a very soft sponge), which can dislodge contaminants such as particles and residues using the fluid medium. In must be noted, however, that in another example, top and bottom brushes 212 and 212 ′ can be constructed from any suitable material so long as the material can dislodge particles and residues remaining on top and bottom surfaces of the wafer 108 .
In one embodiment, top and bottom surfaces 108 a and 108 b are cleaned using de-ionized water or any aqueous or semi-aqueous chemical solution. It must be appreciated by one having ordinary skill in the art that the fluid medium 227 can be any suitable fluid medium capable of cleaning top and bottom surfaces of the wafer and transmitting high frequency acoustic energy (e.g., Standard Cleaning I (SC1), DI water, ammonia containing chemical mixtures, HF containing chemical mixtures, surfactant containing chemical mixtures, etc.). In one implementation, the scrubbing-AE cleaning fluid medium 227 may be a cleaning fluid as described in U.S. Pat. No. 6,405,399, issued on Jun. 18, 2002, having inventors Jeffrey J. Farber and Julia S. Svirchevski, and entitled “Method and System of Cleaning a Wafer After Chemical Mechanical Polishing or Plasma Processing.” This U.S. Patent, which is assigned to Lam Research Corporation, the assignee of the subject application, is incorporated herein by reference.
The cleaning operation using the roller-type brush scrubbing-AE cleaning assembly 200 a can further be understood with respect to the simplified, exploded, cross sectional view shown in FIG. 5B , in accordance with one embodiment of the present invention. In the embodiment shown in FIG. 5B , the roller-type brush scrubbing-AE cleaning assembly 200 b is being applied to the top surface of the wafer 108 . The roller-type brush scrubbing-AE cleaning assembly is shown to include the brush core 240 , the fluid inlet 246 , and a plurality of transducers 233 , each including crystals 232 and respective resonators 230 , and the brush 212 . Each crystal 232 of the plurality of crystals 232 is bonded to a face of a respective resonator 230 , on the first side, and is attached to the brush core 240 , on the second side. In one example, the brush 212 is configured to be disposed over the brush core 240 such that the resonators 230 are entirely covered by the brush 212 . In this manner, the face of each resonator 130 is bonded to the corresponding crystal 132 while the back of each resonator 130 is in contact with the brush 212 . The plurality of openings such as 212 a – 212 i is defined in the brush 212 so as to facilitate traveling of AE.
A plurality of orifices 240 a – 240 h is defined in the brush core 240 . The fluid medium 227 is shown to be initially introduced into the brush core 240 through the fluid inlet 246 . Thereafter, the fluid medium 227 is guided to the respective gaps 231 defined between each pair of adjacent resonators 232 , and ultimately into the brush 112 and the openings such as 212 a – 212 i.
In the embodiment of FIG. 5B , the roller-type brush scrubbing-AE cleaning assembly cleans the wafer as follows: The fluid medium 227 is implemented to saturate the brush 212 and form a meniscus 236 on the wafer top surface 108 a . The fluid medium 227 is guided to the brush 212 and thus the wafer surface 108 first through the orifices 240 a – 240 e and then the nearby gaps 231 . In this manner, while the brush 212 is applied to the wafer top surface 108 a with pressure, extra fluid medium 227 in the brush 212 is squeezed out as excess fluid 237 into the openings 212 a – 212 i . In this embodiment, saturation of the brush 212 further leads to formation of the layer of meniscus 236 on the wafer surface. The meniscus 236 and the excess fluid 237 facilitate the transmission of AE to the wafer surface during the cleaning operation.
The application of the brush 212 onto the wafer top surface 108 a using the fluid medium 227 enables mechanical cleaning of the wafer top surface 108 a , thus defining areas 239 . In this manner, contaminants defined on the planer surface of the wafer top surface 108 a can easily be removed by brush scrubbing. Embodiments of the present invention, however, simultaneously clean the wafer top surface 108 a using high frequency acoustic energy imparted from the resonators 232 to the wafer top surface 108 a through the excess liquid 237 defined in the exemplary openings 212 a – 212 i . The AE cleaning areas are shown as areas 239 b . The high frequency acoustic energy cleaning can be implemented to dislodge contaminants defined deep within the topography features, substantially enhancing the cleaning operation performed by brush scrubbing.
FIG. 5C is a simplified cross sectional view of an exemplary roller-type brush scrubbing-AE cleaning assembly, in accordance with one embodiment of the present invention. As can be seen, the plurality of transducers 233 , as shown by the resonators 232 and the brush 212 are disposed on the outer surface of the brush core 240 in an alternate arrangement. That is, each pair of transducers 233 is separated by at least a portion of brush 212 . In this manner, the high frequency acoustic energy imparted by the resonators can easily travel through the small openings 212 and onto the wafer top surface 108 a . As can be appreciated, each of the plurality of orifices 240 a – 240 d is in contact with a portion of the brush 212 , introducing fluid medium 227 into the cleaning interface through the brush 212 . In one example, excess fluid medium 227 further creates the layer of meniscus on the wafer surface. In this manner, the high frequency acoustic energy imparted by the resonators 232 can travel through the fluid medium 227 in the exemplary openings 212 a–h and the meniscus 236 on to the wafer surface.
FIG. 5D is a simplified, exploded, cross sectional view of yet another exemplary roller-type brush scrubbing-AE cleaning assembly, in accordance with another embodiment of the present invention. In the embodiment of FIG. 5D , each of the plurality of crystals 332 is shown to be electrically connected to a electrical connection 332 . As can be seen, the plurality of resonators 232 and brush 312 are dispose on the outer surface of the brush core 240 in an alternate arrangement. In this manner, power can be integrated in the brush core to be provided to the transducers. By powering the crystals 232 using the electrical connections 334 , high frequency acoustic energy can be generated.
In one embodiment, the transducers 233 can cover substantially the entire outer surface of the brush core 240 . In another embodiment, the transducers 233 can be defined on the outer surface of the brush core 240 such that transducers 233 cover less than an entire surface of the brush core 240 . In such an embodiment, the openings 212 a – 212 i defined in the brush 312 can be configured to merely cover the transducers rather than the entire surface of the brush core. Furthermore, as can be appreciated, a length of the transducers can be configured to be equivalent to the diameter of the wafer 108 .
In one exemplary embodiment, a brush 312 can include a plurality of slits 312 a and brush patches 312 b , in accordance with one embodiment as shown in FIG. 5E . The embodiment of FIG. 5E illustrates an unrolled exemplary roller-type brush 312 . As shown, the brush 312 includes a plurality of slits 312 b , with each slit 312 b including a plurality of brush patches 312 a . In one preferred embodiment, each slit 312 b is configured to be disposed over the brush core 240 such that each of the brush slits 312 is defined over a transducer. The brush patches 312 a are configured to improve the strength of the brush 312 , substantially reducing the possibility of having a tear in the brush 312 . One must appreciate that the brush patches are defined out of phase. In this manner, lack of generation of acoustic energy resulting form being covered by each of the brush patches 312 is compensated by the adjacent transducers.
FIG. 6 is a simplified three-dimensional view of a pair of exemplary roller-type brush scrubbing-AE cleaning assemblies 200 ′ a and 200 ′ b , in accordance with one embodiment of the present invention. As shown, fluid medium 227 is introduced onto the brush 212 and the wafer top surface 108 a through a top nozzle 226 . In this manner, fluid medium 227 is dripped onto the brush 212 , saturating the brush 212 while creating a meniscus on the wafer top surface 108 a . The fluid medium 227 defined in the exemplary openings 212 a–h of the brush 212 enables the high frequency acoustic energy to travel and be applied on the wafer top surface 108 a . In this manner, the wafer top surface 108 a is cleaned by substantially concurrently using both mechanical action and the generated high frequency acoustic energy.
In accordance with one implementation, the wafer backside 108 b of the wafer 108 can be cleaned using a bottom roller-type brush scrubbing-AE cleaning assembly 200 ′ b . Similar to the top assembly 200 ′ a , in one embodiment, the fluid medium 227 is sprayed onto the wafer backside 108 b using a pressurized nozzle 226 b (not shown in this Figure).
FIG. 7 is a simplified cross sectional view of an exemplary multi-station cleaning module 400 including a plurality of single-wafer combination cleaning assemblies 400 a – 400 c , in accordance with one embodiment of the present invention. As can be seen, the cleaning module 400 includes a chamber 411 , an arm control module 416 , and an electrical connection module 450 . The first single-wafer combination cleaning assembly 400 a includes top and bottom brush-scrubbing-AE cleaning assemblies 120 a and 120 a ′, each connected to the arm control module 416 using a respective arm 418 a and 418 ′ a . The wafer 108 is engaged by a pair of rollers 424 a and 424 ′ a , each connected to the electrical connection module 450 . Nozzles 126 a and 126 a ′ are configured to respectively spray fluid medium onto the wafer top and bottom surfaces 108 a and 108 b . The fluid medium introduced into the cleaning interface is configured to create a layer of meniscus on the wafer surfaces 108 a and 108 b and to saturate the brushes in the brush-scrubbing cleaning assemblies 120 a and 120 ′ a . As described in more detail above, the high frequency acoustic energy can easily travel through the fluid medium, allowing the acoustic energy imparted by the resonators to be applied on to the wafer surfaces.
Still referring to FIG. 7 , the second single-wafer combination cleaning assembly 400 b includes a top and bottom brush-scrubbing-AE cleaning assemblies 120 b and 120 b ′, each connected to the arm control module using a respective arm 418 b and 418 ′ b . The wafer 108 ′ is engaged by a pair of rollers 424 b and 424 ′ b , each connected to the electrical connection module 450 . Nozzles 126 b and 126 b ′ are configured to respectively spray fluid medium onto the wafer top and bottom surfaces 108 ′ a and 108 ′ b . The fluid medium introduced into the cleaning interface is configured to create a layer of meniscus on the wafer surfaces 108 ′ a and 108 ′ b and to saturate the brushes in the brush-scrubbing cleaning assemblies 120 b and 120 ′ b.
The third single-wafer combination cleaning assembly 400 c includes a top and bottom brush-scrubbing-AE cleaning assemblies 120 c and 120 ′ c , each connected to the arm control module using a respective arm 418 c and 418 ′ c . The wafer 108 ″ is engaged by a pair of rollers 424 c and 424 ′ c , each connected to the electrical connection module 450 . Nozzles 126 c and 126 c ′ are configured to respectively spray fluid medium onto the wafer top and bottom surfaces 108 ″ a and 108 ″ b . The fluid medium introduced onto the cleaning interface is configured to create a layer of meniscus on the wafer surfaces 108 ″ a and 108 ″ b and to saturate the brushes in the brush-scrubbing cleaning assemblies 120 c and 120 ′ c.
As can be seen, each pair of adjacent single-wafer combination cleaning assemblies 400 a – 400 c is separated by a shield 450 a and 450 b , respectively. In this manner, fluid medium introduced into each of the single-wafer combination cleaning assembly 400 a – 440 c cannot contaminate the cleaning operation performed in the adjacent cleaning assemblies. Furthermore, several wafers, each made of different materials, can be cleaned substantially simultaneously in the multi-station cleaning module of the present invention. As can be appreciated, the embodiments of the present invention prevent the introduction of chemicals implemented in different single-wafer combination cleaning assembly to contaminate the adjacent stations. Of course, multiple wafers can be simultaneously cleaned implementing both a brush scrubber and high frequency acoustic energy, removing contaminants defined in the planer surfaces as well as deep topography features of the wafer.
FIG. 8 is a flowchart diagram 800 of method operations performed in making a brush scrubbing-AE cleaning assembly, in accordance with one embodiment of the present invention. The method begins in operation 802 in which a transducer is provided. The transducer includes a resonator and a crystal. The crystal is defined on the first side of the resonator. The method continues to operation 804 in which a plurality of openings is defined in a brush. In one embodiment, the brush is a flat brush. In one embodiment, the plurality of openings can perform the function as nodules during the cleaning operation. Next, in operation 806 , the brush is placed over the second side of the resonator.
FIG. 9 is a flowchart diagram 900 of method operations performed in making a roller-type brush scrubbing-AE cleaning assembly, in accordance with another embodiment of the present invention. The method begins in operation 902 in which a brush core is provided followed by operation 904 in which a plurality of orifices is defined in the brush core. Continuing to operation 906 , a plurality of transducers is defined on the brush core. Thereafter, in operation 908 , each transducer is defined on the brush core without covering all of the orifices in the brush core. In one embodiment, the entire outer surface of the brush core can be covered by transducers. In such scenario, the brush can cover the entire outer surface of the brush core. In another embodiment, transducers are defined on certain portion of the brush core. In such embodiment, openings are defined on the sections of the brush configured to be disposed on the transducers. Proceeding to operation 910 , a brush having a plurality of openings is provided. In operation 912 , the brush is defined over the brush core and the transducers such that the openings in the brush are defined at least partially on the transducers.
It should be appreciated that the brush scrubbing-high frequency acoustic energy cleaning assembly of the present invention can be implemented to clean wafer surfaces vertically or horizontally. Additionally, although the embodiments described herein have been primarily directed toward cleaning semiconductor substrates, it should be understood that the brush scrubbing-AE cleaning assembly of the present invention is well suited for cleaning any type of substrate. The invention has been described herein in terms of several exemplary embodiments. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention. The embodiments and preferred features described above should be considered exemplary, with the invention being defined by the appended claims.
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A substrate cleaning apparatus is provided. The apparatus includes a transducer capable of resonating at a high frequency and a brush material attached to a surface of the transducer. The brush material includes at least one passage extending to the surface of the transducer and is configured to be applied to a surface of a substrate. When the transducer resonates at the high frequency, the transducer is capable of imparting acoustic energy to the surface of the substrate at a location of the at least one passage.
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